CN112597642B - High Wen Jixiang state evaluation method based on metal inspection - Google Patents
High Wen Jixiang state evaluation method based on metal inspection Download PDFInfo
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Abstract
A high Wen Jixiang state evaluation method based on metal inspection comprises the following steps; 1) Explicitly evaluating the object and the basic information; 2) The specific stage of the whole life cycle of the object is clearly evaluated; 3) Calculating a state correction factor C S; 4) Defining detailed evaluation points; 5) Making a metal inspection scheme and implementing the scheme; 6) Obtaining a metal inspection result; 7) Evaluating point states; 8) And evaluating the state of the evaluation object. The invention can help technicians in the thermal power plant to better formulate the maintenance strategy.
Description
Technical Field
The invention relates to the technical field of state evaluation of high-temperature equipment of a thermal power plant, in particular to a high Wen Jixiang state evaluation method based on metal inspection.
Background
The high-temperature header is an important part of a boiler system of a thermal power plant, and in recent years, along with the change of external environment, various large-scale high-parameter thermal power generating units are forced to become peak shaving units, so that the high Wen Jixiang is in a worse working condition in the operation process and is more easily influenced by the action of heat alternating load. In particular to a header cylinder, which belongs to thick-wall equipment, has quite high temperature difference stress, wherein the temperature difference between the inner wall and the outer wall of the header cylinder is linearly distributed along the wall thickness, and the larger the thickness is, the larger the temperature difference is, and the larger the stress is. Since the height Wen Jixiang is located outside the boiler, there is a risk of significant personal safety and economic loss if a cylinder leak event occurs, and accurate assessment of the high Wen Jixiang condition is necessary.
For high Wen Jixiang, there have been reported stress and strength analyses such as stress and strength analyses of the outlet header of the high-temperature superheater of the steel of the document "SA 335-P91", hot working processes, 2016 (12) ", and fatigue-creep life analyses such as fatigue-creep life analyses of pressed parts based on European standard EN12952, university of Chongqing university (Nature sciences), 2016 (11)". Whether stress and strength analysis or fatigue-creep life analysis is performed, various conditions are required: the assessment personnel are required to have abundant metal material basic knowledge, mechanical calculation knowledge, service life assessment knowledge and experience; complete design data and design data need to be collected; complete operation history data needs to be collected; complete and comprehensive metal inspection related data needs to be collected; comprehensive laboratory analysis data of samples of the same material are required as a reference group, etc. These conditions determine that the development of stress and strength analysis, fatigue-creep life analysis, etc. techniques are limited to professional technical institutions and personnel, and that the collection of these basic data and data, complete and comprehensive metal inspection, and laboratory analysis can lead to increased plant overhaul costs and labor costs.
Therefore, a method with universality needs to be explored, and the state of the high Wen Jixiang can be evaluated by only obtaining the existing metal test data without having abundant metal material basic knowledge, mechanical calculation knowledge, service life evaluation knowledge and experience and having no need of bearing extra test cost, so that the thermal power plant technicians are directly helped to formulate a maintenance strategy.
Disclosure of Invention
In order to overcome the technical problems, the invention aims to provide a high Wen Jixiang state evaluation method based on metal inspection, which helps technicians in a thermal power plant to better formulate a maintenance strategy.
In order to achieve the above purpose, the technical scheme adopted by the invention and the beneficial effects of the invention are as follows:
A high Wen Jixiang state evaluation method based on metal inspection comprises the following steps;
1) The basic information of the high Wen Jixiang is defined by taking the high Wen Jixiang as an evaluation object;
2) Specific stages of the full life cycle in which Wen Jixiang is located are specified;
3) Calculating a state correction factor C S;
4) Defining detailed evaluation points;
5) Making a metal inspection scheme and implementing the scheme;
6) Obtaining a metal inspection result;
7) Evaluating point states;
8) And (5) evaluating the state of the high-temperature header.
The basic information in the step 1) comprises design drawings, design diameter, design wall thickness and design materials;
The specific operation steps of the step 2) are as follows:
Determining which of the early, mid, end and end stages of the full life cycle the high Wen Jixiang is in;
| All stages of the life cycle | Time ranges for each phase of the full life cycle |
| Early stage | (0,0.2Lc] |
| Mid-stage | (0.2Lc～0.7Lc] |
| End stage | (0.7Lc～0.9Lc] |
| End stage | (0.9Lc～Lc] |
Wherein L c is the design life, and generally defines 300000 unit operation hours.
The specific operation steps in the step 3) are as follows:
Determining a corresponding state correction factor C S based on the stage of the explicit evaluation object in the step 2);
| All stages of the life cycle | State factor C S |
| Early stage | 1+1c |
| Mid-stage | 1 |
| End stage | 1+2c |
| End stage | 1+5c |
Defining c as a correction factor, and according to the design and manufacturing data collected in the step 1), actually taking a value according to the following table.
| Several cases of correction factor c | Correction factor c takes value |
| No abnormality is found in the design and manufacturing stage | 0.01 |
| Few anomalies exist in the design and manufacture stage, but normal use is not affected | 0.02 |
| There are many anomalies in the design and manufacturing stage, and normal after repair | 0.05 |
The specific operation steps of the step 4) are as follows:
All evaluation points of the evaluation object are explicitly evaluated and classified into two main classes: the base material class evaluation point and the weld class evaluation point are distinguished by the subscripts bm and wd, respectively.
The specific operation steps of the step 5) are as follows:
Considering the maintenance plan, time and cost comprehensively, selecting and implementing a proper project-designated metal inspection scheme from macro inspection, coarse expansion inspection, spectrum inspection, wall thickness measurement, hardness inspection, oxide skin measurement, metallographic inspection and nondestructive inspection (comprising ultrasonic waves, magnetic powder, penetration and rays) aiming at all evaluation points determined in the step 1).
The specific operation steps of the step 6) are as follows:
According to the metal inspection items determined in the step 5), obtaining all metal inspection results of the evaluation points, classifying the state parameters into three categories according to the metal inspection results, and confirming the state parameters corresponding to all metal inspection items of all the evaluation points;
The specific operation steps of the step 7) are as follows:
performing state evaluation on the single evaluation point according to the metal inspection result obtained in the step 6), and defining the state of the single evaluation point as C j, wherein an evaluation model is shown in a formula (1);
if Max{CPqi-j,CPgi-j,CPmi-j}＝1,
else if Max{CPqi-j,CPgi-j,CPmi-j}≠1
Cj＝1
(1)
The result of the value of the state C j of the evaluation point normally falls in the range of the [0,1] interval, if the value of C j is 0, the state of the evaluation point is optimal, and when the value of C j changes from 0 to 1, the state of the evaluation point is worse;
The weights Q qi、Qgi and Q mi of the three state parameters in the formula (1) are valued to give the rule of the formula (2);
the specific operation steps in the step 8) are as follows:
counting all the evaluation points obtained in the step 7) according to the classification of base metal evaluation points and weld joint evaluation points, counting the number n of base metal evaluation points and the number m of weld joint evaluation points, and then carrying out overall evaluation of the state C on the evaluation object, wherein an evaluation model is shown in a formula (11);
If the state C value of the evaluation object is 0, the state of the evaluation object is considered to be optimal, and when the P value changes from 0 to 1, the state of the evaluation object gradually becomes worse; when the C value is larger than 0.5, the state of the evaluation object is general, and the state of some evaluation points is poor, so that the evaluation object is required to be focused by technicians; when the C value is larger than 0.75, the state of the evaluation object is poor, and the states of most evaluation points are poor; particularly, when the state C value of the evaluation object is gradually increased when the evaluation object is in the final stage and the final stage of the whole life cycle, the poor state of the evaluation object is also verified, and the enterprise is ready for the whole replacement of the evaluation object.
The evaluation object is high Wen Jixiang, and the evaluation point is selected from a high Wen Jixiang base material and a welding line.
The first type of state parameters in the step 6): macroscopic state parameter CP q1-j, result of macroscopic inspection MR q1-j: { no defect found, defect found out }, as shown in formula (3):
The first type of state parameters in the step 6): component state parameter CP q2-j, result from spectroscopic examination MR q2-j: { pass, fail } is defined as shown in formula (4):
The second type of state parameters in the step 6): tissue state parameter CP g1-j, result from metallographic examination MR g1-j: { level 1, level 2, level 3, level 4, level 5 } is defined as shown in formula (5):
The second type of state parameters in the step 6): nondestructive state parameters CP g2-j, and nondestructive detection results MR g2-j of ultrasonic waves, magnetic powder, permeation, rays and the like: { stage I, stage II, stage III, stage IV } is defined as shown in formula (6):
The third type of state parameters in the step 6): the distension state parameter CP m1-j, defined by the result MR m1-j of the distension inspection, is shown as equation (7):
In the formula (7), D 0 is a designed diameter, and the unit is mm;
the third type of state parameters in the step 6): the wall thickness state parameter CP m2-j, defined by the result MR m2-j of the wall thickness check, is shown as equation (8):
the third type of state parameters in the step 6): the hardness state parameter CP m3-j is defined by the result MR m3-j of the hardness test, as shown in formula (9):
The third type of state parameters in the step 6): the oxidation state parameter CP m4-j, defined by the result MR m4-j of the oxide scale measurement, is shown as formula (10):
The invention has the beneficial effects that:
According to the invention, the state evaluation of the high Wen Jixiang can be performed by only obtaining the existing metal inspection data without the need of having abundant metal material basic knowledge, mechanical calculation knowledge, life evaluation knowledge and experience and bearing additional test cost, so that the technical staff of the thermal power plant can be directly helped to formulate a maintenance strategy.
Drawings
FIG. 1 is a schematic diagram of a state evaluation flow according to the present invention.
Detailed Description
The invention is further described below with reference to the drawings and examples.
As shown in fig. 1:
1) Explicitly evaluating object and basic information
The method can be used for evaluating whether the object to be evaluated is the high-temperature header, the high-temperature superheater outlet header or the high-temperature reheater outlet header.
In addition, information such as design drawing, design diameter, design wall thickness, design material and the like of the object needs to be collected and clearly evaluated.
2) Specific stage of the life cycle in which the object is evaluated
The state of the evaluation object has a certain relation with the specific stage of the full life cycle in which the evaluation object is positioned, and the state of the equipment is not good due to design and manufacturing defects and installation left hidden danger in the early stage of the full life cycle. With the continuous familiarity of operators with the machine set, after entering the mid-stage of the full life cycle, the evaluation object reaches an optimal state and can last for a long period of time. When the end stage of the full life cycle is entered, the state of the evaluation object gradually deteriorates under the influence of the long-term peak shaving operation of the unit. When the material enters the final stage of the whole life cycle, the material is gradually aged under the high-temperature high-pressure service condition for a long time, and the rapid deterioration of the state of the object is evaluated.
It is clear which of the early, mid, end and end phases of the full life cycle the subject is in.
Wherein L c is the design life, and generally defines 300000 unit operation hours.
3) Calculating a state correction factor C S
Based on 2) the stage in which the explicit evaluation object is located, its corresponding state correction factor C S is determined.
| All stages of the life cycle | State factor C S |
| Early stage | 1+1c |
| Mid-stage | 1 |
| End stage | 1+2c |
| End stage | 1+5c |
Defining c as a correction factor, which is actually valued according to the following table based on the design and manufacturing data collected in 1).
| Several cases of correction factor c | Correction factor c takes value |
| No abnormality is found in the design and manufacturing stage | 0.01 |
| Few anomalies exist in the design and manufacture stage, but normal use is not affected | 0.02 |
| There are many anomalies in the design and manufacturing stage, and normal after repair | 0.05 |
If all indexes in the design and manufacturing data are normal and no major problem is found, c takes a value of 0.01, otherwise, according to the problem found in the design and manufacturing stage, an evaluator can also adjust according to the actual situation of the component.
4) Clear detailed evaluation point
In order to know the actual state of the evaluation object in detail, it is generally recommended to test the evaluation object by selecting a plurality of positions (base materials, weld joints), and the test points are also called evaluation points because they finally participate in the state evaluation, and the evaluation points are classified into two main categories: the base material class evaluation point and the weld class evaluation point are distinguished by the subscripts bm and wd, respectively.
5) Making a metal inspection scheme and implementing
Considering the maintenance plan, time and cost comprehensively, selecting and implementing a proper project-specified metal inspection scheme from macro inspection, coarse expansion inspection, spectrum inspection, wall thickness measurement, hardness inspection, oxide skin measurement, metallographic inspection and nondestructive inspection (comprising ultrasonic waves, magnetic powder, penetration and rays) aiming at all the evaluation points determined in the step 1).
6) Obtaining a metal inspection result
And 5) according to the determined metal inspection items, obtaining all metal inspection results of the evaluation points, classifying the state parameters into three categories according to the metal inspection results, and confirming the state parameters corresponding to all metal inspection items of all the evaluation points, wherein the table is shown below.
7) Evaluation point state evaluation
According to the metal test result obtained in the step 6), carrying out state evaluation on the single evaluation point, defining the state of the single evaluation point as C j, wherein an evaluation model is shown in a formula (1), when one or more parameter values in three types of state parameters CP qi-j、CPgi-j or CP mi-j are 1, defining the state C j of the evaluation point to take the value of 1, otherwise, defining the state C j of the evaluation point as the weighted sum of the three types of state parameters CP qi-j、CPgi-j or CP mi-j and multiplying the weighted sum by a state correction factor C S.
The result of the state of evaluation point C j is normally within the interval 0,1, and if the value of C j is 0, the state of evaluation point is optimal, and when the value of C j changes from 0 to 1, the state of evaluation point is worse.
The importance of various metal inspection projects, the implementation frequency, the result accuracy and other factors are comprehensively considered, and the rule of the formula (2) is given for the values of weights Q qi、Qgi and Q mi of three types of state parameters in the formula (1).
The following gives an evaluation method of three types of state parameters of a single evaluation point.
7.1 State parameter evaluation of the first class
7.1.1 Macro state parameter evaluation corresponding to macro inspection
The result MR q1-j of the macroscopic inspection is generally one of { no defect found, out of specification defect found } set, and the definition of the corresponding macroscopic state parameter CP q1-j is shown in formula (3).
7.1.2 Spectral examination of the corresponding component state parameter assessment
The result of the spectral inspection MR q2-j is generally { pass, fail }, and the pass or fail conclusion is obtained by comparing whether the result meets the requirements with the national standard or the industry standard, and the definition of the corresponding component state parameter CP q2-j is shown in the formula (4).
7.2 State parameter evaluation of the second class
7.2.1 Metallographic examination corresponding tissue state parameter evaluation
The result MR g1-j of the metallographic examination is { grade 1, grade 2, grade 3, grade 4, grade 5 }, different metal materials have different industry standard guidance grades, and the definition of the corresponding structure state parameter CP g1-j is shown in the formula (5).
7.2.2 Non-destructive state parameter assessment corresponding to non-destructive inspection
The nondestructive testing items can be classified into ultrasonic, magnetic powder, penetration and ray detection, all the detection results MR g2-j are { I level, II level, III level and IV level }, if a plurality of nondestructive testing items are implemented, the nondestructive testing result with the highest selection rating is selected, and the definition of the corresponding nondestructive state parameter CP g2-j is shown in the formula (6).
7.3 Third class state parameter evaluation
7.3.1 Evaluation of the corresponding distension Condition parameters for distension checking
The outer diameter creep of the evaluation object gradually occurs even when the evaluation object runs at a high temperature for a long time, and when the creep is serious, the evaluation object is in a poor state, for this reason, the inflation rough inspection needs to be performed at the end stage and the end stage of the whole life cycle of the evaluation object, and the definition of the inflation rough state parameter CP m1-j corresponding to the result MR m1-j of the inflation rough inspection is shown in the formula (7).
In formula (7), D 0 is a design diameter in mm.
7.3.2 Wall thickness state parameter estimation corresponding to wall thickness inspection
The high-temperature oxidation of the evaluation object can be generated by the erosion and corrosion of steam in the high-temperature operation process, and the process consumes the base metal of the evaluation object, so that the wall thickness of the evaluation object is thinned, larger stress is born, and the evaluation object has a worse state. The definition of the wall thickness state parameter CP m2-j corresponding to the result MR m2-j of the wall thickness check is shown in expression (8).
In the formula (8), d 0 is a design wall thickness in mm.
7.3.3 Hardness check corresponding hardness status parameter assessment
The aging phenomenon of the evaluation object occurs gradually when the evaluation object is operated under the high-temperature condition, so that the gradual reduction of the hardness is caused, the state of the evaluation object is poor due to the reduction of the hardness, and the failure possibly occurs. The hardness state parameter CP m3-j corresponding to the result MR m3-j of the hardness test is defined as shown in expression (9).
7.3.4 Oxidation state parameter estimation corresponding to scale measurement
The evaluation object is oxidized at high temperature when being contacted with high-temperature high-pressure steam, and the formed inner wall oxide layer increases the heat transfer resistance of the evaluation object and the high-temperature high-pressure steam, so that the actual use temperature of the metal of the evaluation object is increased along with the operation time, the thickness of the metal reflects the aging degree of the evaluation object to a certain extent, and the thicker the oxide skin is, the worse the state of the evaluation object is. The definition of the oxidation state parameter CP m4-j corresponding to the result MR m4-j of the oxide scale measurement is shown in formula (10).
8) Evaluation object state evaluation
And (3) counting all the evaluation points obtained in the step 7) according to the classification of the base metal class evaluation points and the weld joint class evaluation points, counting the number n of the base metal class evaluation points and the number m of the weld joint class evaluation points, and then carrying out overall evaluation of the state C on the evaluation object, wherein an evaluation model is shown in a formula (11).
If the state C value of the evaluation object is 0, the state of the evaluation object is considered to be optimal, and when the P value is changed from 0 to 1, the state of the evaluation object gradually becomes worse. When the C value is greater than 0.5, the evaluation object state is generally poor in some evaluation point states, and attention of a technician is paid. When the C value is greater than 0.75, the state of the evaluation object is poor, and most evaluation points are poor. Particularly, when the state C value of the evaluation object is gradually increased when the evaluation object is in the final stage and the final stage of the whole life cycle, the poor state of the evaluation object is also verified, and the enterprise is ready for the whole replacement of the evaluation object.
By adopting the technical scheme to evaluate and obtain the state of the height Wen Jixiang, not only can technicians in a thermal power plant be helped to know the actual state of the height Wen Jixiang, but also the change trend of the state can be predicted by aiming at the state evaluation results of the same evaluation point for a plurality of times, and the state results of all the evaluation points can be synthesized to evaluate the overall state of the height Wen Jixiang, so that the method has important significance in making a maintenance plan and a replacement strategy.
Claims (6)
1. A high Wen Jixiang state evaluation method based on metal inspection, which is characterized by comprising the following steps of;
1) The basic information of the high Wen Jixiang is defined by taking the high Wen Jixiang as an evaluation object;
2) Specific stages of the full life cycle in which Wen Jixiang is located are specified;
3) Calculating a state correction factor C S;
4) Defining detailed evaluation points;
5) Making a metal inspection scheme and implementing the scheme;
6) Obtaining a metal inspection result;
7) Evaluating point states;
8) High-temperature header state evaluation;
The specific operation steps of the step 2) are as follows:
Determining which of the early, mid, end and end stages of the full life cycle the high Wen Jixiang is in;
Wherein, L c is the design life, and generally defines 300000 unit operation hours;
the specific operation steps in the step 3) are as follows:
Determining a corresponding state correction factor C S based on the stage of the explicit evaluation object in the step 2);
Defining c as a correction factor, and according to the design and manufacturing data collected in the step 1), determining the actual value according to the following table;
The specific operation steps of the step 5) are as follows:
Comprehensively considering maintenance plan, time and cost, selecting a proper project-specified metal inspection scheme from macro inspection, coarse expansion inspection, spectrum inspection, wall thickness measurement, hardness inspection, oxide scale measurement, metallographic inspection and nondestructive inspection for all evaluation points determined in the step 1), and implementing the project-specified metal inspection scheme;
the specific operation steps of the step 6) are as follows:
According to the metal inspection items determined in the step 5), obtaining all metal inspection results of the evaluation points, classifying the state parameters into three categories according to the metal inspection results, and confirming the state parameters corresponding to all metal inspection items of all the evaluation points;
2. The method for evaluating the state of high Wen Jixiang based on metal inspection according to claim 1, wherein the basic information in step 1) includes design drawing, design diameter, design wall thickness, design material;
The evaluation object is high Wen Jixiang, and the evaluation point is selected from a high Wen Jixiang base material and a welding line.
3. The method for evaluating the state of high Wen Jixiang based on metal inspection according to claim 1, wherein the specific operation steps of the step 4) are as follows:
All evaluation points of the evaluation object are explicitly evaluated and classified into two main classes: the base material class evaluation point and the weld class evaluation point are distinguished by the subscripts bm and wd, respectively.
4. The method for evaluating the state of high Wen Jixiang based on metal inspection according to claim 1, wherein the specific operation steps of the step 7) are as follows:
performing state evaluation on the single evaluation point according to the metal inspection result obtained in the step 6), and defining the state of the single evaluation point as C j, wherein an evaluation model is shown in a formula (1);
if Max{CPqi-j,CPgi-j,CPmi-j}＝1,
Cj＝1
else if Max{CPqi-j,CPgi-j,CPmi-j}≠1
The result of the value of the state C j of the evaluation point normally falls in the range of the [0,1] interval, if the value of C j is 0, the state of the evaluation point is optimal, and when the value of C j changes from 0 to 1, the state of the evaluation point is worse;
The weights Q qi、Qgi and Q mi of the three state parameters in the formula (1) are valued to give the rule of the formula (2);
5. the method for evaluating the state of high Wen Jixiang based on metal inspection according to claim 1, wherein the specific operation steps in the step 8) are as follows:
counting all the evaluation points obtained in the step 7) according to the classification of base metal evaluation points and weld joint evaluation points, counting the number n of base metal evaluation points and the number m of weld joint evaluation points, and then carrying out overall evaluation of the state C on the evaluation object, wherein an evaluation model is shown in a formula (11);
The base material evaluation point and the weld joint evaluation point are respectively distinguished by subscripts bm and wd, the state of a single evaluation point is defined as C j, the state C value of an evaluation object is 0, the state of the evaluation object is considered to be optimal, and when the C value changes from 0 to 1, the state of the evaluation object gradually becomes worse; when the C value is larger than 0.5, the state of the evaluation object is general, and the state of some evaluation points is poor, so that the evaluation object is required to be focused by technicians; when the C value is larger than 0.75, the state of the evaluation object is poor, and the states of most evaluation points are poor; particularly, when the state C value of the evaluation object is gradually increased when the evaluation object is in the final stage and the final stage of the whole life cycle, the poor state of the evaluation object is also verified, and the enterprise is ready for the whole replacement of the evaluation object.
6. The method for evaluating the state of high Wen Jixiang based on metal inspection according to claim 1, wherein the first type of state parameters in the step 6) are: macroscopic state parameter CP q1-j, result of macroscopic inspection MR q1-j: { no defect found, defect found out }, as shown in formula (3):
The first type of state parameters in the step 6): component state parameter CP q2-j, result from spectroscopic examination MR q2-j: { pass, fail } is defined as shown in formula (4):
The second type of state parameters in the step 6): tissue state parameter CP g1-j, result from metallographic examination MR g1-j: { level 1, level 2, level 3, level 4, level 5 } is defined as shown in formula (5):
the second type of state parameters in the step 6): nondestructive state parameter CP g2-j, obtained by ultrasonic, magnetic powder, permeation and ray nondestructive detection result MR g2-j: { stage I, stage II, stage III, stage IV } is defined as shown in formula (6):
The third type of state parameters in the step 6): the distension state parameter CP m1-j, defined by the result MR m1-j of the distension inspection, is shown as equation (7):
In the formula (7), D 0 is a designed diameter, and the unit is mm;
the third type of state parameters in the step 6): the wall thickness state parameter CP m2-j, defined by the result MR m2-j of the wall thickness check, is shown as equation (8):
the third type of state parameters in the step 6): the hardness state parameter CP m3-j is defined by the result MR m3-j of the hardness test, as shown in formula (9):
The third type of state parameters in the step 6): the oxidation state parameter CP m4-j, defined by the result MR m4-j of the oxide scale measurement, is shown as formula (10):
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| CN113532898B (en) * | 2021-07-08 | 2025-02-14 | 西安热工研究院有限公司 | A method for evaluating the state of a supercritical or ultra-supercritical boiler steam-water separator body |
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| CN113869707B (en) * | 2021-09-24 | 2025-02-07 | 西安热工研究院有限公司 | A method for evaluating the condition of steam turbine medium-pressure steam pipe based on field inspection parameters |
| CN113869708B (en) * | 2021-09-24 | 2025-01-28 | 西安热工研究院有限公司 | A method for evaluating the condition of a high-pressure steam pipe of a steam turbine |
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