液化石油气铁道罐车失效分析及应力腐蚀控制
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摘要
近年来,液化石油气在工业和人民生活中得到日益广泛的应用,储运液化石油气的液化石油气铁道罐车不断增加。随着我国石化企业逐年增加进口高含硫原油的加工,致使液化石油气所含硫化氢腐蚀介质的增加,对储运设备造成腐蚀及应力腐蚀日益严重的现象,引起了人们的重视和关注。
本文通过对液化石油气铁道罐车结构及受力分析、说明它的失效形式主要是腐蚀和腐蚀疲劳,引起失效的主要因素是腐蚀;通过对罐体出现裂纹及鼓泡现象的分析,提出液化石油气铁道罐车腐蚀主要形式是湿H_2S环境引起的材料应力腐蚀开裂(SSCC)和氢鼓泡(HB),对液化石油气铁道罐车影响最大的腐蚀是湿的H_2S环境引起的材料应力腐蚀开裂,通过对液化石油气铁道罐车湿的硫化氢应力腐蚀的机理、特征进一步分析,提出了焊接残余应力、硫化氢浓度、环境温度、材料因素和设计结构是影响应力腐蚀的主要因素;提出防护和控制液化石油气铁道罐车的应力腐蚀应从设计、制造及使用管理等三个方面着手。设计方面选材应合理,避免结构的应力集中;制造方面应严格控制所用材料的质量,制定成熟合理的焊接工艺,减小焊接残余应力,严格控制制造质量;使用管理方面应控制硫化氢浓度,降低介质的腐蚀性,加强维护管理。为设计、制造及使用管理等三方面提供了防护和控制液化石油气路罐车应力腐蚀的见解。
In recent years, LPG has been broadly used in industry and civil area which leads to continuous increasing of rail tank car transporting & storing LPG. The increase of processing imported high-sulfur crude oil year after year that results in the increase of erosion medium as sulfurated hydrogen which leads to increasing corrosion in storage equipments has drawn serious notice and much attention.Through explanation of LPG rail tank car structure and stress analyses and analyzing crack on the tank & bulb phenomenon, the paper states that stress corrosion on rail tank car mainly comes from stress corrosion crack occurred around the welding line on material in humid sulfurated hydrogen environment. The main form is HB and SSCC. Through further analyses of theory and characteristics in stress corrosion of Sulfurated hydrogen in LPG on tank body, the author presents main factors that affect stress corrosion such as remained welding stress, concentration of Sulfurated hydrogen, ambient temperature, material and designed structure and three aspects (design, manufacture, operation management) from which to resist and control corrosion stress. Material chosen in design should be reasonable to avoid stress concentration. Material quality control in manufacture should be strict and welding process should be feasible and reasonable to decrease remained welding stress. Controlling concentration of Sulfurated hydrogen, lessening causticity in medium in management should be strengthened. The author provides solutions for resisting and controlling stress corrosion on LPG rail tank car from design, manufacture and operation management.
本文通过对液化石油气铁道罐车结构及受力分析、说明它的失效形式主要是腐蚀和腐蚀疲劳,引起失效的主要因素是腐蚀;通过对罐体出现裂纹及鼓泡现象的分析,提出液化石油气铁道罐车腐蚀主要形式是湿H_2S环境引起的材料应力腐蚀开裂(SSCC)和氢鼓泡(HB),对液化石油气铁道罐车影响最大的腐蚀是湿的H_2S环境引起的材料应力腐蚀开裂,通过对液化石油气铁道罐车湿的硫化氢应力腐蚀的机理、特征进一步分析,提出了焊接残余应力、硫化氢浓度、环境温度、材料因素和设计结构是影响应力腐蚀的主要因素;提出防护和控制液化石油气铁道罐车的应力腐蚀应从设计、制造及使用管理等三个方面着手。设计方面选材应合理,避免结构的应力集中;制造方面应严格控制所用材料的质量,制定成熟合理的焊接工艺,减小焊接残余应力,严格控制制造质量;使用管理方面应控制硫化氢浓度,降低介质的腐蚀性,加强维护管理。为设计、制造及使用管理等三方面提供了防护和控制液化石油气路罐车应力腐蚀的见解。
In recent years, LPG has been broadly used in industry and civil area which leads to continuous increasing of rail tank car transporting & storing LPG. The increase of processing imported high-sulfur crude oil year after year that results in the increase of erosion medium as sulfurated hydrogen which leads to increasing corrosion in storage equipments has drawn serious notice and much attention.Through explanation of LPG rail tank car structure and stress analyses and analyzing crack on the tank & bulb phenomenon, the paper states that stress corrosion on rail tank car mainly comes from stress corrosion crack occurred around the welding line on material in humid sulfurated hydrogen environment. The main form is HB and SSCC. Through further analyses of theory and characteristics in stress corrosion of Sulfurated hydrogen in LPG on tank body, the author presents main factors that affect stress corrosion such as remained welding stress, concentration of Sulfurated hydrogen, ambient temperature, material and designed structure and three aspects (design, manufacture, operation management) from which to resist and control corrosion stress. Material chosen in design should be reasonable to avoid stress concentration. Material quality control in manufacture should be strict and welding process should be feasible and reasonable to decrease remained welding stress. Controlling concentration of Sulfurated hydrogen, lessening causticity in medium in management should be strengthened. The author provides solutions for resisting and controlling stress corrosion on LPG rail tank car from design, manufacture and operation management.
引文
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[2] 张志宇.化工腐蚀与防护[M].北京:化学工业出版社,2005.2
[3] 张兴军.在用压力容器常见的几种腐蚀及其检测方法.锅炉压力容器安全技术,2002.5
[4] 黄建中,左禹.材料的耐蚀性和腐蚀数据.北京:化学工业出版社,2003.1
[5] 孙秋霞.材料腐蚀与控制[M].北京:冶金工业出版社,2004.7:73-75
[6] 左景伊.应力腐蚀破裂[M].西安交通大学出版社,1985.6
[7] Parkins R N. Stress Corrosion Cracking-The Slow Strain Rate Technique[M]. Ed by Vgiansky, Payer, 1977.
[8] [加]R.温斯顿.里维(R.Winstion Revie).尤利格腐蚀手册.北京:化学工业出版社,2005.8
[9] 李建国.压力容器设计的力学基础及其标准应用[M].北京:机械工业出版社,2004.1
[10] 任凌波.任晓蕾.压力容器腐蚀与控制[M].北京:化学工业出版社,2003.8:209-220
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[14] 朱龙居.压力容器制造过程中应引起重视的几个问题.特种设备安全技术,2005,1
[15] 徐慧波等.压力容器简体纵缝埋弧焊终端裂纹的防止.压力容器,2005,7
[16] 霍立兴.焊接结构的断裂行为及评定[M].北京:机械工业出版社,2000.1
[17] 陈学东等.石化企业典型压力容器安全分析与延寿技术.第三界全国压 力容器使用管理技术会议.无锡,1999.9
[18] 于振海.管壳式换热器腐蚀原因分析.锅炉压力容器安全技术,2002.2
[19] 雍漫江,盛艳萍.400m~3氧气球罐焊缝缺陷的返修处理.锅炉压力容器安全技术,2002.3
[20] 卢志明等.水闪蒸罐筒体焊缝的裂纹成因分析.压力容器,1999.4
[21] 孔令全.热水饱和塔裂纹成因分析.压力容器,1999.4
[22] 阎长周.液化石油气贮罐氢致分层的超声检测.压力容器,2005.8
[23] 蒋俊.液化石油气球罐氢鼓泡缺陷成因分析与换片处理.特种设备安全技术,2005,5
[24] 任晓蕾,巴爱叶.压力容器钢板分层缺陷检测及处理.锅炉压力容器安全技术,2002.5
[25] 肖纪美.应力作用下的金属腐蚀[M].北京:化学工业出版社,1990.3
[26] 陈文汨等.低碳钢焊缝的应力腐蚀和酸腐蚀.腐蚀与防护,2002,2
[27] 顾卫东。WEL-TEN610CF钢应力腐蚀行为及防腐研究.压力容器,2005.5
[28] 古特曼.金石译.金属力学化学与腐蚀防护[M]北京:科学出版社,1989.
[29] 阎勇贵,吴建华,陈光章.原油储罐内底板的腐蚀防护现状与展望.腐蚀与防护,2002,5
[30] 李宁.焊缝余高及焊缝咬边对压力容器使用寿命的影响.特种设备安全技术,2005,6
[2] 张志宇.化工腐蚀与防护[M].北京:化学工业出版社,2005.2
[3] 张兴军.在用压力容器常见的几种腐蚀及其检测方法.锅炉压力容器安全技术,2002.5
[4] 黄建中,左禹.材料的耐蚀性和腐蚀数据.北京:化学工业出版社,2003.1
[5] 孙秋霞.材料腐蚀与控制[M].北京:冶金工业出版社,2004.7:73-75
[6] 左景伊.应力腐蚀破裂[M].西安交通大学出版社,1985.6
[7] Parkins R N. Stress Corrosion Cracking-The Slow Strain Rate Technique[M]. Ed by Vgiansky, Payer, 1977.
[8] [加]R.温斯顿.里维(R.Winstion Revie).尤利格腐蚀手册.北京:化学工业出版社,2005.8
[9] 李建国.压力容器设计的力学基础及其标准应用[M].北京:机械工业出版社,2004.1
[10] 任凌波.任晓蕾.压力容器腐蚀与控制[M].北京:化学工业出版社,2003.8:209-220
[11] 秦晓钟,腾明德等.世界压力容器用钢手册.北京:机械工业出版社,1995.10
[12] 秦晓钟,腾明德等.世界压力容器用钢手册.北京:机械工业出版社,1995.10
[13] 王宽福等.压力容器焊接结构工程分析[M].北京:化学工业出版社,1998.5
[14] 朱龙居.压力容器制造过程中应引起重视的几个问题.特种设备安全技术,2005,1
[15] 徐慧波等.压力容器简体纵缝埋弧焊终端裂纹的防止.压力容器,2005,7
[16] 霍立兴.焊接结构的断裂行为及评定[M].北京:机械工业出版社,2000.1
[17] 陈学东等.石化企业典型压力容器安全分析与延寿技术.第三界全国压 力容器使用管理技术会议.无锡,1999.9
[18] 于振海.管壳式换热器腐蚀原因分析.锅炉压力容器安全技术,2002.2
[19] 雍漫江,盛艳萍.400m~3氧气球罐焊缝缺陷的返修处理.锅炉压力容器安全技术,2002.3
[20] 卢志明等.水闪蒸罐筒体焊缝的裂纹成因分析.压力容器,1999.4
[21] 孔令全.热水饱和塔裂纹成因分析.压力容器,1999.4
[22] 阎长周.液化石油气贮罐氢致分层的超声检测.压力容器,2005.8
[23] 蒋俊.液化石油气球罐氢鼓泡缺陷成因分析与换片处理.特种设备安全技术,2005,5
[24] 任晓蕾,巴爱叶.压力容器钢板分层缺陷检测及处理.锅炉压力容器安全技术,2002.5
[25] 肖纪美.应力作用下的金属腐蚀[M].北京:化学工业出版社,1990.3
[26] 陈文汨等.低碳钢焊缝的应力腐蚀和酸腐蚀.腐蚀与防护,2002,2
[27] 顾卫东。WEL-TEN610CF钢应力腐蚀行为及防腐研究.压力容器,2005.5
[28] 古特曼.金石译.金属力学化学与腐蚀防护[M]北京:科学出版社,1989.
[29] 阎勇贵,吴建华,陈光章.原油储罐内底板的腐蚀防护现状与展望.腐蚀与防护,2002,5
[30] 李宁.焊缝余高及焊缝咬边对压力容器使用寿命的影响.特种设备安全技术,2005,6