CN113434985B - State evaluation method for tube seat and connecting tube of steam-water separator of supercritical or ultra-supercritical boiler - Google Patents
State evaluation method for tube seat and connecting tube of steam-water separator of supercritical or ultra-supercritical boiler Download PDFInfo
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Abstract
Description
技术领域technical field
本发明属于火电厂设备状态评估技术领域,特别涉及一种超临界或超超临界锅炉汽水分离器管座与接管的状态评估方法。The invention belongs to the technical field of state evaluation of thermal power plant equipment, in particular to a method for state evaluation of a supercritical or ultra-supercritical boiler steam-water separator pipe seat and connecting pipe.
背景技术Background technique
超临界或超超临界锅炉汽水分离器是火力发电厂锅炉系统的重要部件,近年来,大型高参数超临界或超超临界火电机组频繁参与电网调峰运行,这使得超临界或超超临界锅炉汽水分离器在运行过程中处于较恶劣的工况条件,容易受到热交变载荷作用的影响。特别是汽水分离器管座和接管区域存在着较大的应力集中现象,接管数目的越多则应力集中更加明显,而且,管座处焊缝密集,在高温高压变载荷的影响下,焊缝组织状态恶化、组织脆化加大失效风险。此外,由于超临界或超超临界锅炉汽水分离器管座和接管位于锅炉外部,如果发生失效,会引起重安全事故,因此有必要较为准确的评估超临界或超超临界锅炉汽水分离器管座和接管的状态。The steam-water separator of supercritical or ultra-supercritical boiler is an important part of the boiler system of thermal power plants. The steam-water separator is in relatively harsh working conditions during operation, and is easily affected by thermal alternating loads. In particular, there is a large stress concentration phenomenon in the pipe seat and the connecting pipe area of the steam-water separator. The more the pipes are, the more obvious the stress concentration is. Moreover, the welds at the pipe seat are dense. Under the influence of high temperature, high pressure and variable load, the weld seam The deterioration of the organizational state and the fragility of the tissue increase the risk of failure. In addition, because the supercritical or ultra-supercritical boiler steam-water separator pipe seat and connecting pipe are located outside the boiler, if it fails, it will cause serious safety accidents, so it is necessary to evaluate the supercritical or ultra-supercritical boiler steam-water separator pipe seat more accurately and takeover status.
针对超临界或超超临界锅炉汽水分离器,已有文献报道过基于ANSYS软件对汽水分离器蒸汽入口处切向斜接结构的瞬态热固耦合的应力分析及应力分布,如文献“汽水分离器启动阶段蒸汽入口切向斜接结构应力分析研究,电站辅机,2013(2)”,有文献报道过基于有限元方法分析靠近连接管椭圆孔长轴处的热应力集中,如文献“600MW超临界锅炉汽水分离器内压应力有限元分析,锅炉技术,2009(1)”,也有文献报道过汽水分离器外壁接管角焊缝裂纹原因探讨,如文献“中压汽水分离器外壁接管角焊缝裂纹探讨与处理,贵州化工,2012(2)”。专门针对汽水分离器管座与接管的状态分析或寿命评估却鲜见报道。对汽水分离器管座与接管进行应力分析或寿命评估,需要具备以下多个条件:需要评估人员具有丰富的数学分析基础知识、金属材料基础知识、力学计算知识、寿命评估知识及经验;需要收集完整的设计资料和设计数据;需要收集完整的运行历史数据;需要收集完整的、全面的金属检验相关数据;需要构建应力场、温度场模型;需要同材质的试样进行全面的实验室分析数据作为参照组等。这些复杂的条件决定了应力分析、寿命损耗计算等技术的开展仅仅局限于专业技术机构及人员,而且这些基本资料和数据的收集、完整又全面的金属检验以及实验室分析会导致电厂检修成本和人力成本的增加。For the steam-water separator of supercritical or ultra-supercritical boilers, the literature has reported the stress analysis and stress distribution of the transient thermo-solid coupling of the tangential miter joint structure at the steam inlet of the steam-water separator based on ANSYS software, such as the literature "Steam-water separation Research on Stress Analysis of Steam Inlet Tangential Miter Joint Structure during Start-Up Stage, Power Station Auxiliary Equipment, 2013 (2)", there are reports based on the finite element method to analyze the thermal stress concentration near the long axis of the elliptical hole of the connecting pipe, such as the literature "600MW Finite element analysis of the internal pressure stress of the supercritical boiler steam-water separator, Boiler Technology, 2009 (1)", there are also reports on the cause of cracks in the fillet weld of the outer wall of the steam-water separator, such as the document "The fillet weld of the outer wall of the medium-pressure steam-water separator Discussion and treatment of seam cracks, Guizhou Chemical Industry, 2012 (2)". There are few reports on the state analysis or life evaluation of the steam-water separator pipe seat and connection pipe. Stress analysis or life assessment of the steam-water separator pipe seat and connecting pipe needs to meet the following conditions: the evaluator needs to have rich basic knowledge of mathematical analysis, basic knowledge of metal materials, mechanical calculation knowledge, life assessment knowledge and experience; needs to collect Complete design information and design data; need to collect complete operating history data; need to collect complete and comprehensive metal inspection related data; need to build stress field and temperature field models; need to conduct comprehensive laboratory analysis data for samples of the same material as a reference group etc. These complicated conditions determine that the development of technologies such as stress analysis and life loss calculation is limited to professional technical institutions and personnel, and the collection of these basic materials and data, complete and comprehensive metal inspection and laboratory analysis will lead to power plant maintenance costs and Increase in labor costs.
为此,需要寻找一种具有普适性的方法,无需评估人员具有丰富的数学分析基础知识、金属材料基础知识、力学计算知识、寿命评估知识及经验,也无需承担额外的试验费用成本,仅通过获得已有的金属检验数据,便可对超临界或超超临界锅炉汽水分离器管座和接管进行状态评估,从而直接帮助火电厂技术人员制定检修策略。To this end, it is necessary to find a universal method that does not require evaluators to have rich basic knowledge of mathematical analysis, basic knowledge of metal materials, mechanical calculation knowledge, life evaluation knowledge and experience, and does not need to bear additional test costs. By obtaining the existing metal inspection data, the status assessment of the supercritical or ultra-supercritical boiler steam-water separator tube seat and connection can be carried out, thus directly helping thermal power plant technicians to formulate maintenance strategies.
发明内容Contents of the invention
为了克服以上技术问题,本发明的目的在于提供一种超临界或超超临界锅炉汽水分离器管座与接管的状态评估方法,帮助火电厂技术锅炉或金属专业人员更好的制定检修策略。In order to overcome the above technical problems, the object of the present invention is to provide a method for evaluating the state of the tube base and connecting pipe of the steam-water separator of a supercritical or ultra-supercritical boiler, so as to help technical boiler or metal professionals in thermal power plants to better formulate maintenance strategies.
为了实现上述目的,本发明采用的技术方案和本发明的有益效果是:In order to achieve the above object, the technical scheme adopted in the present invention and the beneficial effects of the present invention are:
一种超临界或超超临界锅炉汽水分离器管座与接管的状态评估方法,包括以下步骤;A method for evaluating the state of a supercritical or ultra-supercritical boiler steam-water separator pipe seat and connecting pipe, comprising the following steps;
1)明确评估对象及基本信息;1) Clarify the evaluation object and basic information;
2)明确详细评估点;2) Define detailed evaluation points;
3)明确评估对象所处全运行寿命周期的具体阶段;3) Clarify the specific stage of the full operation life cycle of the assessment object;
4)计算状态因子CS;4) Calculate the state factor C S ;
5)计算修正因子CC;5) Calculating the correction factor C C ;
6)制定金属检验方案并实施;6) Formulate and implement a metal inspection plan;
7)获取金属检验结果;7) Obtain metal inspection results;
8)评估点状态评估;8) Assessment of the status of the assessment point;
9)评估对象状态评估;9) Evaluation of the status of the evaluation object;
10)评估结果归档及反馈。10) Archiving and feedback of evaluation results.
所述步骤1)的评估对象为超临界或超超临界锅炉汽水分离器管座和接管,基本信息包括设计图纸,设计直径、设计壁厚、设计材质以及最近一次检修记录档案;The evaluation object of said step 1) is a supercritical or ultra-supercritical boiler steam-water separator tube seat and a connecting pipe, and the basic information includes design drawings, design diameter, design wall thickness, design material and the last maintenance record file;
所述步骤2)具体操作步骤为:Described step 2) specific operation steps are:
综合考虑检修计划、时间、成本以及历次检修结果,有针对性的确定评估点,并将评估点分为两类:接管和管座,分别以下角标nc和ts区分。Comprehensively consider the maintenance plan, time, cost and previous maintenance results, determine the evaluation points in a targeted manner, and divide the evaluation points into two categories: connecting pipes and pipe sockets, which are distinguished by the subscripts nc and ts respectively.
所述步骤3)具体操作步骤为:Described step 3) specific operation steps are:
明确评估对象处于全运行寿命周期的前期阶段、中期阶段、末期阶段和终末期阶段中的哪个阶段;It is clear which stage the evaluation object is in the early stage, middle stage, final stage and final stage of the full operation life cycle;
其中,Lc为设计寿命,一般定义为机组的设计寿命30年。Among them, L c is the design life, which is generally defined as the design life of the unit is 30 years.
所述步骤4)中计算状态因子的具体操作步骤为:The specific operation steps of calculating state factor in described step 4) are:
基于步骤3)明确的评估对象所处全运行寿命周期阶段,确定其相应的状态因子CS;Based on step 3) where the evaluation object is in the full operation life cycle stage, determine its corresponding state factor C S ;
其中根据步骤1)收集的设计和制造资料,依照下表查找s的取值。According to the design and manufacturing data collected in step 1), look up the value of s according to the table below.
所述步骤5)中计算修正因子的具体操作步骤为:The specific operation steps for calculating the correction factor in the step 5) are:
基于评估对象最近一次评估结果的反馈,根据式(1)确定修正因子CC;Based on the feedback of the latest evaluation result of the evaluation object, the correction factor C C is determined according to formula (1);
式中,参数δ和c的取值,从下表中查找。In the formula, the values of parameters δ and c can be found from the table below.
所述步骤6)具体操作步骤为:Described step 6) specific operation steps are:
综合考虑检修计划、时间、成本以及历次检修结果,针对步骤2)确定的评估点,从宏观检验、表面探伤、无损探伤、金相检查、管径检查、壁厚测量、硬度检查、氧化皮厚度测量中选择合适的项目制定金属检验方案并实施。Comprehensively considering the maintenance plan, time, cost and previous maintenance results, for the evaluation points determined in step 2), from macroscopic inspection, surface flaw detection, non-destructive flaw detection, metallographic inspection, pipe diameter inspection, wall thickness measurement, hardness inspection, scale thickness Select appropriate items in the measurement to formulate and implement a metal inspection plan.
所述步骤7)具体的操作步骤为:Described step 7) concrete operation steps are:
根据步骤6)确定的金属检验项目,获取评估点的各项金属检验结果,按照金属检验结果将状态参数分为三大类,并确认各评估点各项金属检验项目对应的状态参数CP及权重Q。According to the metal inspection items determined in step 6), obtain the metal inspection results of the evaluation points, divide the state parameters into three categories according to the metal inspection results, and confirm the state parameters CP and weights corresponding to the metal inspection items of each evaluation point Q.
所述步骤8)具体操作步骤为:Described step 8) specific operation steps are:
依据步骤7)获取的金属检验结果,对单个评估点进行状态评估,定义单个评估点的状态为Ck,评估模型如式(2)所示;According to the metal inspection results obtained in step 7), the state of a single evaluation point is evaluated, and the state of a single evaluation point is defined as C k , and the evaluation model is shown in formula (2);
评估点的状态Ck的数值结果正常落在[0,4]区间范围内,Ck的数值从0向4变化时,评估点的状态越来越差。The numerical result of the state C k of the evaluation point normally falls within the range of [0,4], and when the value of C k changes from 0 to 4, the state of the evaluation point becomes worse and worse.
所述式(2)中三类状态参数的权重QIi、QIIi和QIIIi的取值,给出式(3)的规则;The value of the weight Q Ii , Q IIi and Q IIIi of the three types of state parameters in the formula (2) provides the rule of the formula (3);
所述步骤9)中具体操作步骤为:Described step 9) in concrete operation steps are:
对步骤8)得到的所有评估点,按照接管和管座的分类(下角标分别是nc和ts)进行统计,统计接管评估点数量m和管座评估点数量n,然后对评估对象进行整体评估,最终状态值的评估模型如式(12)所示;For all the evaluation points obtained in step 8), statistics are made according to the classification of the nozzles and sockets (the subscripts are nc and ts, respectively), and the number m of evaluation points of the nozzles and the number n of evaluation points of the sockets are counted, and then the evaluation object is evaluated as a whole , the evaluation model of the final state value is shown in formula (12);
评估对象的状态C值为0,则认为评估对象的状态最佳,当C值从0向4变化时,评估对象的状态逐渐变差;当C值大于2.5时,评估对象状态一般,但是有部分评估点状态较差,要引起技术人员关注,并对部分评估点及时进行维护或更换处理;当C值大于3.2时,评估对象状态较差,有多数评估点状态不佳。如果个别评估点状态较差,可对个别评估点进行更换处理。如果评估对象整体状态较差,特别是处于全运行寿命周期的末期和终末期阶段时,企业应做好评估对象整体更换的准备。If the state C value of the evaluation object is 0, it is considered that the state of the evaluation object is the best. When the C value changes from 0 to 4, the state of the evaluation object gradually becomes worse; when the C value is greater than 2.5, the state of the evaluation object is average, but there are Some assessment points are in poor condition, so technicians should pay attention to them, and timely maintain or replace some assessment points; when the C value is greater than 3.2, the condition of the assessment object is poor, and most of the assessment points are in poor condition. If individual evaluation points are in poor condition, individual evaluation points can be replaced. If the overall status of the assessment object is poor, especially when it is at the end and terminal stage of the full operation life cycle, the enterprise should be prepared for the overall replacement of the assessment object.
所述步骤10)中具体操作步骤为:The specific operation steps in the step 10) are:
将步骤9)得到的评估对象的状态评估结果完整记录并归档,为下一次评估进行反馈用于计算步骤5)的修正因子。Completely record and file the state evaluation results of the evaluation object obtained in step 9), and provide feedback for the next evaluation to calculate the correction factor in step 5).
所述的步骤8)中第一类状态参数:宏观状态参数CPI1-k,由宏观检验的结果RI1-k:{未发现缺陷,发现少量可疑缺陷,发明显缺陷}定义,如式(4)所示:The first type of state parameter in the step 8): the macroscopic state parameter CP I1-k , which is defined by the result R I1-k of the macroscopic inspection: {no defect found, a small amount of suspicious defect found, and obvious defect found}, such as the formula ( 4) as shown:
所述的步骤8)中第一类状态参数:表面状态参数CPI2-k,由表面探伤检查的结果RI2-k:{未发现缺陷,发现表面缺陷但打磨后消除,发现表面缺陷但打磨后仍然存在}定义,如式(5)所示:The first type of state parameter in the step 8): surface state parameter CP I2-k , the result R I2-k of the surface flaw detection inspection: {No defects are found, surface defects are found but eliminated after grinding, surface defects are found but polished } still exists after the definition, as shown in formula (5):
所述的步骤8)中第二类状态参数:无损状态参数CPII1-k,由无损探伤的结果RII1-k:{I级,II级,III级,IV级}定义,如式(6)所示:The second type of state parameter in the step 8): the non-destructive state parameter CP II1-k , which is defined by the result R II1-k of the non-destructive testing: {level I, level II, level III, level IV}, as shown in formula (6 ) as shown:
所述的步骤8)中第二类状态参数:组织状态参数CPII2-k,由金相检查的结果RII2-k:{1级,2级,3级,4级,5级}定义,如式(7)所示:The second type of state parameter in the step 8): the tissue state parameter CP II2-k , which is defined by the metallographic inspection result R II2-k : {level 1, level 2, level 3, level 4, level 5}, As shown in formula (7):
所述的步骤8)中第三类状态参数:管径状态参数CPIII1-k,由管径检查的结果RIII1-k定义,如式(8)所示:The third type of state parameter in said step 8): the pipe diameter state parameter CP III1-k , which is defined by the result R III1-k of the pipe diameter inspection, as shown in formula (8):
式(8)中,D0为设计管径,单位为mm;e为极限蠕胀率,单位为%,对于汽水分离器接管,极限蠕胀率取值如下表所示:In formula (8), D 0 is the design pipe diameter, in mm; e is the ultimate creep expansion rate, in %. For the steam-water separator connection, the limit creep expansion rate is shown in the following table:
所述的步骤8)中第三类状态参数:壁厚状态参数CPIII2-k,由壁厚检查的结果RIII2-k定义,如式(9)所示:The third type of state parameter in said step 8): the wall thickness state parameter CP III2-k , which is defined by the result R III2-k of the wall thickness inspection, as shown in formula (9):
式(9)中,d0为设计壁厚,单位为mm;In formula (9), d 0 is the design wall thickness, the unit is mm;
所述的步骤8)中第三类状态参数:硬度状态参数CPIII3-k,由硬度检查的结果RIII3-k定义,如式(10)所示:The third type of state parameter in said step 8): the hardness state parameter CP III3-k , which is defined by the result R III3-k of the hardness check, as shown in formula (10):
式(10)中的硬度为布氏硬度,HBL和HBH分别为极限硬度最小值和极限硬度最大值,对于汽水分离器接管,常见材质的HBL和HBH取值汇总如下表所示:The hardness in formula (10) is the Brinell hardness, HB L and HB H are the minimum limit hardness and the maximum limit hardness respectively. For the steam-water separator connection, the values of HB L and HB H of common materials are summarized in the following table :
所述的步骤8)中第三类状态参数:氧化皮状态参数CPIII4-k,由内壁氧化皮检查的结果RIII4-k定义,如式(11)所示:The third type of state parameter in said step 8): the oxide scale state parameter CP III4-k , which is defined by the result R III4-k of the inner wall oxide scale inspection, as shown in formula (11):
式(11)中,XH为最大允许内壁氧化皮厚度,单位为mm。对于汽水分离器接管,常见材质的XH取值汇总见下表所示:In formula (11), X H is the maximum permissible oxide skin thickness on the inner wall, in mm. For the connection pipe of the steam-water separator, the X H values of common materials are summarized in the table below:
本发明的有益效果:Beneficial effects of the present invention:
本发明无需评估人员具有丰富的金属材料基础知识、力学计算知识、寿命评估知识及经验,也无需承担额外的试验费用成本,基于针对超临界或超超临界锅炉汽水分离器管座和接管的宏观检验、表面探伤、无损探伤、金相检查、管径检查、壁厚测量、硬度检查、氧化皮厚度测量这些常规的金属检验数据,通过状态因子和修正因子的校正,对超临界或超超临界锅炉汽水分离器管座和接管进行状态评估,从而直接帮助火电厂技术人员制定下次检修策略,如果超临界或超超临界锅炉汽水分离器管座和接管个别位置状态较差,可单独更换,如果整体状态较差,企业应做好评估对象整体更换的准备。The present invention does not require evaluators to have rich basic knowledge of metal materials, mechanical calculation knowledge, life evaluation knowledge and experience, and does not need to bear additional test costs. Inspection, surface flaw detection, non-destructive flaw detection, metallographic inspection, pipe diameter inspection, wall thickness measurement, hardness inspection, scale thickness measurement, these routine metal inspection data, through the correction of state factor and correction factor, supercritical or ultra supercritical The state assessment of the pipe seat and connecting pipe of the steam-water separator of the boiler can directly help the technicians of the thermal power plant to formulate the next maintenance strategy. If the pipe seat and the connecting pipe of the supercritical or ultra-supercritical boiler are in poor condition, they can be replaced separately. If the overall status is poor, the enterprise should prepare for the overall replacement of the evaluation object.
以某660MW超临界锅炉左侧汽水分离器管座和接管于2020年12月C修的结果为例,按照此发明方法实施状态评估,其评估过程及最终结果如下所示。Taking the results of C repair of the left steam-water separator tube seat and connecting pipe of a 660MW supercritical boiler in December 2020 as an example, the state assessment was carried out according to the inventive method. The assessment process and final results are shown below.
附图说明Description of drawings
图1是本发明状态评估流程示意图。Fig. 1 is a schematic diagram of the status evaluation process of the present invention.
具体实施方式Detailed ways
下面结合附图和实施案例对本发明作进一步的描述。The present invention will be further described below in conjunction with the accompanying drawings and examples of implementation.
如图1所示:As shown in Figure 1:
1)明确评估对象及基本信息1) Clarify the evaluation object and basic information
首先明确评估对象是超临界或超超临界锅炉汽水分离器接管和管座。First of all, it is clear that the evaluation object is the supercritical or ultra supercritical boiler steam-water separator nozzle and socket.
此外,还需要收集并明确评估对象的设计图纸、设计直径、设计壁厚、设计材质以及最近一次检修记录档案。In addition, it is also necessary to collect and clarify the design drawings, design diameter, design wall thickness, design material and the latest maintenance record file of the evaluation object.
2)明确详细评估点2) Clear detailed evaluation points
为了详细了解评估对象的实际状态,一般建议对评估对象选取多个位置(接管和管座)进行检验,由于检验点最终会参与状态评估,因此又称为评估点。并将评估点分为两类:接管和管座,分别以下角标nc和ts区分。In order to understand the actual state of the evaluation object in detail, it is generally recommended to select multiple locations (connectors and pipe sockets) for inspection on the evaluation object. Since the inspection points will eventually participate in the state evaluation, they are also called evaluation points. And the evaluation points are divided into two categories: connecting pipes and sockets, which are distinguished by the subscripts nc and ts respectively.
3)明确评估对象所处全运行寿命周期的具体阶段3) Clarify the specific stage of the full operation life cycle of the evaluation object
评估对象的状态与其所处的全运行寿命周期的具体阶段有一定关系,在全运行寿命周期的前期阶段,由设计制造缺陷以及安装遗留隐患导致状态并不优良。随着机组的稳定运行,进入全运行寿命周期的中期阶段,评估对象达到了最佳状态,并能持续很长一段时间。当进入全运行寿命周期的末期阶段,在机组长期调峰运行的影响下,评估对象状态逐渐劣化。当进入全运行寿命周期的终末期阶段,长期在高温高压服役条件下,材料逐步加速老化,评估对象状态急速劣化。The state of the evaluation object has a certain relationship with the specific stage of the full operation life cycle. In the early stage of the full operation life cycle, the state is not good due to design and manufacturing defects and hidden dangers left over from installation. With the stable operation of the unit and entering the middle stage of the full operation life cycle, the evaluation object has reached the best state and can last for a long time. When entering the final stage of the full operation life cycle, under the influence of the long-term peak-shaving operation of the unit, the state of the evaluation object gradually deteriorates. When entering the final stage of the full operating life cycle, under the long-term service conditions of high temperature and high pressure, the aging of materials is gradually accelerated, and the state of the evaluation object deteriorates rapidly.
明确评估对象处于全运行寿命周期的前期阶段、中期阶段、末期阶段和终末期阶段中的哪个阶段;It is clear which stage the evaluation object is in the early stage, middle stage, final stage and final stage of the full operation life cycle;
其中,Lc为设计寿命,一般定义为机组的设计寿命30年。Among them, L c is the design life, which is generally defined as the design life of the unit is 30 years.
4)计算状态因子CS 4) Calculate the state factor C S
基于3)明确的评估对象所处阶段,确定其相应的状态因子CS;Based on 3) the stage of the evaluation object, determine its corresponding state factor C S ;
其中根据1)收集的设计和制造资料,依照下表查找s的取值。According to the design and manufacturing data collected in 1), look up the value of s according to the table below.
如果设计、制造资料中所有指标正常,未发现重大问题,则c取值0.01,否则,根据在设计、制造阶段发现的问题但评估人员也可根据部件实际情况进行调整。If all the indicators in the design and manufacturing data are normal and no major problems are found, then the value of c is 0.01, otherwise, according to the problems found in the design and manufacturing stages, the evaluators can also make adjustments according to the actual conditions of the components.
5)计算修正因子CC 5) Calculate the correction factor C C
基于评估对象最近一次评估结果的反馈,根据式(1)确定修正因子CC;Based on the feedback of the latest evaluation result of the evaluation object, the correction factor C C is determined according to formula (1);
式中,参数δ和c的取值,从下表中查找。In the formula, the values of parameters δ and c can be found from the table below.
6)制定金属检验方案并实施6) Formulate and implement a metal inspection plan
综合考虑检修计划、时间、成本以及历次检修结果,针对步骤2)确定的评估点,从宏观检验、表面探伤、无损探伤、金相检查、管径检查、壁厚测量、硬度检查、氧化皮厚度测量中选择合适的项目制定金属检验方案并实施。Comprehensively considering the maintenance plan, time, cost and previous maintenance results, for the evaluation points determined in step 2), from macroscopic inspection, surface flaw detection, non-destructive flaw detection, metallographic inspection, pipe diameter inspection, wall thickness measurement, hardness inspection, scale thickness Select appropriate items in the measurement to formulate and implement a metal inspection plan.
7)获取金属检验结果7) Obtain metal inspection results
根据步骤6)确定的金属检验项目,获取评估点的各项金属检验结果,按照金属检验结果将状态参数分为三大类,并确认各评估点各项金属检验项目对应的状态参数CP及权重Q。According to the metal inspection items determined in step 6), obtain the metal inspection results of the evaluation points, divide the state parameters into three categories according to the metal inspection results, and confirm the state parameters CP and weights corresponding to the metal inspection items of each evaluation point Q.
8)评估点状态评估8) Evaluation point status evaluation
依据7)获取的金属检验结果,对单个评估点进行状态评估,定义单个评估点的状态为Ck,评估模型如式(2)所示。Based on the metal inspection results obtained in 7), the state of a single evaluation point is evaluated, and the state of a single evaluation point is defined as C k , and the evaluation model is shown in formula (2).
评估点的状态Ck的数值结果正常落在[0,4]区间范围内,Ck的数值从0向4变化时,评估点的状态越来越差。The numerical result of the state C k of the evaluation point normally falls within the range of [0,4], and when the value of C k changes from 0 to 4, the state of the evaluation point becomes worse and worse.
综合考虑各种金属检验项目的重要性以及其实施频率、结果准确性等因素,对于所述式(2)中三类状态参数的权重QIi、QIIi和QIIIi的取值,给出式(3)的规则;Considering the importance of various metal inspection items and their implementation frequency, result accuracy and other factors, for the weights Q Ii , Q IIi and Q IIIi of the three types of state parameters in the above formula (2), the formula (3) the rules;
下面给出单个评估点三类状态参数的评估方法。The evaluation methods of the three types of state parameters of a single evaluation point are given below.
8.1)第一类状态参数评估8.1) The first type of state parameter evaluation
8.1.1)宏观检验对应的宏观状态参数评估8.1.1) Evaluation of macro state parameters corresponding to macro inspection
宏观检验的结果RI1-k一般为{未发现缺陷,发现缺陷,发现超标缺陷}集合中的其中一项,其对应的宏观状态参数CPI1-k的定义如式(4)所示。The result of macro inspection R I1-k is generally one of the items in the set of {no defect found, defect found, defect found exceeding the standard}, and the definition of the corresponding macro state parameter CP I1-k is shown in formula (4).
8.1.2)表面探伤对应的表面状态参数评估8.1.2) Evaluation of surface state parameters corresponding to surface flaw detection
表面探伤检查的结果RI2-k一般为{未发现缺陷,发现表面缺陷但打磨后消除,发现表面缺陷但打磨后仍然存在},其对应的表面状态参数CPI2-k的定义如式(5)所示。The result of surface flaw detection R I2-k is generally {no defect found, surface defect found but eliminated after grinding, surface defect found but still exists after grinding}, and the corresponding surface state parameter CP I2-k is defined as formula (5 ) shown.
8.2)第二类状态参数评估8.2) Evaluation of the second type of state parameters
8.2.1)无损探伤对应的无损状态参数评估8.2.1) Evaluation of non-destructive state parameters corresponding to non-destructive testing
无损探伤项目可分为超声波、磁粉、渗透、射线检测,无损探伤的结果RII1-k一般定义为{I级,II级,III级,IV级},如果实施了多个无损探伤项目,选择评级最高的为无损探伤结果,其对应的无损状态参数CPII1-k的定义如式(6)所示。Non-destructive testing items can be divided into ultrasonic, magnetic particle, penetrant, and radiographic testing. The results of non-destructive testing R II1-k are generally defined as {level I, level II, level III, level IV}. If multiple non-destructive testing items are implemented, select The highest rating is the result of non-destructive testing, and the definition of the corresponding non-destructive state parameter CP II1-k is shown in formula (6).
8.2.2)金相检查对应的无损状态参数评估8.2.2) Evaluation of non-destructive state parameters corresponding to metallographic inspection
金相检查的结果RII2-k一般定义为{1级,2级,3级,4级,5级},其对应的组织状态参数CPII2-k的定义如式(7)所示。The results of metallographic examination R II2-k are generally defined as {grade 1, grade 2, grade 3, grade 4, grade 5}, and the definition of the corresponding tissue state parameter CP II2-k is shown in formula (7).
8.3)第三类状态参数评估8.3) The third type of state parameter evaluation
8.3.1)管径检查对应的壁厚状态参数评估8.3.1) Evaluation of wall thickness state parameters corresponding to pipe diameter inspection
评估对象在高温条件运行会逐渐发生外径蠕胀,蠕胀严重时容易引起失效。When the evaluation object operates under high temperature conditions, the outer diameter creep will gradually occur, and when the creep expansion is severe, it will easily lead to failure.
管径检查的结果RIII1-k对应的管径状态参数CPIII1-k的定义如式(8)所示。The definition of the pipe diameter state parameter CP III1-k corresponding to the pipe diameter inspection result R III1- k is shown in formula (8).
式(8)中,D0为设计管径,单位为mm;e为极限蠕胀率,单位为%,对于汽水分离器接管,极限蠕胀率取值如下表所示。In formula (8), D 0 is the design pipe diameter in mm; e is the ultimate creep expansion rate in %. For the steam-water separator connection, the limit creep expansion rate is shown in the table below.
8.3.2)壁厚检查对应的壁厚状态参数评估8.3.2) Evaluation of wall thickness state parameters corresponding to wall thickness inspection
评估对象内壁在高温蒸汽的冲蚀及腐蚀作用下会产生高温氧化,逐渐消耗评估对象的基体金属,使得壁厚减薄,从而具有更劣的状态。Under the erosion and corrosion of high-temperature steam, the inner wall of the evaluation object will produce high-temperature oxidation, which will gradually consume the base metal of the evaluation object, making the wall thickness thinner, and thus have a worse state.
壁厚检查的结果RIII2-k对应的壁厚状态参数CPIII2-k的定义如式(9)所示。The wall thickness state parameter CP III2-k corresponding to the wall thickness inspection result R III2-k is defined as shown in formula (9).
式(9)中,d0为设计壁厚,单位为mm。In formula (9), d 0 is the design wall thickness in mm.
8.3.3)硬度检查对应的硬度状态参数评估8.3.3) Evaluation of hardness state parameters corresponding to hardness inspection
评估对象在高温条件下逐渐发生老化,从而硬度逐渐降低、状态变差,最终可能导致失效。The evaluation object will gradually age under high temperature conditions, so the hardness will gradually decrease and the state will deteriorate, which may eventually lead to failure.
硬度检查的结果RIII3-k对应的硬度状态参数CPIII3-k的定义如式(10)所示。The hardness state parameter CP III3-k corresponding to the hardness test result R III3- k is defined as shown in formula (10).
式(10)中的硬度为布氏硬度,HBL和HBH分别为极限硬度最小值和极限硬度最大值,对于汽水分离器接管,常见材质的HBL和HBH取值汇总如下表所示:The hardness in formula (10) is the Brinell hardness, HB L and HB H are the minimum limit hardness and the maximum limit hardness respectively. For the steam-water separator connection, the values of HB L and HB H of common materials are summarized in the following table :
8.3.4)内壁氧化皮检查对应的氧化皮状态参数评估8.3.4) Evaluation of the scale state parameters corresponding to the scale inspection on the inner wall
评估对象内壁在高温蒸汽的冲蚀及腐蚀作用下会产生高温氧化,形成的内壁氧化层增加传热热阻,使得评估对象实际使用温度升高,材料老化加剧。Under the erosion and corrosion of high-temperature steam, the inner wall of the evaluation object will undergo high-temperature oxidation, and the formed inner wall oxide layer will increase the heat transfer resistance, which will increase the actual use temperature of the evaluation object and aggravate the aging of the material.
内壁氧化皮检查的结果RIII4-k对应的氧化皮状态参数CPIII4-k的定义如式(11)所示。The definition of the scale state parameter CP III4-k corresponding to the scale inspection result R III4- k on the inner wall is shown in formula (11).
式(11),XH为最大允许内壁氧化皮厚度,单位为mm。对于汽水分离器接管,常见材质的XH取值汇总见下表所示:Equation (11), X H is the maximum allowable oxide skin thickness on the inner wall, in mm. For the connection pipe of the steam-water separator, the X H values of common materials are summarized in the table below:
9)评估对象状态评估9) Evaluation of the status of the evaluation object
对8)得到的所有评估点,按照接管和管座的分类(下角标分别是nc和ts)进行统计,统计接管评估点数量m和管座评估点数量n,然后对评估对象进行整体评估,最终状态值的评估模型如式(12)所示。For all the evaluation points obtained in 8), according to the classification of the nozzles and the sockets (the subscripts are nc and ts), the statistics are made, the number m of the nozzle evaluation points and the number n of the socket evaluation points are counted, and then the evaluation object is evaluated as a whole. The evaluation model of the final state value is shown in formula (12).
评估对象的状态C值为0,则认为评估对象的状态最佳,当C值从0向4变化时,评估对象的状态逐渐变差;当C值大于2.5时,评估对象状态一般,但是有部分评估点状态较差,要引起技术人员关注,并对部分评估点及时进行维护或更换处理;当C值大于3.2时,评估对象状态较差,有多数评估点状态不佳。如果个别评估点状态较差,可对个别评估点进行更换处理。如果评估对象整体状态较差,特别是处于全运行寿命周期的末期和终末期阶段时,企业应做好评估对象整体更换的准备。If the state C value of the evaluation object is 0, it is considered that the state of the evaluation object is the best. When the C value changes from 0 to 4, the state of the evaluation object gradually becomes worse; when the C value is greater than 2.5, the state of the evaluation object is average, but there are Some assessment points are in poor condition, so technicians should pay attention to them, and timely maintain or replace some assessment points; when the C value is greater than 3.2, the condition of the assessment object is poor, and most of the assessment points are in poor condition. If individual evaluation points are in poor condition, individual evaluation points can be replaced. If the overall status of the assessment object is poor, especially when it is at the end and terminal stage of the full operation life cycle, the enterprise should be prepared for the overall replacement of the assessment object.
10)评估结果归档及反馈10) Archiving and feedback of evaluation results
将步骤9)得到的评估对象的状态评估结果完整记录并归档,为下一次评估进行反馈用于计算步骤5)的修正因子。Completely record and file the state evaluation results of the evaluation object obtained in step 9), and provide feedback for the next evaluation to calculate the correction factor in step 5).
采用以上技术方案评估得到超临界或超超临界锅炉汽水分离器管座和接管的状态,不但能够帮助火电厂技术人员了解超临界或超超临界锅炉汽水分离器管座和接管的的实际状态,且可通过针对同一评估点多次状态评估结果预测其状态的变化趋势,也可综合所有评估点的状态结果对超临界或超超临界锅炉汽水分离器管座和接管的整体的状态进行评估,对制定检修计划及更换策略具有重要意义。Using the above technical schemes to evaluate the state of the supercritical or ultra-supercritical boiler steam-water separator pipe seat and connecting pipe can not only help thermal power plant technicians understand the actual state of the supercritical or ultra-supercritical boiler steam-water separator pipe seat and connecting pipe, And it can predict the change trend of its state through multiple state evaluation results for the same evaluation point, and can also evaluate the overall state of the supercritical or ultra-supercritical boiler steam-water separator tube seat and connection by integrating the state results of all evaluation points. It is of great significance to formulate maintenance plan and replacement strategy.
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