660MW超超临界汽轮机转子热应力有限元计算与寿命研究
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摘要
随着国民经济的发展,我国用户用电量的不断增加,目前承担尖峰负荷的中小机组比例却越来越少,越来越多的大型汽轮机组需要参与调峰。频繁的启停、变负荷等非稳态工况运行,会使汽轮机转子温度变化增大,产生较大的温度梯度,从而产生较大的交变热应力,导致部件产生低周疲劳损耗；同时转子在恒定高温下长期运行,转子材料会发生蠕变现象,使其导致高温蠕变损耗；低周疲劳与高温蠕变的交互作用使转子产生裂纹,其逐渐扩展会导致转子断裂,这将严重影响机组运行的安全性。因此深入研究机组转子寿命损耗对确保电站设备的安全、经济运行具有重要意义。
本论文第一部分介绍了选题的背景、意义以及国内外的研究现状；第二部分描述了一维递推算法和有限元算法的理论基础；第三部分以某电厂660MW超超临界汽轮机转子为研究对象,利用ansys软件对其进行模型的建立、网格的划分、边界条件的设定；第四部分模拟计算了机组冷态启动、温态启动、热态启动、正常停机的温度场、合成应力场,以及稳定运行时的等效蠕变应力场,利用非对称循环法、持久强度曲线计算了危险部位的致裂低周疲劳寿命损耗和致裂高温蠕变寿命损耗,在此基础上计算汽轮机高中压转子在蠕变和低周疲劳交互作用下一年的总裂纹萌生寿命损耗,并给出汽轮机安全、经济运行的建议。
With the development of our country's economy, the users of electricity consumption are increasing while a number of small and medium-sized unit is being out of service, more and more large steam turbine units are running on peak load. With frequent starting and stopping or variable load non-steady-state operating, temperature of steam turbine rotor will change sharply, which leads to a large temperature gradient and then produces larger alternating thermal stress, thus results to low cycle fatigue loss. At the same time, rotor runs in constant high temperature for a long term, materials creep phenomena will occur. So that it causes loss of high temperature creep. The interaction of Low-cycle fatigue and creep make rotor crack. Gradually extended cracks will make rotor fracture and will seriously affect security running of unit. So it is greatly significant for safe and economical operation of power plant equipment to in-depth study on the life loss of unit.
The first part of this paper described the background, significance of subject, and the research status of domestic and foreign countries. The second part described the theoretical basis of a dimensional recursive methods and finite element algorithm. The third part made a660MW unit's ultra-supercritical steam turbine rotors to be research object, using ANSYS software to established model, mesh and set boundary condition. The forth part used simulation to calculate the temperature field and stress field of the cold start-up, warm start-up, hot start-up and normal stop, and calculated the equivalent creep stress field of stable operation. Besides the paper used unsymmetrical cycled method and lasting strength curves to calculate dangerous section's loss of low cycle fatigue and high temperature creep, and then calculated the total loss of high and medium pressure steam turbine rotor in a year time under the interaction of creep and low cycle fatigue. At last it gave suggestions of steam turbine safe and economic operation.
本论文第一部分介绍了选题的背景、意义以及国内外的研究现状；第二部分描述了一维递推算法和有限元算法的理论基础；第三部分以某电厂660MW超超临界汽轮机转子为研究对象,利用ansys软件对其进行模型的建立、网格的划分、边界条件的设定；第四部分模拟计算了机组冷态启动、温态启动、热态启动、正常停机的温度场、合成应力场,以及稳定运行时的等效蠕变应力场,利用非对称循环法、持久强度曲线计算了危险部位的致裂低周疲劳寿命损耗和致裂高温蠕变寿命损耗,在此基础上计算汽轮机高中压转子在蠕变和低周疲劳交互作用下一年的总裂纹萌生寿命损耗,并给出汽轮机安全、经济运行的建议。
With the development of our country's economy, the users of electricity consumption are increasing while a number of small and medium-sized unit is being out of service, more and more large steam turbine units are running on peak load. With frequent starting and stopping or variable load non-steady-state operating, temperature of steam turbine rotor will change sharply, which leads to a large temperature gradient and then produces larger alternating thermal stress, thus results to low cycle fatigue loss. At the same time, rotor runs in constant high temperature for a long term, materials creep phenomena will occur. So that it causes loss of high temperature creep. The interaction of Low-cycle fatigue and creep make rotor crack. Gradually extended cracks will make rotor fracture and will seriously affect security running of unit. So it is greatly significant for safe and economical operation of power plant equipment to in-depth study on the life loss of unit.
The first part of this paper described the background, significance of subject, and the research status of domestic and foreign countries. The second part described the theoretical basis of a dimensional recursive methods and finite element algorithm. The third part made a660MW unit's ultra-supercritical steam turbine rotors to be research object, using ANSYS software to established model, mesh and set boundary condition. The forth part used simulation to calculate the temperature field and stress field of the cold start-up, warm start-up, hot start-up and normal stop, and calculated the equivalent creep stress field of stable operation. Besides the paper used unsymmetrical cycled method and lasting strength curves to calculate dangerous section's loss of low cycle fatigue and high temperature creep, and then calculated the total loss of high and medium pressure steam turbine rotor in a year time under the interaction of creep and low cycle fatigue. At last it gave suggestions of steam turbine safe and economic operation.
引文
[1]张保衡.大容量火电机组寿命管理与调峰运行[M].北京：水利电力出版社,1988
[2]黄其励.火力发电可持续发展新技术[J].中国电力,2002,35(1)：8-12
[3]Fujikawa T. Advanced technology of steam turbine and boiler for 100-Owm high temperature power plant [M]. Dec.1999
[4]黄竹青.发展调峰机组和大机组调峰的若干问题[J].长沙电力学院学报(自然科学版),1997,12(2)：196-200
[5]Jianping Jing, Yi Sun. A Continuum Damage Mechanics Model on Low Cyele Fatigue Life Assessment of steam Turbine rotor [J]. international journal of pressure vessel sand piping,2001,78(1):59-64
[6]T. T. shih. G. A. Clark. Effeets of Temperature and Frequency on the Fatigue Crack Growth Rate Properties of a 1950 Vintage Cr Mo V rotor Material [J], ASTM STP677,1979:125-143
[7]安骏.600MW机组汽轮机的寿命管理研究[J].华东电力,2005,33(7)：64-67
[8]徐灏.疲劳强度[M].北京：高等教育出版社,1988
[9]Viswanathan R. Damage Mechanisms and Life Assessment of High temperature Components [M]. ASM International:Carnes publication services,1989
[10]韩中合,田松峰,马晓芳.火电厂汽机设备及运行[M].北京：中国电力出版社,2002
[11]黄仙,倪维斗.汽轮机转子热应力的“复频率”建模研究[J].动力工程学报,1995,15(6)：6-11
[12]R. Viswanathan. Damage Mechanism sand life assessment of High-Temperature Componets[J]. ASMInternational,1989:18-22
[13]Lemaitre J, Chaboehe J L. Mechanics of Solid Materials[M]. Cambridge: Cambridge University Press,1998
[14]孙奉仲.大型汽轮机运行[M].北京：中国电力出版社,2005
[15]刘静静,杨昆.汽轮机转子热应力在线监测的递推算法[J].现代电力,2000,17(1)：1-5
[16]刘静静.元宝山600MW汽轮机组热应力控制系统的设计[D].北京：华北电力大学(北京),1997
[17]Kakac S, Yener Y. Heat conduction.2nd ed. [M]. Washington:Hemisphere Publishing corporation,1986
[18]张亚欧,谷志飞,宋勇.ANSYS7.0有限元分析实用教程[M].北京：清华大学出版社,2004
[19]莫维尼ANSYS理论与应用[M].北京：电子工业出版社,2008
[20]杨世铭,陶文铨.传热学[M].北京：高等教育出版社,1998
[21]王新敏.结构分析单元与应用[M].北京：人民交通出版社,2011
[22]Grigullu, SandnerH. Heat conduction[M]. Washington:Hemisphere Publishing corporation-1984
[23]刘相新,孟宪颐.基础与应用教程[M].北京：科学出版社,2006
[24]史进渊,杨宇等.大型汽轮机部件低周疲劳安全寿命的设计和评定[J].应用力学学报,2004,21(3)：153-156
[25]胡先约.汽轮机寿命管理与调峰中的若干问题[J].动力工程,1985(1)：1-13
[26]穆霞英.蠕变力学[M].西安：西安交通大学出版社,1990
[27]J. Betten. Creep Mechanics[M]. Berlin:Springer-Verlag GMBH&Co,2005
[28]任浩仁,盛德仁,任容,等.600MW机组中压缸启动过程的优化研究[J].动力工程,2002,22(5)：1954-1958
[29]楼晓阳,盛德仁,陈坚红,等.135MW汽轮机无中心孔转子热应力有限元计算及低周疲劳寿命分析[J].浙江电力,2007(2)：10-14
[30]邬文睿.超超临界汽轮机转子高温强度研究[D].上海：上海交通大学,2009
[31]武新坐,宋春汀,张新江,等.汽轮机转子热应力简化计算公式的选取[J].汽轮机技术,2000,42(1)：20-23
[32]白云,杨继明,陈荐,等.调级根部弹性槽深度对转子热应力的影响[J].热力发电,2010,39(3)：36-39
[33]黄保海,李维特.汽轮机转子换热系数的计算分析[J].电站系统工程,1999,15(4)：12-15
[34]袁鹏飞,盛德仁,陈坚红,等.汽轮机转子热疲劳寿命损耗监测面的有限元分析[J].电站系统工程,2004,(3)：32-35
[35]袁利军.300MW机组中压缸启动热应力计算与启动优化[D].华北电力大学,2005：12-25
[36]Jurgen Schemmel, Beschreibung des Verformungs. Festigkeits-und Versagensverhaltensvon Komponenten im Kriechbereich unter instation rer Beanspruchung mit einemelastisch-viskoplastischen Werkstoffmodell [D].Stuttgart:Universit t Stuttgart,2003
[37]史进渊,杨宇,邓志成,等.大功率电站汽轮机寿命预测与可靠性设计[M].北 京：中国电力出版社,2011
[38]刘靖,韩静涛,李欣.超(超)临界转子用钢12Cr钢高温力学性能研究[A].第七届中国钢铁年会大会论文集(中),2009：466-471
[39]Markus Rauch. Entwicklung eines Lebensdauerkonzeptes fur Schaufel-Welle-Verbindungen station rer Turbinenaus Nickel basis-und 10%-Chromlegierungen [D]. Stuttgart:Universitt Stuttgart,2006
[40]G. Merckling. Long-term Creep Rupture Strength Assessment:Development of theEuropean Collaborative Creep Committee Post-assessment Tests [J]. Pressure Vesselsand Piping,2008,2(13):2-12
[41]史进渊,孙庆,杨宇,等.大型汽轮机部件蠕变寿命的设计和评估[J].中国电机工程学报,2002,22(3)：103-107
[2]黄其励.火力发电可持续发展新技术[J].中国电力,2002,35(1)：8-12
[3]Fujikawa T. Advanced technology of steam turbine and boiler for 100-Owm high temperature power plant [M]. Dec.1999
[4]黄竹青.发展调峰机组和大机组调峰的若干问题[J].长沙电力学院学报(自然科学版),1997,12(2)：196-200
[5]Jianping Jing, Yi Sun. A Continuum Damage Mechanics Model on Low Cyele Fatigue Life Assessment of steam Turbine rotor [J]. international journal of pressure vessel sand piping,2001,78(1):59-64
[6]T. T. shih. G. A. Clark. Effeets of Temperature and Frequency on the Fatigue Crack Growth Rate Properties of a 1950 Vintage Cr Mo V rotor Material [J], ASTM STP677,1979:125-143
[7]安骏.600MW机组汽轮机的寿命管理研究[J].华东电力,2005,33(7)：64-67
[8]徐灏.疲劳强度[M].北京：高等教育出版社,1988
[9]Viswanathan R. Damage Mechanisms and Life Assessment of High temperature Components [M]. ASM International:Carnes publication services,1989
[10]韩中合,田松峰,马晓芳.火电厂汽机设备及运行[M].北京：中国电力出版社,2002
[11]黄仙,倪维斗.汽轮机转子热应力的“复频率”建模研究[J].动力工程学报,1995,15(6)：6-11
[12]R. Viswanathan. Damage Mechanism sand life assessment of High-Temperature Componets[J]. ASMInternational,1989:18-22
[13]Lemaitre J, Chaboehe J L. Mechanics of Solid Materials[M]. Cambridge: Cambridge University Press,1998
[14]孙奉仲.大型汽轮机运行[M].北京：中国电力出版社,2005
[15]刘静静,杨昆.汽轮机转子热应力在线监测的递推算法[J].现代电力,2000,17(1)：1-5
[16]刘静静.元宝山600MW汽轮机组热应力控制系统的设计[D].北京：华北电力大学(北京),1997
[17]Kakac S, Yener Y. Heat conduction.2nd ed. [M]. Washington:Hemisphere Publishing corporation,1986
[18]张亚欧,谷志飞,宋勇.ANSYS7.0有限元分析实用教程[M].北京：清华大学出版社,2004
[19]莫维尼ANSYS理论与应用[M].北京：电子工业出版社,2008
[20]杨世铭,陶文铨.传热学[M].北京：高等教育出版社,1998
[21]王新敏.结构分析单元与应用[M].北京：人民交通出版社,2011
[22]Grigullu, SandnerH. Heat conduction[M]. Washington:Hemisphere Publishing corporation-1984
[23]刘相新,孟宪颐.基础与应用教程[M].北京：科学出版社,2006
[24]史进渊,杨宇等.大型汽轮机部件低周疲劳安全寿命的设计和评定[J].应用力学学报,2004,21(3)：153-156
[25]胡先约.汽轮机寿命管理与调峰中的若干问题[J].动力工程,1985(1)：1-13
[26]穆霞英.蠕变力学[M].西安：西安交通大学出版社,1990
[27]J. Betten. Creep Mechanics[M]. Berlin:Springer-Verlag GMBH&Co,2005
[28]任浩仁,盛德仁,任容,等.600MW机组中压缸启动过程的优化研究[J].动力工程,2002,22(5)：1954-1958
[29]楼晓阳,盛德仁,陈坚红,等.135MW汽轮机无中心孔转子热应力有限元计算及低周疲劳寿命分析[J].浙江电力,2007(2)：10-14
[30]邬文睿.超超临界汽轮机转子高温强度研究[D].上海：上海交通大学,2009
[31]武新坐,宋春汀,张新江,等.汽轮机转子热应力简化计算公式的选取[J].汽轮机技术,2000,42(1)：20-23
[32]白云,杨继明,陈荐,等.调级根部弹性槽深度对转子热应力的影响[J].热力发电,2010,39(3)：36-39
[33]黄保海,李维特.汽轮机转子换热系数的计算分析[J].电站系统工程,1999,15(4)：12-15
[34]袁鹏飞,盛德仁,陈坚红,等.汽轮机转子热疲劳寿命损耗监测面的有限元分析[J].电站系统工程,2004,(3)：32-35
[35]袁利军.300MW机组中压缸启动热应力计算与启动优化[D].华北电力大学,2005：12-25
[36]Jurgen Schemmel, Beschreibung des Verformungs. Festigkeits-und Versagensverhaltensvon Komponenten im Kriechbereich unter instation rer Beanspruchung mit einemelastisch-viskoplastischen Werkstoffmodell [D].Stuttgart:Universit t Stuttgart,2003
[37]史进渊,杨宇,邓志成,等.大功率电站汽轮机寿命预测与可靠性设计[M].北 京：中国电力出版社,2011
[38]刘靖,韩静涛,李欣.超(超)临界转子用钢12Cr钢高温力学性能研究[A].第七届中国钢铁年会大会论文集(中),2009：466-471
[39]Markus Rauch. Entwicklung eines Lebensdauerkonzeptes fur Schaufel-Welle-Verbindungen station rer Turbinenaus Nickel basis-und 10%-Chromlegierungen [D]. Stuttgart:Universitt Stuttgart,2006
[40]G. Merckling. Long-term Creep Rupture Strength Assessment:Development of theEuropean Collaborative Creep Committee Post-assessment Tests [J]. Pressure Vesselsand Piping,2008,2(13):2-12
[41]史进渊,孙庆,杨宇,等.大型汽轮机部件蠕变寿命的设计和评估[J].中国电机工程学报,2002,22(3)：103-107