船用锅炉过热器管束胀口应力应变分析
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摘要
蒸汽过热器是船用锅炉的重要组成部分之一,在整个蒸汽动力装置中占有极其重要的地位。过热器的作用是将汽包中产生的饱和蒸汽进一步加热成更高温度的过热蒸汽以满足船舶航行的需求。过热器的换热管与集箱管板通常采用胀接方式连接,有时在运行过程中会出现胀口渗漏的现象。
本文为找出过热器管束胀口渗漏原因,进行了以下研究：
1.在综合了国内外大量文献资料的基础上,采用ANSYS大型有限元分析软件,经过适当简化,建立了船用锅炉过热器集箱与换热管的单管胀接接头三维有限元分析模型。通过弹塑性有限元分析,考察12Cr1MoVg、1Cr19Ni11Nb、GH984三种常用过热器管材与集箱的冷态胀接性能。分析结果表明：三种材料与集箱的冷态胀接性能良好,管板开槽后可以提高接头的密封性及连接强度,管板开两个槽即可获得较好的胀接性能。
2.对接头在高温工作条件下的密封性能进行了研究,结果表明：以1Cr19Ni11Nb做过热器管材,接头在降温过程中将发生渗漏；对12Cr1MoVg和GH984做管材的接头在循环温度及压力载荷作用下的密封性能做了分析,加载次数对接头密封性的影响较小,温度对接头密封性影响较大。
3.接头经启动停炉后残余接触压力下降,胀口渗漏主要是受管子与管板材料膨胀系数差值的影响,为此本文对管子与管板材料膨胀系数差值做了不同情况的探讨,当管子热膨胀系数高于管板时,接头在降温过程中将可能发生渗漏；当管子比管板热膨胀系数低时,接头有可能在升温过程中发生渗漏。
通过以上研究,为防止过热器胀口渗漏提出了一些建议,对工程应用具有一定的指导作用。
The steam superheater is one of the most important components of marine boiler. It holds the extremely important status in the entire steam power installment. The function of superheater is further heating the saturated steam generated in the drum to a higher temperature of superheated steam to meet the needs of marine navigation. The tubes of the superheater and the headers' tube sheet are usually connected by expansion. Sometimes the expansion port of the superheater is finding to be leaky during the operation process.
This thesis focused on the study on the causes of expansion port leakage. The main content of this study were as follows:
1. On the basis of consulting of plenty of literatures about tube-to-tubesheet joint, using ANSYS finite element analysis software, after appropriate simplification, the 3-D finite element model of marine boiler superheater tube-to-tubesheet joint is established. By using elastic-to-plastic finite element analysis of the process of expansion joints,12Cr1MoVg, 1Cr19Ni11Nb, GH984 these three common materials of superheater tubes'expansion performance to the header box were studied. The results of analysis indicated:the three materials all have good cold expansion performance, grooving on the tubesheet has benefit to the expansion joint, two grooves on the tubesheet can make the joint get better expansion performance.
2. Analysis the seal performance of the expansion joint when it is in the high temperature working state. The results indicate:when using 1Cr19Ni11Nb as superheater tubes, the joint can keep in touch and seal. It will leak in the cooling process.Exert temperature and pressure cyclic loads on the joint, then analysis the load cycle number on the impact of sealing performence of joint. The results indicate:with the increase of the load cycle number, the residual contact pressure in the joint decreased slightly in the cooling process. This thesis also inspected high temperature on the impact of sealing performance of the joint, when using 12Cr1MoVg and GH984 as the tube. FEA results show that the higher the working temperature is, the lower the residual contact pressure is after from the high temperature state to the room temperature.
3. The residual contact pressure of the joint decrease after start and shutdown the boiler, and expansion leakage. This mainly caused by the difference of coefficient of thermal expansion between tube and tubesheet. This thesis discussed the cases that tube and tubesheet have different coefficient of thermal expansion. It finds that when the tube's coefficient of thermal expansion is higher than the tubesheet's, the joint will leak during the cooling process. When the tube's coefficient of thermal expansion is lower than the tubesheet's, the joint will leak during the heating process.
Through the above theoretical reseach, it gives some advice to avoid expansion port leak, and has some significance for application.
本文为找出过热器管束胀口渗漏原因,进行了以下研究：
1.在综合了国内外大量文献资料的基础上,采用ANSYS大型有限元分析软件,经过适当简化,建立了船用锅炉过热器集箱与换热管的单管胀接接头三维有限元分析模型。通过弹塑性有限元分析,考察12Cr1MoVg、1Cr19Ni11Nb、GH984三种常用过热器管材与集箱的冷态胀接性能。分析结果表明：三种材料与集箱的冷态胀接性能良好,管板开槽后可以提高接头的密封性及连接强度,管板开两个槽即可获得较好的胀接性能。
2.对接头在高温工作条件下的密封性能进行了研究,结果表明：以1Cr19Ni11Nb做过热器管材,接头在降温过程中将发生渗漏；对12Cr1MoVg和GH984做管材的接头在循环温度及压力载荷作用下的密封性能做了分析,加载次数对接头密封性的影响较小,温度对接头密封性影响较大。
3.接头经启动停炉后残余接触压力下降,胀口渗漏主要是受管子与管板材料膨胀系数差值的影响,为此本文对管子与管板材料膨胀系数差值做了不同情况的探讨,当管子热膨胀系数高于管板时,接头在降温过程中将可能发生渗漏；当管子比管板热膨胀系数低时,接头有可能在升温过程中发生渗漏。
通过以上研究,为防止过热器胀口渗漏提出了一些建议,对工程应用具有一定的指导作用。
The steam superheater is one of the most important components of marine boiler. It holds the extremely important status in the entire steam power installment. The function of superheater is further heating the saturated steam generated in the drum to a higher temperature of superheated steam to meet the needs of marine navigation. The tubes of the superheater and the headers' tube sheet are usually connected by expansion. Sometimes the expansion port of the superheater is finding to be leaky during the operation process.
This thesis focused on the study on the causes of expansion port leakage. The main content of this study were as follows:
1. On the basis of consulting of plenty of literatures about tube-to-tubesheet joint, using ANSYS finite element analysis software, after appropriate simplification, the 3-D finite element model of marine boiler superheater tube-to-tubesheet joint is established. By using elastic-to-plastic finite element analysis of the process of expansion joints,12Cr1MoVg, 1Cr19Ni11Nb, GH984 these three common materials of superheater tubes'expansion performance to the header box were studied. The results of analysis indicated:the three materials all have good cold expansion performance, grooving on the tubesheet has benefit to the expansion joint, two grooves on the tubesheet can make the joint get better expansion performance.
2. Analysis the seal performance of the expansion joint when it is in the high temperature working state. The results indicate:when using 1Cr19Ni11Nb as superheater tubes, the joint can keep in touch and seal. It will leak in the cooling process.Exert temperature and pressure cyclic loads on the joint, then analysis the load cycle number on the impact of sealing performence of joint. The results indicate:with the increase of the load cycle number, the residual contact pressure in the joint decreased slightly in the cooling process. This thesis also inspected high temperature on the impact of sealing performance of the joint, when using 12Cr1MoVg and GH984 as the tube. FEA results show that the higher the working temperature is, the lower the residual contact pressure is after from the high temperature state to the room temperature.
3. The residual contact pressure of the joint decrease after start and shutdown the boiler, and expansion leakage. This mainly caused by the difference of coefficient of thermal expansion between tube and tubesheet. This thesis discussed the cases that tube and tubesheet have different coefficient of thermal expansion. It finds that when the tube's coefficient of thermal expansion is higher than the tubesheet's, the joint will leak during the cooling process. When the tube's coefficient of thermal expansion is lower than the tubesheet's, the joint will leak during the heating process.
Through the above theoretical reseach, it gives some advice to avoid expansion port leak, and has some significance for application.
引文
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[2]陈学俊,陈听宽主编.锅炉原理(下册)[M].第二版.北京：机械工业出版社,1991：16-50
[3]李文军.管壳式换热器的胀接工艺[J].压力容器,2001,18(3)：58-59
[4]葛乐同.换热器管子与管板胀接技术及最新进展[J].江苏化工,1996,24(5)：37-41
[5]王刚.换热器管子与管板胀接工艺分析[J].青海大学学报,2004,22(2)：36-38
[6]GB151-1999,管壳式换热器[S].北京,中国国家质量技术监督局,1999
[7]段红卫.换热器液压胀接接头强度的研究[D].北京：北京化工大学,2004,9
[8]金庆大.换热器管板和管子橡胶胀管技术极其应用[J].化工设备设计,1981,(3)：55-64
[9]石庭瑞,颜惠庚.换热器的液压胀接技术及其应用要点[J].石油机械,2001,(2)：55-57
[10]颜惠庚.换热管液袋式液压胀接装备和技术[D].上海：华东理工大学,1998
[11]于新奇.过程装备机械基础[M].北京：北京大学出版社,2009：304-305
[12]Krips H, and Podhorsky M, Tube Expansion-A New Method for the Anchoring of Tubes[J].1976,No.7:418-426
[13]Krips H, Podhorsky M, Neue Konstrukitonswege im Apparatebau mit Hilfe deshydraulischen Aufweitens[J].1984,25(3):41-46
[14]Podhorsky M and Kips H, Waermeastauscher-Aktuelle Problem der Konstruktion und Berechung[J].FDBR Fachbuchreihe, Vol,5,1990
[15]Chaaban A, Morin E, Ma H, and Bazergui A, Finite Element Analysis of Hydraulically Expanded Tube-to-Tubesheet Joints[C]:ASME-PVP Conference Vol.173,19-25,1989
[16]Chaaban A, Morin E, Ma H, and Bazergui A, Tube-to-Tubesheet Joint:A Proposed Equation for the Equivalent Sleeve Diameter Used in the Single-Tube Model. Journal of Pressure Vessel Technology of ASME.1992,114(2):19-22
[17]Kohlpainter W.R.. Calculation of Hydraulically Expanded Tube-to-Tubesheet Joints. Journal of Pressure Vessel Technology of ASME.1995,117(2):24-30
[18]Scott D A, Wolgemuth G A, and Aikin J A, Hydraulically Expended Tube-to-Tubesheet Joints[J].ASME Journal of Pressure Vessel Technology,1984,106(2):104-109
[19]Druez J, Bazergui A, and Pettigrew M J, Residual Stress in Roller-Expanded Thin Tubes[J].Experimental Mechanics,1985, Vol.24,316-324
[20]Updike D P, Kalnins A and Caldwell S M, Residual Stresses in Tube-Tubesheet Joints With Grooves[J] Journal of Pressure Vessel Technology,1992, Vol.114:249-251
[21]Allam M, Chaaban A, Bazergui A. Estimation of Residual Stresses in Hydraulically Expanded Tube-to-Tubesheet Joints[J]. Trans. ASME Journal of Pressure Vessel Technology,1998,120(5):129-137
[22]Shuaib A N, Merah N, Allam I. Investigation of Heat Exchanger Tube Sheet Hole Enlargement[R]. ME2203 Final Report, King Fahd University of Petroleum and Petroleum, Dhahran, Saudi Arabia,2001
[23]N.Merah, A. Al-Zayer, Shuaib, A.Arif. Finite element evaluation of clearance effect on tube-to-tubesheet joint strength. International Journal of Pressure Vessels and Piping 80,2003,879-885
[24]徐鸿.包括热载荷在内胀接接头加载的弹塑性分析[J].压力容器,1985,2(1)：29-35
[25]颜惠庚,张炳生,葛乐通,李培宁.换热器的液压胀管研究(一)：胀接压力的确定[J].压力容器,1996,13(2)：36-40
[26]颜惠庚,张炳生,葛乐通,李培宁.换热器的液压胀管研究(二)：残余接触压力与摩擦系数[J].压力容器,1996,13(4)：39-43
[27]颜惠庚,张炳生,葛乐通,李培宁.换热器的液压胀管研究(三)：管板开槽宽度的选择[J].压力容器,1997,14(3)：24-28
[28]颜惠庚,张炳生,葛乐通,李培宁.换热器的液压胀管研究(四)：液压胀接接头的拉脱力和压脱力[J].压力容器,1998,(5)：25-28
[29]汪亚芬.薄壁管胀接工艺及其应用[J].压力容器,2003,20(7)：16-19
[30]王贤虎.锅炉胀接和影响胀接质量的因素[J].锅炉制造,1997,(3)：32-34
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