CN102505970A - Device and method for monitoring crack propagation life of turbine rotor - Google Patents

Device and method for monitoring crack propagation life of turbine rotor Download PDF

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Publication number
CN102505970A
CN102505970A CN2011104139147A CN201110413914A CN102505970A CN 102505970 A CN102505970 A CN 102505970A CN 2011104139147 A CN2011104139147 A CN 2011104139147A CN 201110413914 A CN201110413914 A CN 201110413914A CN 102505970 A CN102505970 A CN 102505970A
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crack
life
turbine rotor
rotor
propagation
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CN102505970B (en
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史进渊
杨宇
邓志成
汪勇
刘传亮
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Shanghai Power Equipment Research Institute Co Ltd
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Abstract

The invention provides a device and a method for monitoring internal crack propagation life of a turbine rotor. The device is characterized by consisting of an ultrasonic flaw detector, a calculation server, a database server, a webpage server and a user side browser, wherein the ultrasonic flaw detector is connected with the database server; the calculation server and the database server are connected with the webpage server; and the webpage server is connected with the database server, the calculation server and the user side browser respectively. The device and the method have the advantages that: the residual crack propagation life of the turbine rotor can be calculated on line and monitored regularly; if the residual crack propagation life of the turbine rotor is relatively short, the residual crack propagation life of the turbine rotor is rationally used by immediately overhauling (A-level overhaul); therefore, a technical scheme that the residual crack propagation life of the turbine rotor is monitored regularly is achieved.

Description

The supervising device and method of crack propagation life of turbine rotor
Technical field
The present invention relates to the supervising device in turbine rotor propagation of internal cracks life-span and method, belong to steam turbine technology field.
Background technology
The characteristics of turbine rotor, is that size is big, rotates at a high speed that turbine rotor produces big principal stress during startup, shutdown and overspeed test.The defect detecting test that turbine rotor is produced in forging and process can not find crackle, during steam turbine operation, and turbine rotor is in the presence of big principal stress, it would be possible to expand to defect detecting test visible crack.During steam turbine operation, turbine rotor is in the presence of big principal stress, and rotor defect detecting test visible crack constantly extends.When turbine rotor Crack Extension to rotor crack position critical crack size when, turbine rotor be possible to occur brittle fracture, cause steam turbine damage accident.Existing turbine rotor service life supervision technology, gives the monitoring method of the crack initiation life of turbine rotor, and the monitoring of the crack propagation life of in-service turbine rotor, also available without suitable apparatus and method.
The content of the invention
It is an object of the invention to provide a kind of supervising device in turbine rotor propagation of internal cracks life-span and method, the regular monitoring of crack propagation life of turbine rotor is realized.
To realize object above, the technical scheme is that providing a kind of supervising device in turbine rotor propagation of internal cracks life-span, it is characterized in that, it is made up of supersonic detector, calculation server, database server, web page server and user terminal browser, supersonic detector is connected with database server, calculation server is connected with database server and web page server, and web page server is connected with database server, calculation server and user terminal browser respectively.
The monitoring method in the turbine rotor propagation of internal cracks life-span used present invention also offers said apparatus, it is characterized in that, adopt the computer software of the crack propagation life of turbine rotor shown a C language, operate on calculation server, applied to the monitoring of crack propagation life of turbine rotor, concretely comprise the following steps：
The first step：Flaw detection determines the crack size of turbine rotor：
During steam turbine opens the maintenance of cylinder, place position and the crack size of crackle are determined using supersonic detector, position where crackle refers to three coordinate values of rotor Ellipse crack center, and crack size refers to the minor axis radius of internal rotor Ellipse crack and rotor surface half elliptic crackleaAnd major axis radiusc；
Second step：The maximum principal stress at position where calculating crackle：
For internal rotor crackle, the maximum principal stress that cold start, warm starting, hot starting, hot start, very hot startup and 110% nominal operation over speed of rotation test totally five kinds of transient processes is calculated, symbol is used respectively
Figure 298695DEST_PATH_IMAGE001
、
Figure 2011104139147100002DEST_PATH_IMAGE002
、
Figure 905257DEST_PATH_IMAGE003
、
Figure 2011104139147100002DEST_PATH_IMAGE004
With
Figure 101883DEST_PATH_IMAGE005
Represent； 
3rd step：Calculate the critical crack size of turbine rotor：
Turbine rotoriPlant the critical crack size of transient condition
Figure 2011104139147100002DEST_PATH_IMAGE006
Calculation formula be：
    
Figure 590633DEST_PATH_IMAGE007
In formula：
Figure 2011104139147100002DEST_PATH_IMAGE008
--- theiPlant the maximum principal stress of transient condition
      
Figure 530907DEST_PATH_IMAGE009
--- Ellipse crack minor axis radius
     
Figure 2011104139147100002DEST_PATH_IMAGE010
--- with crack shape parameterQRelevant constant,
For underbead crack,
Figure 929659DEST_PATH_IMAGE011
For face crack,
C --- Ellipse crack major axis radius
        
Figure 2011104139147100002DEST_PATH_IMAGE014
--- cross the RADIAL and the angle of transverse at any point on crackle contour
4th step：Calculate crack propagation life of turbine rotor
TheiPlant the crack propagation life of turbine rotor of transient condition
Figure 273233DEST_PATH_IMAGE015
Calculation formula be：
    
Figure 2011104139147100002DEST_PATH_IMAGE016
In formula：
Figure 748689DEST_PATH_IMAGE017
、
Figure 2011104139147100002DEST_PATH_IMAGE018
--- rotor material crack expansion test constant；
5th step：Calculate overspeed test process rotor crack extension life-span integration loss：
During the overspeed test of turbine rotor, internal rotor and rotor surface principal stress all than larger, turbine rotor is due to crack propagation life integration loss caused by overspeed testCalculation formula be：
In formula：
Figure 602692DEST_PATH_IMAGE021
--- overspeed test of steam turbine number of times
--- the crack propagation life during overspeed test；
6th step：Calculate turbine rotor propagation of internal cracks life-span integration loss：
In the start-up course of steam turbine, maximum principal stress appears in internal rotor, turbine rotor propagation of internal cracks life-span integration loss
Figure 3718DEST_PATH_IMAGE023
Calculation formula be：
Figure 2011104139147100002DEST_PATH_IMAGE024
In formula：
    
Figure 285794DEST_PATH_IMAGE025
--- the cold start number of times of actual motion
    
Figure 2011104139147100002DEST_PATH_IMAGE026
--- the warm starting number of times of actual motion
    
Figure 721455DEST_PATH_IMAGE027
--- the hot starting, hot start number of times of actual motion
    
Figure 2011104139147100002DEST_PATH_IMAGE028
--- the very hot startup number of times of actual motion
Figure 227523DEST_PATH_IMAGE029
--- crack propagation life during cold start
Figure 2011104139147100002DEST_PATH_IMAGE030
--- crack propagation life during warm starting
Figure 381424DEST_PATH_IMAGE031
--- crack propagation life during hot starting, hot start
Figure 2011104139147100002DEST_PATH_IMAGE032
--- crack propagation life during very hot startup
7th step：Calculate turbine rotor propagation of internal cracks residual life：
Turbine rotor propagation of internal cracks residual life
Figure 201612DEST_PATH_IMAGE033
Calculation formula be：
Figure 2011104139147100002DEST_PATH_IMAGE034
In formula：
    
Figure 488849DEST_PATH_IMAGE035
--- the average annual crack propagation life loss of internal rotor,
Figure 2011104139147100002DEST_PATH_IMAGE036
Figure 103501DEST_PATH_IMAGE037
--- find the calendar year of crackle so far；
8th step：Control Cracks in Turbine Rotors extension residual life
If the propagation of internal cracks residue calendar life-span of turbine rotor
Figure 541436DEST_PATH_IMAGE033
（Or the external crack extension residue calendar life-span
Figure 2011104139147100002DEST_PATH_IMAGE038
）<4 years, within the year scheme of arrangement overhaul（A grades of maintenance）, overhauled or changed according to result of detection；If 4 years≤
Figure 165315DEST_PATH_IMAGE033
（Or
Figure 372306DEST_PATH_IMAGE038
）<8 years, the scheme of arrangement overhaul after 1 year but in 4 years（A grades of maintenance）, overhauled or changed according to result of detection；If 8 years≤
Figure 423438DEST_PATH_IMAGE033
（Or
Figure 286352DEST_PATH_IMAGE038
）<16 years, in scheduled major overhaul next time（A grades of maintenance）In, give detailed defect detecting test；If
Figure 510660DEST_PATH_IMAGE033
（Or
Figure 775419DEST_PATH_IMAGE038
）>=16 years, according to《Electricity power enterprise's overhaul of the equipments directive/guide》（DL/T838）Arrange the scheduled major overhaul of steam turbine（A grades of maintenance）Cycle and scheduled major overhaul project；
9th step：Print out result
Export result of calculation and control measure that Cracks in Turbine Rotors extends residual life, the Optimal Maintenance applied to steam turbine.
Preferably, the second step is concretely comprised the following steps：Set up the mechanical model of the axial symmetry FEM calculation of turbine rotor；Using existing finite element analysis technology, for underbead crack, the maximum principal stress that cold start, warm starting, hot starting, hot start, very hot startup and 110% nominal operation over speed of rotation test totally five kinds of transient processes is calculated.
The invention has the characteristics that：In steam turbine during one's term of military service; during turbine rotor scheduled major overhaul; using supersonic detector; flaw detection draws the face crack and the place position of underbead crack and crack size of turbine rotor; database server is stored in, the monitoring method of the crack propagation life of turbine rotor provided using the present invention, according to monthly different startups and machine stop times; the Crack Extension residual life of quantitative assessment turbine rotor, foundation is provided for the safe operation and Optimal Maintenance of turbine rotor.
It is an advantage of the invention that realize Cracks in Turbine Rotors extension residual life in line computation and regular monitoring；If the Crack Extension residual life of turbine rotor in short-term, passes through timely scheme of arrangement overhaul partially（A grades of maintenance）Carry out the Crack Extension residual life of reasonable employment turbine rotor, reached that regular monitoring Cracks in Turbine Rotors extends the technique effect of residual life.
Brief description of the drawings
Fig. 1 is the block diagram of crack propagation life of turbine rotor supervising device of the present invention；
Fig. 2 is the flow journey of crack propagation life of turbine rotor monitoring method of the present invention；
Fig. 3 is the computer software block diagram that calculation server of the present invention is used；
Fig. 4 is the schematic diagram of certain model 300MW Low Pressure Steam Turbine structures.
Embodiment
Illustrate the present invention with reference to embodiments.
Embodiment
As shown in Figure 1, the block diagram of crack propagation life of turbine rotor supervising device of the present invention, the crack propagation life of turbine rotor device of the present invention is made up of supersonic detector 1, calculation server 2, database server 3, web page server 4 and user terminal browser 5, supersonic detector 1 is connected with database server 3, calculation server 2 is connected with database server 3 and web page server 4, and web page server 4 is connected with database server 3, calculation server 2 and user terminal browser 5 respectively.
As shown in Figure 2, the flow chart of crack propagation life of turbine rotor monitoring method of the present invention, as shown in Figure 3, the computer software block diagram that calculation server of the present invention is used, the software installation is on the calculation server of crack propagation life of turbine rotor, calculating and control applied to crack propagation life of turbine rotor.
For certain model 300MW steam turbines, low pressure rotor is as shown in Figure 4 using the structure of welded disc turbine rotor, in this 300MW steam turbines during one's term of military service, using the computer software shown in the device shown in Fig. 1, the flow chart shown in Fig. 2 and Fig. 3, the result of calculation of low pressure rotor crack propagation life is calculated.
The first step：During steam turbine opens the maintenance of cylinder, place position and the crack size of crackle are determined using supersonic detector, measuring the corresponding rotor mother metal position A of this 300MW Low Pressure Steam Turbine intermediate welds using supersonic detector has an Ellipse crack, and its minor axis radius isa=2mm, c=10mm；
Second step：Set up the mechanical model of the axial symmetry FEM calculation of turbine rotor, using existing finite element analysis technology, the maximum principal stress that cold start, warm starting, hot starting, hot start, very hot startup and 110% nominal operation over speed of rotation test totally five kinds of transient processes is calculated, symbol is used respectively
Figure 59770DEST_PATH_IMAGE001
、
Figure 206718DEST_PATH_IMAGE002
、
Figure 172400DEST_PATH_IMAGE003
、With
Figure 746918DEST_PATH_IMAGE005
Represent；
3rd step：Calculate the critical crack size of turbine rotor：
Turbine rotoriPlant the critical crack size of transient condition
Figure 646740DEST_PATH_IMAGE006
Calculation formula be：
    
Figure 147604DEST_PATH_IMAGE007
In formula：
Figure 183694DEST_PATH_IMAGE008
--- theiPlant the maximum principal stress of transient condition
      
Figure 809847DEST_PATH_IMAGE009
--- Ellipse crack minor axis radius
     
Figure 869070DEST_PATH_IMAGE010
--- with crack shape parameterQRelevant constant,
For underbead crack,
Figure 238871DEST_PATH_IMAGE011
For face crack,
Figure 332729DEST_PATH_IMAGE012
C --- Ellipse crack major axis radius
        
Figure 738620DEST_PATH_IMAGE014
--- cross the RADIAL and the angle of transverse at any point on crackle contour
4th step：Calculate crack propagation life of turbine rotor
TheiPlant the crack propagation life of turbine rotor of transient condition
Figure 584216DEST_PATH_IMAGE015
Calculation formula be：
    
Figure 594897DEST_PATH_IMAGE016
In formula：
Figure 500537DEST_PATH_IMAGE017
、
Figure 596669DEST_PATH_IMAGE018
--- rotor material crack expansion test constant,
Figure 308273DEST_PATH_IMAGE017
=9.2×10-12、
Figure 376723DEST_PATH_IMAGE018
=2.54；
The maximum principal stress of the different start operating performance of this 300MW Low Pressure Steam Turbines position A correspondences and overspeed test operating mode
Figure 515580DEST_PATH_IMAGE039
, critical crack size
Figure 2011104139147100002DEST_PATH_IMAGE040
And crack propagation life
Figure 771112DEST_PATH_IMAGE015
Result of calculation is listed in table 1；
[table 1]
Sequence number Operating mode Maximum principal stress
Figure 286407DEST_PATH_IMAGE039
（MPa）		 Critical crack size
Figure 209364DEST_PATH_IMAGE040
（mm）		 Crack propagation life
Figure 519122DEST_PATH_IMAGE015
（It is secondary）
1 Cold start 507.66 35.6 2167
2 Warm starting 447.30 47.2 3292
3 Hot starting, hot start 426.14 52.6 3865
4 Very hot startup 433.30 51.0 3688
5 Overspeed test 550.48 29.3 1608
5th step：This 300MW steam turbines put into operation from September, 1989, carry out overspeed test altogether 25 times in September, 2011, this Low Pressure Steam Turbine is due to crack propagation life integration loss caused by overspeed test
Figure 324267DEST_PATH_IMAGE019
Result of calculation be：
Figure 312427DEST_PATH_IMAGE041
6th step：This steam turbine puts into operation in September, 2011, the cold start number of times of actual motion from September, 1989
Figure 152207DEST_PATH_IMAGE025
=71, the warm starting number of times of actual motion
Figure 632867DEST_PATH_IMAGE026
=502, the hot starting, hot start number of times of actual motion
Figure 128571DEST_PATH_IMAGE027
=2106 times, the very hot startup number of times of actual motion
Figure 720089DEST_PATH_IMAGE028
=108 times, this 300MW Low Pressure Steam Turbines position A crack propagation life integration loss
Figure 617638DEST_PATH_IMAGE023
Result of calculation be：
Figure 2011104139147100002DEST_PATH_IMAGE042
7th step：This Low Pressure Steam Turbine finds that crackle has been on active service 22 years so far,m=22, have
Figure 269199DEST_PATH_IMAGE036
Figure 986619DEST_PATH_IMAGE043
, this 300MW Low Pressure Steam Turbines position A Crack Extension residual lifes
Figure 381829DEST_PATH_IMAGE033
Result of calculation be：
Figure 2011104139147100002DEST_PATH_IMAGE044
Figure 133884DEST_PATH_IMAGE045
Year
8th step and the 9th step：The result of calculation 4 years of model 300MW Low Pressure Steam Turbines position A Crack Extension residual lifes≤
Figure 956346DEST_PATH_IMAGE033
=6.4 years<8 years, the control measure of recommendation were：The scheme of arrangement overhaul after 1 year but in 4 years（A grades of maintenance）, overhauled or changed according to result of detection, print out result.
The supervising device and method of the crack propagation life of turbine rotor provided using the present invention, quantitatively calculate the Crack Extension residual life of this 300MW Low Pressure Steam Turbines and recommend control measure, according to the crack propagation life of the low pressure rotor come scheme of arrangement overhaul（A grades of maintenance）, foundation is provided for the safe operation and Optimal Maintenance of this 300MW Low Pressure Steam Turbines.

Claims (3)

1. a kind of supervising device in turbine rotor propagation of internal cracks life-span, it is characterized in that, it is made up of supersonic detector, calculation server, database server, web page server and user terminal browser, supersonic detector is connected with database server, calculation server is connected with database server and web page server, and web page server is connected with database server, calculation server and user terminal browser respectively.
2. the monitoring method in the turbine rotor propagation of internal cracks life-span that the device described in claim 1 is used, it is characterized in that, adopt the computer software of the crack propagation life of turbine rotor shown a C language, operate on calculation server, applied to the monitoring of crack propagation life of turbine rotor, concretely comprise the following steps：
The first step：Flaw detection determines the crack size of turbine rotor：
During steam turbine opens the maintenance of cylinder, place position and the crack size of crackle are determined using supersonic detector, crack size refers to the minor axis radius of internal rotor Ellipse crack and rotor surface half elliptic crackleaAnd major axis radiusc；
Second step：The maximum principal stress at position where calculating crackle：
For underbead crack, the maximum principal stress that cold start, warm starting, hot starting, hot start, very hot startup and 110% nominal operation over speed of rotation test totally five kinds of transient processes is calculated, symbol is used respectively
Figure 2011104139147100001DEST_PATH_IMAGE001
、
Figure 427266DEST_PATH_IMAGE002
、
Figure 2011104139147100001DEST_PATH_IMAGE003
、
Figure 973785DEST_PATH_IMAGE004
WithRepresent； 
3rd step：Calculate the critical crack size of turbine rotor：
Turbine rotoriPlant the critical crack size of transient condition
Figure 147277DEST_PATH_IMAGE006
Calculation formula be：
    
Figure 2011104139147100001DEST_PATH_IMAGE007
In formula：
Figure 95641DEST_PATH_IMAGE008
--- theiPlant the maximum principal stress of transient condition
     
Figure 2011104139147100001DEST_PATH_IMAGE009
--- Ellipse crack minor axis radius
    
Figure 998351DEST_PATH_IMAGE010
--- with crack shape parameterQRelevant constant,
For underbead crack,
Figure 2011104139147100001DEST_PATH_IMAGE011
For face crack,
C --- Ellipse crack major axis radius
       
Figure 478191DEST_PATH_IMAGE014
--- cross the RADIAL and the angle of transverse at any point on crackle contour
4th step：Calculate crack propagation life of turbine rotor
TheiPlant the crack propagation life of turbine rotor of transient condition
Figure 2011104139147100001DEST_PATH_IMAGE015
Calculation formula be：
    
Figure 546641DEST_PATH_IMAGE016
In formula：
、
Figure 623181DEST_PATH_IMAGE018
--- rotor material crack expansion test constant；
5th step：Calculate overspeed test process rotor crack extension life-span integration loss：
Turbine rotor is due to crack propagation life integration loss caused by overspeed test
Figure 2011104139147100001DEST_PATH_IMAGE019
Calculation formula be：
Figure 144292DEST_PATH_IMAGE020
In formula：
Figure 2011104139147100001DEST_PATH_IMAGE021
--- overspeed test of steam turbine number of times
--- the crack propagation life during overspeed test；
6th step：Calculate turbine rotor propagation of internal cracks life-span integration loss：
Turbine rotor propagation of internal cracks life-span integration loss
Figure 2011104139147100001DEST_PATH_IMAGE023
Calculation formula be：
Figure 316965DEST_PATH_IMAGE024
In formula：
    
Figure 2011104139147100001DEST_PATH_IMAGE025
--- the cold start number of times of actual motion
    
Figure 564407DEST_PATH_IMAGE026
--- the warm starting number of times of actual motion
    
Figure 2011104139147100001DEST_PATH_IMAGE027
--- the hot starting, hot start number of times of actual motion
    
Figure 572814DEST_PATH_IMAGE028
--- the very hot startup number of times of actual motion
Figure 2011104139147100001DEST_PATH_IMAGE029
--- crack propagation life during cold start
Figure 560974DEST_PATH_IMAGE030
--- crack propagation life during warm starting
Figure 2011104139147100001DEST_PATH_IMAGE031
--- crack propagation life during hot starting, hot start
--- crack propagation life during very hot startup
7th step：Calculate turbine rotor propagation of internal cracks residual life：
Turbine rotor propagation of internal cracks residual life
Figure 2011104139147100001DEST_PATH_IMAGE033
Calculation formula be：
Figure 819097DEST_PATH_IMAGE034
In formula：
    
Figure 2011104139147100001DEST_PATH_IMAGE035
--- the average annual crack propagation life loss of internal rotor,
Figure 49221DEST_PATH_IMAGE036
Figure 2011104139147100001DEST_PATH_IMAGE037
--- find the calendar year of crackle so far；
8th step：Control Cracks in Turbine Rotors extension residual life
If the propagation of internal cracks residue calendar life-span of turbine rotor
Figure 844002DEST_PATH_IMAGE033
Or the external crack extension residue calendar life-span
Figure 538288DEST_PATH_IMAGE038
<4 years, scheme of arrangement overhaul within the year was overhauled or changed according to result of detection；If 4 years≤
Figure 189849DEST_PATH_IMAGE033
Or
Figure 172849DEST_PATH_IMAGE038
<8 years, the scheme of arrangement overhaul after 1 year but in 4 years was overhauled or changed according to result of detection；If 8 years≤
Figure 568058DEST_PATH_IMAGE033
Or
Figure 116851DEST_PATH_IMAGE038
<16 years, in scheduled major overhaul next time, give detailed defect detecting test；IfOr
Figure 409609DEST_PATH_IMAGE038
>=16 years, according to《Electricity power enterprise's overhaul of the equipments directive/guide》Arrange scheduled major overhaul cycle and the scheduled major overhaul project of steam turbine；
9th step：Print out result
Export result of calculation and control measure that Cracks in Turbine Rotors extends residual life, the Optimal Maintenance applied to steam turbine.
3. the monitoring method of crack propagation life of turbine rotor as claimed in claim 2, it is characterised in that the second step is concretely comprised the following steps：Set up the mechanical model of the axial symmetry FEM calculation of turbine rotor, using existing finite element analysis technology, the maximum principal stress that cold start, warm starting, hot starting, hot start, very hot startup and 110% nominal operation over speed of rotation test totally five kinds of transient processes is calculated；For outside crackle, the maximum principal stress that shutdown at sliding parameters, orderly closedown, accidental shutdown and 110% nominal operation over speed of rotation test totally four kinds of transient processes is calculated.
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CN102606230A (en) * 2012-02-28 2012-07-25 上海发电设备成套设计研究院 Device and method for monitoring crack extension life of retaining ring of steam turbine generator
CN103926855A (en) * 2014-05-04 2014-07-16 天津理工大学 Method for delaying crack growth of rotor through electromagnetic actuator
CN104481601A (en) * 2014-09-15 2015-04-01 上海发电设备成套设计研究院 Monitoring method of crack propagation life of low-cycle fatigue and high-cycle fatigue of steam turbine rotor
CN104636134A (en) * 2014-12-31 2015-05-20 小米科技有限责任公司 State prompting method and device
CN106290385A (en) * 2016-08-15 2017-01-04 上海发电设备成套设计研究院 The supervising device of the rotor surface manufacturing defect of steam turbine and gas turbine and method
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US9954991B2 (en) 2014-12-31 2018-04-24 Xiaomi Inc. Status notification method and device
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CN102606230B (en) * 2012-02-28 2014-08-20 上海发电设备成套设计研究院 Device and method for monitoring crack extension life of retaining ring of steam turbine generator
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