大型石灰石—石膏湿法烟气脱硫系统可靠性研究
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摘要
我国燃煤电厂烟气脱硫系统(FGD)处于大规模的建设和运行初期,脱硫系统的运行状态已经成为发电企业上网脱硫电价考核的依据,烟气脱硫系统的可靠性差,难以满足电厂安全、可靠、经济、高效的要求。国内FGD可靠性方面的研究开展较少,主要以脱硫效率和投运率来度量FGD的可靠性。本文从可靠性评价、影响因素分析和维修策略优化等几个方面对烟气脱硫系统的可靠性进行研究,研究成果如下:
根据脱硫系统特性,结合有关系统运行考核指标要求,划分系统可靠性状态,建立了脱硫系统可靠性评价体系。提出了统计FGD运行工况和评价可靠性水平的特征指标;给出了可用系数(AF)等可靠性特征量真值的点估计和区间估计方法。定义检修系数为可靠性特征量以建立脱硫系统可靠性增长模型,利用该模型描述脱硫系统可靠性增长状态;烟气脱硫设施建设完成或技术改造后,需对设施的可靠性状态进行验收验证,论文给出了可靠性特征量的定时截尾验证方案,并进行了可靠性实例验证。
在综合分析了系统设计、工艺条件、设备健康状态、运行控制、副产品处置对FGD系统可靠性影响的基础上,探讨了影响脱硫烟道、增压风机、烟道风门挡板、气-气换热器、浆液循环泵、吸收塔、石灰石制备系统、石膏脱水系统等主设备健康状态的因素,研究结果表明腐蚀、结垢、磨损、堵塞、积灰、泄漏等是影响主设备可靠性的主要原因,提出通过改善工艺条件、优化运行控制、加强维护检修以提高主设备可靠性的综合措施。
以2×600MW湿法FGD运行可靠性为研究对象,分析了已建成脱硫系统的运行可靠性。构建了运行可靠性功能框图;建立了系统运行可靠性模型;将投运率(SR)设为系统运行可靠性中可靠度的特征量,采用预计故障率分配法分配总的可靠性指标,进行了实例计算;提出了各子系统中可靠性指标的分配方法;划分该运行可靠性模型为系统、子系统、设备、部件四个层次;对构成部件进行了故障模式、影响及危害度分析;确立了影响运行可靠性的关键设备部件及故障模式,为系统优化提供了依据。
综合设备及部件所处环境的介质性质、干湿状态、温度、磨损、侵蚀性离子等情况,为采取针对性的防护措施,进行了腐蚀、磨损状态区域划分。对FGD防腐材料的失效机理进行了探讨,将有关损伤容限理论引入到玻璃鳞片防腐层的评价中,对在役玻璃鳞片防腐层失效损伤进行了阶段划分,定义了每个阶段的失效特征和处理措施,为玻璃鳞片防腐层的施工、检查、检修维护提供了依据。建立了纤维增强塑料(FRP)构件老化过程的可靠度及使用寿命的计算模型。从设计、运行监控和检修维护三方面分析了FGD的结垢原因,针对系统中最易发生结垢的设备和部件,提出了相应的综合防垢措施。
将以可靠性为中心的维修引入到FGD的维修策略优化中,设计了湿法FGD系统维修策略优化流程,采用定性的方法分析了烟气脱硫系统故障发生概率,采用系统的观点评估了故障后果危害程度等级,建立了FGD风险评价矩阵,根据风险评价的结果实现对设备的分类和定修。
The flue-gas desulphurization (FGD) system in coal-fired power plants is in the initial period of large-scale construction and operation in China. Strict monitoring began to be conducted over the operating status of the desulphurization system, which has already become an evidence of assessment on the onto-grid electricity prices for FGD equipment in power plants. It is very hard for the enterprise to reach the requirements of power plant on security, reliability, economization and high efficiency due to poor reliability of desulphurization system. At present, few researches are developed on the reliability of FGD. Most of thermal power plants have measured FGD reliabilities mainly in accordance with the desulphurization efficiency and the service rate. The article has dealt with the reliability of flue-gas desulphurization system from these aspects including the assessment of reliability, analysis of factors and Optimization of maintainment.
The evaluation system for the reliability of FGD system is established in accordance with the feature of desulphurization system and the requirements of operating verification index. Firstly, it is necessary to make reasonable division on the status of FGD reliability; secondly, to proposed 12 characteristic; finally, Procedure for point estimates and confidence intervals of 5 characteristic is provided. The maintenance factor is given to describe the status of reliability so as to set up the model of FGD reliability growth. After the flue-gas desulphurization facilities have been constructed, the acceptance inspection and compliance test are required to be done on the reliability status of the facilities. The total time for acceptance inspection and the appraisal evidences shall be determined for reliability characteristic qualities. A project of verification test shows the effectiveness of the proposed method in the article.
In the article, detail analyses are made on the factors which may affect the health conditions of main equipments including desulphurization flue, booster fan, flue damper, flue gas heat exchanger, circulation slurry pump, absorption tower, limestone preparing system and plaster dehydrating system. Corrosion, scaling, wear, clogging, fouling and leaks are thought to be main reasons which may affect the reliability of main equipment. Comprehensive measures have been provided to improve the reliability of main equipment through the enhancement of process conditions, the control of optimum operation and the increase of maintenance and repairing.
Taking the reliability of 2×600MW wet-process FGD operation as research object, its operational reliability is researched with the tool of reliability design technology. The reliability block diagram of the system is drawn; reliability model is established according to the logic and relationships of the subsystems; fix the service rate (SR) as the characteristic quantity of reliability in the system operational reliability; allocate total reliability indexes by using estimated failure rate allocation method and calculate the examples; divide the operational reliability model into four levels such as system, subsystem, equipment and parts; make failure mode, effects and criticality analysis (FMECA) on those parts; establish key equipment parts which may affect operational reliability of the system and its failure mode so as to supply analysis evidence for the optimization of the system.
In accordance to media property of the environment to which main equipment and equipment parts attribute, dry/wet state, temperature, wear and the corrosive ion concentration, it is divided into strong corrosive division, weak corrosive division, non-corrosive division, strong wear division and weak wear division. The failure mechanism of anticorrosive material used in FGD installations is approached. By introducing relevant theories related to damage tolerance into the evaluation of glass-flake coatings, put forward the evaluation test method on damage tolerance of glass-flake coatings, formulate the steps of damage tolerance evaluation and enact the evaluation test standard on damage tolerance of glass-flake coatings. The damage failure period of anti-corrosive glass-flake coatings is divided into four stages, stipulating the failure features of every stage and treatment measures with strong operation. Aiming at more use of fiber reinforce plastic (FRP) structural components in FGD system and the failure to judge its aging in the course of use, the reliability of aging course for FRP structural components and the model for service life calculation are seted up.
Reliability centered maintenance (RCM) is introduced into the maintenance and inspection of FGD system. The optimization procedure of maintenance strategy is designed. In the course of the implementation of maintenance strategy optimization, the norms to evaluate the probability of failure occurrence in FGD system has been formulated by virtue of qualitative method. The influence of the failure upon the equipment itself and the whole system is estimated by taking the systematic view. The matrix of FGD risk evaluation is established, and the classification of equipment and regular maintenance in accordance with the result of risk evaluation is realized
根据脱硫系统特性,结合有关系统运行考核指标要求,划分系统可靠性状态,建立了脱硫系统可靠性评价体系。提出了统计FGD运行工况和评价可靠性水平的特征指标;给出了可用系数(AF)等可靠性特征量真值的点估计和区间估计方法。定义检修系数为可靠性特征量以建立脱硫系统可靠性增长模型,利用该模型描述脱硫系统可靠性增长状态;烟气脱硫设施建设完成或技术改造后,需对设施的可靠性状态进行验收验证,论文给出了可靠性特征量的定时截尾验证方案,并进行了可靠性实例验证。
在综合分析了系统设计、工艺条件、设备健康状态、运行控制、副产品处置对FGD系统可靠性影响的基础上,探讨了影响脱硫烟道、增压风机、烟道风门挡板、气-气换热器、浆液循环泵、吸收塔、石灰石制备系统、石膏脱水系统等主设备健康状态的因素,研究结果表明腐蚀、结垢、磨损、堵塞、积灰、泄漏等是影响主设备可靠性的主要原因,提出通过改善工艺条件、优化运行控制、加强维护检修以提高主设备可靠性的综合措施。
以2×600MW湿法FGD运行可靠性为研究对象,分析了已建成脱硫系统的运行可靠性。构建了运行可靠性功能框图;建立了系统运行可靠性模型;将投运率(SR)设为系统运行可靠性中可靠度的特征量,采用预计故障率分配法分配总的可靠性指标,进行了实例计算;提出了各子系统中可靠性指标的分配方法;划分该运行可靠性模型为系统、子系统、设备、部件四个层次;对构成部件进行了故障模式、影响及危害度分析;确立了影响运行可靠性的关键设备部件及故障模式,为系统优化提供了依据。
综合设备及部件所处环境的介质性质、干湿状态、温度、磨损、侵蚀性离子等情况,为采取针对性的防护措施,进行了腐蚀、磨损状态区域划分。对FGD防腐材料的失效机理进行了探讨,将有关损伤容限理论引入到玻璃鳞片防腐层的评价中,对在役玻璃鳞片防腐层失效损伤进行了阶段划分,定义了每个阶段的失效特征和处理措施,为玻璃鳞片防腐层的施工、检查、检修维护提供了依据。建立了纤维增强塑料(FRP)构件老化过程的可靠度及使用寿命的计算模型。从设计、运行监控和检修维护三方面分析了FGD的结垢原因,针对系统中最易发生结垢的设备和部件,提出了相应的综合防垢措施。
将以可靠性为中心的维修引入到FGD的维修策略优化中,设计了湿法FGD系统维修策略优化流程,采用定性的方法分析了烟气脱硫系统故障发生概率,采用系统的观点评估了故障后果危害程度等级,建立了FGD风险评价矩阵,根据风险评价的结果实现对设备的分类和定修。
The flue-gas desulphurization (FGD) system in coal-fired power plants is in the initial period of large-scale construction and operation in China. Strict monitoring began to be conducted over the operating status of the desulphurization system, which has already become an evidence of assessment on the onto-grid electricity prices for FGD equipment in power plants. It is very hard for the enterprise to reach the requirements of power plant on security, reliability, economization and high efficiency due to poor reliability of desulphurization system. At present, few researches are developed on the reliability of FGD. Most of thermal power plants have measured FGD reliabilities mainly in accordance with the desulphurization efficiency and the service rate. The article has dealt with the reliability of flue-gas desulphurization system from these aspects including the assessment of reliability, analysis of factors and Optimization of maintainment.
The evaluation system for the reliability of FGD system is established in accordance with the feature of desulphurization system and the requirements of operating verification index. Firstly, it is necessary to make reasonable division on the status of FGD reliability; secondly, to proposed 12 characteristic; finally, Procedure for point estimates and confidence intervals of 5 characteristic is provided. The maintenance factor is given to describe the status of reliability so as to set up the model of FGD reliability growth. After the flue-gas desulphurization facilities have been constructed, the acceptance inspection and compliance test are required to be done on the reliability status of the facilities. The total time for acceptance inspection and the appraisal evidences shall be determined for reliability characteristic qualities. A project of verification test shows the effectiveness of the proposed method in the article.
In the article, detail analyses are made on the factors which may affect the health conditions of main equipments including desulphurization flue, booster fan, flue damper, flue gas heat exchanger, circulation slurry pump, absorption tower, limestone preparing system and plaster dehydrating system. Corrosion, scaling, wear, clogging, fouling and leaks are thought to be main reasons which may affect the reliability of main equipment. Comprehensive measures have been provided to improve the reliability of main equipment through the enhancement of process conditions, the control of optimum operation and the increase of maintenance and repairing.
Taking the reliability of 2×600MW wet-process FGD operation as research object, its operational reliability is researched with the tool of reliability design technology. The reliability block diagram of the system is drawn; reliability model is established according to the logic and relationships of the subsystems; fix the service rate (SR) as the characteristic quantity of reliability in the system operational reliability; allocate total reliability indexes by using estimated failure rate allocation method and calculate the examples; divide the operational reliability model into four levels such as system, subsystem, equipment and parts; make failure mode, effects and criticality analysis (FMECA) on those parts; establish key equipment parts which may affect operational reliability of the system and its failure mode so as to supply analysis evidence for the optimization of the system.
In accordance to media property of the environment to which main equipment and equipment parts attribute, dry/wet state, temperature, wear and the corrosive ion concentration, it is divided into strong corrosive division, weak corrosive division, non-corrosive division, strong wear division and weak wear division. The failure mechanism of anticorrosive material used in FGD installations is approached. By introducing relevant theories related to damage tolerance into the evaluation of glass-flake coatings, put forward the evaluation test method on damage tolerance of glass-flake coatings, formulate the steps of damage tolerance evaluation and enact the evaluation test standard on damage tolerance of glass-flake coatings. The damage failure period of anti-corrosive glass-flake coatings is divided into four stages, stipulating the failure features of every stage and treatment measures with strong operation. Aiming at more use of fiber reinforce plastic (FRP) structural components in FGD system and the failure to judge its aging in the course of use, the reliability of aging course for FRP structural components and the model for service life calculation are seted up.
Reliability centered maintenance (RCM) is introduced into the maintenance and inspection of FGD system. The optimization procedure of maintenance strategy is designed. In the course of the implementation of maintenance strategy optimization, the norms to evaluate the probability of failure occurrence in FGD system has been formulated by virtue of qualitative method. The influence of the failure upon the equipment itself and the whole system is estimated by taking the systematic view. The matrix of FGD risk evaluation is established, and the classification of equipment and regular maintenance in accordance with the result of risk evaluation is realized
引文
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