淮北发电厂300MW锅炉高温管道剩余寿命评估
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摘要
电站锅炉过热器管和再热器管是锅炉内部的主要受热面结构件，它们是否安全稳定地运行直接关系到整个电厂的安危，频繁爆管事故影响了电厂的经济效益和社会效益。锅炉过热器管和再热器管失效机理的分析和寿命的预测是提高电厂机组运行可靠度的有效手段。受淮北发电厂委托，本文对在役300MW机组锅炉内局部高温管段的使用寿命评估。
首先，本文为了提高故障诊断和状态检测的准确性和增强锅炉运行的可靠性，深入探讨了锅炉过热器管和再热器管失效机理和可靠性理论，将管道的寿命损伤通过拟合的Larson—Miller函数进行表征，从而得出各参数对寿命的影响，确认运行温度、工作应力和服役时间是寿命损伤的主要因素。
其次，由于管件的真实使用温度是预测其寿命的关键因素，因此，本文通过对未用管材按照几种不同的加热规范在实验室进行模拟加热，测定其加热后的硬度，找出显微硬度与热强参数的关系。利用“内壁氧化层厚度法”和“显微硬度法”对实验管件的实际使用温度进行了分析和计算。
然后，通过试验研究了过热器和再热器管12Cr2MoWVTiB钢材的金相组织、合金元素对管道寿命的影响，分析了管材在高温长期运行后金相组织和合金元素分布的变化情况，对管材寿命进行定性评估。
最后，根据上述持久强度外推分析法、金相试验研究综合评估了截取在役的过热器和再热器管材的寿命。
The tubes of superheater and reheater are the main component of the heat exchangers in power plant boilers. Whether they run safely and stably or not is directly count for much the safe of the whole plant operation. And the frequent tube leakage of heat surface impact upon the economy benefits and the society benefits of the power plant. This paper evaluates the life of the 300MW high temperature boiler tubes that have been being used in Huaibei power plant.
The dissertation goes deep into the tube failure mechanism and the reliability theory in order to improve the diagnosis and monitor veracity and tone up the operation reliability. The parameters of the tube life lapse is expressed by the Larson-Miller function and the effect of the parameters on the life is derived. And it is confirmed the operation temperature and the pressure and the service time are the main factors of the life lapse.
Then because the real operation temperature of the tube is the critical factor for predicting the tube lifetime, we heat some unused tubes in the lab. Then we measuer the rigidity of them and find the relationship between the hardness and heat - intensity parameter. The paper analylizes and caculates the operation temperature of the tube through the methods of the inner oxide scale thickness and rigidity. On this basis the paper calculates the remain life of the experimental tubes.
It is researched that the influence on the tube lifetime of the metallographic structure and the alloy element by testing the superheater and reheater tube which is made of 12Cr2MoWVTiB steel. The metallographic change and the distribution of alloy elements after the tube has run in the high temperature condition for longtime is more believable and franker to evaluate the tubes remain life time.
In the end of the dissertation, the lifetime of the experimental superheater and reheater tubes that have been used is evaluated by the methods of sress computation and the metallographic tests.
首先，本文为了提高故障诊断和状态检测的准确性和增强锅炉运行的可靠性，深入探讨了锅炉过热器管和再热器管失效机理和可靠性理论，将管道的寿命损伤通过拟合的Larson—Miller函数进行表征，从而得出各参数对寿命的影响，确认运行温度、工作应力和服役时间是寿命损伤的主要因素。
其次，由于管件的真实使用温度是预测其寿命的关键因素，因此，本文通过对未用管材按照几种不同的加热规范在实验室进行模拟加热，测定其加热后的硬度，找出显微硬度与热强参数的关系。利用“内壁氧化层厚度法”和“显微硬度法”对实验管件的实际使用温度进行了分析和计算。
然后，通过试验研究了过热器和再热器管12Cr2MoWVTiB钢材的金相组织、合金元素对管道寿命的影响，分析了管材在高温长期运行后金相组织和合金元素分布的变化情况，对管材寿命进行定性评估。
最后，根据上述持久强度外推分析法、金相试验研究综合评估了截取在役的过热器和再热器管材的寿命。
The tubes of superheater and reheater are the main component of the heat exchangers in power plant boilers. Whether they run safely and stably or not is directly count for much the safe of the whole plant operation. And the frequent tube leakage of heat surface impact upon the economy benefits and the society benefits of the power plant. This paper evaluates the life of the 300MW high temperature boiler tubes that have been being used in Huaibei power plant.
The dissertation goes deep into the tube failure mechanism and the reliability theory in order to improve the diagnosis and monitor veracity and tone up the operation reliability. The parameters of the tube life lapse is expressed by the Larson-Miller function and the effect of the parameters on the life is derived. And it is confirmed the operation temperature and the pressure and the service time are the main factors of the life lapse.
Then because the real operation temperature of the tube is the critical factor for predicting the tube lifetime, we heat some unused tubes in the lab. Then we measuer the rigidity of them and find the relationship between the hardness and heat - intensity parameter. The paper analylizes and caculates the operation temperature of the tube through the methods of the inner oxide scale thickness and rigidity. On this basis the paper calculates the remain life of the experimental tubes.
It is researched that the influence on the tube lifetime of the metallographic structure and the alloy element by testing the superheater and reheater tube which is made of 12Cr2MoWVTiB steel. The metallographic change and the distribution of alloy elements after the tube has run in the high temperature condition for longtime is more believable and franker to evaluate the tubes remain life time.
In the end of the dissertation, the lifetime of the experimental superheater and reheater tubes that have been used is evaluated by the methods of sress computation and the metallographic tests.
引文
[1]Douglas J.Smith, The importance of the best life to increase power plant life, Power Engineering, 1991, 2
[2]John Reason, Measure how fast you're expanding boiler life, Power, July,1986
[3]Thomas C Elliotl, Monitoring power plant performance, Power, October, 1994
[4]廖宏楷，锅炉“四管”爆漏专家系统，热力发电，1998，6
[5]焦庆丰，670t／h锅炉高温对流过热器超温爆管原因分析及技术改进措施，湖南电力，No．4，1998，P9．
[6]Viswanathan,R., EPRI, ASM International, 1989
[7]La E. N.and Anrade, C. Proc. Royal Soc. (London), Vol. A84 (1910) 1
[8]黄明志、石德珂、金志浩，金属力学性能，西安交通大学出版社，1986．P232—233
[9]《金属机械性能》编写组，金属机械性能，机械工业出版社，1982．P198—199
[10]吴非文，火力发电厂高温金属运行，水利电力出版社，1979．P103—107
[11]J. H. Bennewitz, Joint International Conference on Creep, Session 5, 1963,p.81
[12]孔庆平，关于高温蠕变和持久强度的外推方法，技术通讯(金属材料高温强度专辑)，东方锅炉厂，1977．No 6．
[13]上海锅炉厂，上海汽轮机厂，上海材料研究所，高温持久强度外推法评述及电子计算机的应用，技术通讯(金属材料高温强度专辑)，东方锅炉厂，1977．No 6．
[14]田文莉编译，火力发电设备剩余寿命评价技术，电力情报，1994．1
[15]王胜纯，锅炉高温过热器的失效和寿命评估，华北电力技术，1998．1，P50—54
[16]周克毅，国外电站性能检测与诊断情况，动力工程，1992．2
[17]欧阳杰、李金峰、牛晓光等，老化的102钢高温再热器管寿命评估，全国第五界电站金属构件失效分析与寿命管理学术会议论文集，1997，P429—435
[18]朱日彰，金属腐蚀学，冶金工业出版社，1989．P6—47
[19]R.D.Townsend. The CEGB Approach to Residual Life and Plant Life Extension. Materials Forum, Vol.9, No1.1986. P46-48.
[17]欧阳杰、李金峰、牛晓光等，老化的102钢高温再热器管寿命评估，全
国第五界电站金属构件失效分析与寿命管理学术会议论文集，1997，P429—435
[20]川本和夫等。诊断汽轮机剩余寿命的MACNNDE系统．三菱重工技报．1987：24(5)：441—444
[21]A.K.Ray, Y.N.Tiwari. Rwsidual Life Prediction of Service Exposed Main Steam Pipe of Boilers in a Thermal Power Plant, Engineering Failuer Analysis,2000.7:359-376
[22]杨迪、李福欣，显微硬度试验，中国计量出版社，(1988)，P124—129。
[23]程卫国、冯峰、姚东等，MATLAB5.3应用指南，人民邮电出版社，1999．P206—213。
[24]李益民、束国刚、梁昌乾等12CrlMoV钢蠕变寿命研究的θ法，全国第五界电站金属构件失效分析与寿命管理学术会议论文集，1997，P30—44．
[25]ASME Boiler and Pressure Vessel Conde Section 1& Section 3,1977
[26]王致祥、梁志钊、孙国模等，管道应力分析与计算，水利电力出版社，(1983)，P65—67
[27]George H harth, Assess the remaining life of hign-temperature boiler parts,Power, 1985.8
[28]Klok. J. VGB-Conf, Residual Life Assessment, Mannheim, 1992
[29]N. K. Mukhopadhyay, S.G. Chowdhury Remaining Life Estimation of a service Exposed Economizer Tube, Engineering Failure Analysis,1996.6:233-243
[30]束国刚、李益民等，应用θ法外推主蒸汽管道蠕变寿命研究，热力发电，2000(5)
[31]束国刚、李益民、梁昌乾等，10CrMo910钢薄壁主汽管θ法寿命评估及其应用研究，热力发电，2000(4)，P36—41
[32]李金峰、欧阳杰、牛晓光等，102钢高温再热器材质变化规律及寿命研究，河北电力技术，Vol 18，1991．1，P48—50
[33]机电王程金属材料手册，上海科学技术出版社，1990，P420—427
[34]李自力、陈永保，借助实际载荷谱及由此确定的运行寿命损耗预测“薄壁”主蒸汽管道的剩余寿命，全国第五界电站金属构件失效分析与寿命管理学术会议论文集，1997，P6—12．
[35]Kenjiro Komai, Failure Analysis and Prevention in SCC and Corrosion Fatigue Cases, Int. J. Fatigue, Vol.20. No.2 1998.2:145-154
[36]T.Sokolowski, K.Gerke, Evaluation of tube formability and material characteristics:hydraulic bulge testing of tubes, Journal of Materials Processing Technology Vol.98.2000:34-40
[37]李耀君、刘树涛，12CrlMoV钢碳化物粗化动力学研究，热力发电，3，(1993)，P21—24。
[38]潘家祯，压力容器材料使用手册——碳钢及合金钢，化学工业出版社，2000．P344—346
[2]John Reason, Measure how fast you're expanding boiler life, Power, July,1986
[3]Thomas C Elliotl, Monitoring power plant performance, Power, October, 1994
[4]廖宏楷，锅炉“四管”爆漏专家系统，热力发电，1998，6
[5]焦庆丰，670t／h锅炉高温对流过热器超温爆管原因分析及技术改进措施，湖南电力，No．4，1998，P9．
[6]Viswanathan,R., EPRI, ASM International, 1989
[7]La E. N.and Anrade, C. Proc. Royal Soc. (London), Vol. A84 (1910) 1
[8]黄明志、石德珂、金志浩，金属力学性能，西安交通大学出版社，1986．P232—233
[9]《金属机械性能》编写组，金属机械性能，机械工业出版社，1982．P198—199
[10]吴非文，火力发电厂高温金属运行，水利电力出版社，1979．P103—107
[11]J. H. Bennewitz, Joint International Conference on Creep, Session 5, 1963,p.81
[12]孔庆平，关于高温蠕变和持久强度的外推方法，技术通讯(金属材料高温强度专辑)，东方锅炉厂，1977．No 6．
[13]上海锅炉厂，上海汽轮机厂，上海材料研究所，高温持久强度外推法评述及电子计算机的应用，技术通讯(金属材料高温强度专辑)，东方锅炉厂，1977．No 6．
[14]田文莉编译，火力发电设备剩余寿命评价技术，电力情报，1994．1
[15]王胜纯，锅炉高温过热器的失效和寿命评估，华北电力技术，1998．1，P50—54
[16]周克毅，国外电站性能检测与诊断情况，动力工程，1992．2
[17]欧阳杰、李金峰、牛晓光等，老化的102钢高温再热器管寿命评估，全国第五界电站金属构件失效分析与寿命管理学术会议论文集，1997，P429—435
[18]朱日彰，金属腐蚀学，冶金工业出版社，1989．P6—47
[19]R.D.Townsend. The CEGB Approach to Residual Life and Plant Life Extension. Materials Forum, Vol.9, No1.1986. P46-48.
[17]欧阳杰、李金峰、牛晓光等，老化的102钢高温再热器管寿命评估，全
国第五界电站金属构件失效分析与寿命管理学术会议论文集，1997，P429—435
[20]川本和夫等。诊断汽轮机剩余寿命的MACNNDE系统．三菱重工技报．1987：24(5)：441—444
[21]A.K.Ray, Y.N.Tiwari. Rwsidual Life Prediction of Service Exposed Main Steam Pipe of Boilers in a Thermal Power Plant, Engineering Failuer Analysis,2000.7:359-376
[22]杨迪、李福欣，显微硬度试验，中国计量出版社，(1988)，P124—129。
[23]程卫国、冯峰、姚东等，MATLAB5.3应用指南，人民邮电出版社，1999．P206—213。
[24]李益民、束国刚、梁昌乾等12CrlMoV钢蠕变寿命研究的θ法，全国第五界电站金属构件失效分析与寿命管理学术会议论文集，1997，P30—44．
[25]ASME Boiler and Pressure Vessel Conde Section 1& Section 3,1977
[26]王致祥、梁志钊、孙国模等，管道应力分析与计算，水利电力出版社，(1983)，P65—67
[27]George H harth, Assess the remaining life of hign-temperature boiler parts,Power, 1985.8
[28]Klok. J. VGB-Conf, Residual Life Assessment, Mannheim, 1992
[29]N. K. Mukhopadhyay, S.G. Chowdhury Remaining Life Estimation of a service Exposed Economizer Tube, Engineering Failure Analysis,1996.6:233-243
[30]束国刚、李益民等，应用θ法外推主蒸汽管道蠕变寿命研究，热力发电，2000(5)
[31]束国刚、李益民、梁昌乾等，10CrMo910钢薄壁主汽管θ法寿命评估及其应用研究，热力发电，2000(4)，P36—41
[32]李金峰、欧阳杰、牛晓光等，102钢高温再热器材质变化规律及寿命研究，河北电力技术，Vol 18，1991．1，P48—50
[33]机电王程金属材料手册，上海科学技术出版社，1990，P420—427
[34]李自力、陈永保，借助实际载荷谱及由此确定的运行寿命损耗预测“薄壁”主蒸汽管道的剩余寿命，全国第五界电站金属构件失效分析与寿命管理学术会议论文集，1997，P6—12．
[35]Kenjiro Komai, Failure Analysis and Prevention in SCC and Corrosion Fatigue Cases, Int. J. Fatigue, Vol.20. No.2 1998.2:145-154
[36]T.Sokolowski, K.Gerke, Evaluation of tube formability and material characteristics:hydraulic bulge testing of tubes, Journal of Materials Processing Technology Vol.98.2000:34-40
[37]李耀君、刘树涛，12CrlMoV钢碳化物粗化动力学研究，热力发电，3，(1993)，P21—24。
[38]潘家祯，压力容器材料使用手册——碳钢及合金钢，化学工业出版社，2000．P344—346