CN103698150B - A kind of failure comprehensive decision method of great generating equipment - Google Patents

A kind of failure comprehensive decision method of great generating equipment Download PDF

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CN103698150B
CN103698150B CN201410003155.0A CN201410003155A CN103698150B CN 103698150 B CN103698150 B CN 103698150B CN 201410003155 A CN201410003155 A CN 201410003155A CN 103698150 B CN103698150 B CN 103698150B
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analysis
cut
failure
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wear
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CN103698150A (en
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杨振国
龚嶷
祝凯
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Fudan University
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Abstract

The invention belongs to TRT detection technique field, the failure comprehensive decision method of a kind of great generating equipment.The technology specifically comprises the steps of: one, proposing unitary analysis strategy, system considers eight aspect influence factors, including material, designs, manufactures, installs, checks, operates, safeguards and environment;Two, use comprehensive characterization method, cut micro-zone analysis is combined with macroscopic view test, the depth analysis that its surface microscopic feature is carried out after referring to cut is amplified 500 times by so-called micro-zone analysis;Three, set up rapid discrimination technology, the different failure mechanisms under the complex working conditions such as corrosive wear, erosive wear, compound corrosion can be defined in rapidly.

Description

A kind of failure comprehensive decision method of great generating equipment
Technical field
The invention belongs to great generating equipment detection technique field, be specifically related to the failure comprehensive decision method of a kind of great generating equipment.
Background technology
Power industry is the pillar industry of the national economic development, is directly connected to production and the development of other industry.But due to structure diversity and the operating mode complexity of generating equipment especially heat transmission equipment, abnormal Problem of Failure frequently occurs, and economic loss is huge.Therefore, by the inefficacy case study to typical case's heat transmission equipment, develop the failure analysis key technology of large power generating equipment, guard technology and risk assessment technology, be to ensure that the most effectual way of equipment safety operation, significant economic results in society can be brought.
Although it is known that both at home and abroad failure analysis is paid much attention to, carrying out numerous studies, but the failure accidents of exception occurred the most often.On the one hand this is the interactivity of practical situation and comprehensive caused, as uncomfortable in material selection, structure design is not proper, workmanship, mounting means is improper, detection method is conventional, structure property deterioration, maintenance process careless omission, human users is wrong, operating mode medium complicated, external environment condition change, failure mechanism is not clear, safeguard procedures are simple, management system is the tightest;On the other hand it is limitation and the uncertainty of FAILURE ANALYSIS TECHNOLOGY itself.Such as, existing FAILURE ANALYSIS TECHNOLOGY has its suitability when solving the Problem of Failure under single operating mode, but during an inefficacy difficult problem under analyzing complex working condition, either precision or effectiveness all need to develop further and improve.
To this, the present invention uses the research strategy of systematic analysis, creates the failure comprehensive decision method of a kind of great generating equipment.By cooperative cooperating in many ways and research of technique, the innovation achievement of the present invention has been successfully applied in the failure analysis of Up for Qinshan Nuclear Power Plant, Plant in Baoshan, Waigaoqiao Power Plant, Zhe Nengjiahua power plant, large power generating equipment such as Zhejiang energy Jiaxing Power Plant, Kingsoft petrochemical industry power plant etc., and extend to field of non-metallic materials, such as plastic automotive parts, microelectronic chip package and printed circuit board manufacture etc., achieve good economic results in society.
Summary of the invention
The present invention is directed to problem present in background technology, it is proposed that the failure comprehensive decision method of a kind of great generating equipment.
The failure comprehensive decision method of the great generating equipment that the present invention proposes, specifically comprises the following steps that
(1): using wholeness strategy to be analyzed the failure site of great generating equipment, the analysis to failure site considers eight aspect influence factors, including material, designs, manufactures, installs, checks, operates, safeguards and environment;Emphasis checks processing and the duty status of failure site, includes: whether to use Advanced, if having corrosion vestige, if having foreign matters from being blocked, and whether have local mechanical score;Analysis to failure site uses any one method in grand microscopic appearance, chemical valence state, surface-element, phase structure, group composition or hot property;
(2): use comprehensive characterization method, failure site carrying out cut micro-zone analysis and macroscopic view test, wherein cut micro-zone analysis refers to the sign after amplification is more than 500 times to cut surface microscopic feature;The integrating step (1) analysis result to failure site, classifies to failure cause, and sets up the judging principle and method of failure cause;
Described failure cause be divided into following in any one:
(A) if cut ovalize, fascia edge is the most recessed, and inwall and neighbouring surface are the most smooth, then judge that its failure cause is hydrogen blister;
(B) if forming some quasi-circular pits, diameter is between 1.5 ~ 2.5mm, deep for hole shape, shallow for coin shape, and distribution spacing has certain rule, then judge that its failure cause is for mechanical micro-pits;
(C) if being blocked by silt, cut outer wall surface is without wear trace, and cut inwall then has a plurality of parallel narrow bar extruding streak, and because local plastic large deformation produces fold;If by shell jam, cut edge is uneven, in the shape of a hoof, has erosive wear form;If being blocked by rubber strip, the cut such as shell jam when it occurs curling and blocks major part cross section, when it is fully extended, cut blocks with silt;Judge that its failure cause is foreign body (such as silt, shell, rubber strip etc.) blocking;
(3): on the basis of step (2), use three-dimensional stereomicroscope further, scanning electron microscope, energy spectrum analysis, infrared spectrum, Raman spectrum, atomic absorption spectrum, inductively coupled plasma atomic emission, secondary ion mass spectrum, chromatography of ions, x-ray photoelectron power spectrum, X-ray diffraction analysis, x-ray fluorescence analysis, one or more characterization methods in thermogravimetic analysis (TGA) or differential scanning calorimetric analysis, failure site is carried out comprehensive study, set up in corrosive wear, erosive wear, the rapid discrimination technology of the failure mechanism under the complex working conditions such as compound corrosion;
Specific implementation method be following in any one:
Use scanning electron microscope, x-ray photoelectron power spectrum, secondary ion mass spectrum and four kinds of characterizing methods of X-ray diffraction analysis, the micro-raman spectra of failure site cut inside and outside wall edge surface and material composition thereof, protium content, classes of compounds, phase structure etc. are comprehensively analyzed, if finally found that titantium hydride (TiH1.924) existence of crystalline phase, then can define the material failure mechanism of hydrogen blister and hydrogen embrittlement;
Use macroscopic view test that foreign body is analyzed, and combine three-dimensional stereomicroscope and the scanning electron microscope grand microscopic appearance observed result to cut, if finding, cut inwall has a plurality of parallel narrow bar extruding streak and generation fold or cut edge is uneven and in the shape of a hoof, then determines the material failure that foreign matters from being blocked causes;
Use the micro-zone analysis method that scanning electron microscope combines with energy spectrum analysis, if fester in discovery material wear surface generation local, micro-pits, and deposit the mix powder being made up of the dissimilar metal oxide such as titanium oxide or ferrum oxide, then can determine that failure cause is fretting wear;
Use the multiple characterizing methods such as inductively coupled plasma atomic emission, chromatography of ions, three-dimensional stereomicroscope, scanning electron microscope, energy spectrum analysis, if detecting, processing medium composition is widely varied frequently, and coin shape corrosion micropore, point corrosion pit, the micro/nano level needle-like corrosion product etc. on cut surface, then can define the brand-new failure mechanism of acid/base alternating corrosion;
Use scanning electron microscope and two kinds of analysis means of energy spectrum analysis, if the halogen ion of high level in observing failure site surface and the multiple spot corrosion form of section and point corrosion pit, then can determine that out the partial mulching that operation maintenance misoperation causes.
Have the beneficial effects that:
1, the present invention considers material, designs, manufactures, installs, checks, operates, safeguards and the eight aspect influence factors such as environment, effectively uses various modern analytical tool and method, can quickly, be accurately judged to the failure mechanism of great generating equipment;
2, the present invention is in the industries such as electric power, petrochemical industry, chemical industry, metallurgy, and the industrial equipment under similar service condition is formulated effective Failure prevention measure aspect and had universal reference value.
Accompanying drawing explanation
Fig. 1 is the cut macro morphology of the interior heat transfer titanium pipe that lost efficacy of certain heat exchanger tube sheet.Wherein, (a) certain heat-transfer pipe inwall ellipse cut pattern (hydrogen blister), (b) another heat-transfer pipe outer wall brittle cracking pattern (hydrogen embrittlement).
Fig. 2 is the XPS analysis result to Ineffective Titanium pipe ellipse cut.Wherein, a kind of Ti element valence of (a) inwall, (b) outer wall has two kinds of Ti element valences.
Fig. 3 is the sims analysis result of the inside and outside wall surface of cut.Wherein, (a) inwall, (b) outer wall.
Fig. 4 is the XRD diffraction maximum position that cut outer wall near surface exists titantium hydride.
Fig. 5 is the macro morphology of certain heat transfering tube of heat exchanger inwall machinery micro-pits.Wherein, (a) is evenly distributed, (b) coin shape pattern.
Fig. 6 is the heat-transfer pipe outer wall surface pattern that fretting wear causes.Wherein, (a) macro morphology, the metal filings on (b) wear surface, fester in the local on (c) wear surface, micro-pits form.
Fig. 7 is the inefficacy heat-transfer pipe pattern caused by foreign matters from being blocked in certain sea water heat exchanger.Wherein, (a) sedimentation, (b) shell jam, (c) rubber strip blocks.
Fig. 8 is the cut pattern of certain heat exchanger inefficacy heat-transfer pipe corrosion failure.Wherein, (a) macro morphology, (b) coin shape micropore, (c) point corrosion pit and needle-like corrosion product.
Fig. 9 is the pit morphology of certain heat transfering tube of heat exchanger outer wall surface.Wherein, (a) macro morphology, (b) inside and outside wall Profile Correlation, (c) point corrosion pit SEM pattern.
Detailed description of the invention
Below in conjunction with specific embodiment, the present invention is expanded on further.Should be understood that these embodiments are merely to illustrate the present invention and do not limit the scope of the invention.In addition, it is to be understood that after having read the content that the present invention lectures, the present invention can be made various changes or modifications by those skilled in the art, and these equivalent form of values fall within the application appended claims limited range equally.
Embodiment 1 : hydrogen embrittlement and the Inactivation shape of hydrogen blister and analysis
Fig. 1 show in certain large power generating equipment heat exchanger, is positioned at the inefficacy heat transfer titanium pipe cut pattern of tube sheet.Visible wherein left side cut ovalize, is shown in the inwall pattern of Fig. 1 (a), and the obvious ecto-entad in edge is recessed, show that this heat-transfer pipe outer wall is once by certain extruding force effect.Then there is brittle cracking phenomenon at another heat transfer titanium pipe outer wall that lost efficacy, see Fig. 1 (b).
For finding out the cause of above-mentioned rare failure phenomenon, implement following failure analysis strategy this project innovation:
(1) x-ray photoelectron power spectrum surface analysis.Use X-ray photoelectron spectroscopic analysis, determine a kind of valent state of Ti element on this cut inwall microcell surface, be known passivating film TiO2(Fig. 2 (a));But the Ti on cut outer wall microcell surface has two kinds of different valent states, sees Fig. 2 (b), except TiO2Outward, a kind of valence state that cannot match with existing standard.Thus can speculate that this Ti element is certain unknown compound.
(2) secondary ion mass spectrum surface analysis.The composition of secondary ion mass spectrum energy analytical table surface element, is also the analytical tool that uniquely can detect surface nanometer layer protium composition.For determining the kind of cut outer wall the unknown titanium compound, secondary ion mass spectrum is used to carry out micro-zone analysis.As it is shown on figure 3, cut outer wall top layer microcell has the H element of high level, and inwall does not has, and this result demonstrates the unknown titanium compound actually titantium hydride compound of outer wall surface.
(3) X-ray diffraction analysis.For determining the kind of above-mentioned titantium hydride, use X-ray diffraction method (XRD) that cut microcell is carried out surface Phase Structure Analysis further, see Fig. 4, it was demonstrated that titanium pipe outer wall exists a kind of special compound TiH with non-critical chemical ratio composition1.924.This titantium hydride is that this most effectively discloses the basic cause of outer wall surface generation brittle cracking by a kind of brittlement phase generated after hydrogen atom and Titanium base generation chemical reaction.
From this it can be concluded that the titanium tube failure that above oval cut causes with brittle cracking phenomenon respectively hydrogen blister and hydrogen embrittlement.
Embodiment 2 : the Inactivation shape of machinery micro-pits and analysis
Find the heat-transfer pipe inwall of certain heat exchanger, be evenly distributed coin shape micro-pits (Fig. 5 (a)).Through using scanning electron microscope, energy spectrum analysis etc. that depression inner circular cut is carried out micro-raman spectra observation and analysis, see Fig. 5 (b), quickly identify such depression when being to be installed by heat-transfer pipe threading because employing caused by the chucking power of traction fixing head really up to the mark.Therefore, when the fluid media (medium) in heat-transfer pipe flows through this machinery micro-pits, occur as soon as local turbulent, microcosmic flow field there occurs change, fluid creates lasting whirlpool centered by this sunk surface and washes away, and gradually deepen big with depression, the aggravation of erosive wear effect, ultimately result in recess tube wall be quickly washed worn out fall.
From this it can be concluded that the heat-transfer pipe that this coin shape micro-pits is mechanical erection to be caused lost efficacy.
Embodiment 3 : the Inactivation shape of fretting wear and analysis
Fig. 6 (a) show in certain heat exchanger, is positioned at the tube surface cut pattern under gripper shoe.Having the streak that significantly rubs on visible pipe outer wall, also have the bending machinery score that bar is longer simultaneously on this cut, this is clearly what heat-transfer pipe was stayed by accidental cuts when through gripper shoe fixing hole.This score was not the most damaged at that time, but was just on the contact surface of gripper shoe, so when heat exchanger runs, owing to fluid media (medium) fluctuates, heat-transfer pipe inherently occurs irregular fretting wear with gripper shoe.The scanning electron microscope pattern of Fig. 6 (b) clearly demonstrates, the annular wear surface generated with gripper shoe generation fretting wear is had near this score, and on wear surface in addition to deposition has the loose metal filings of one layer of distribution, also fester, the form such as micro-pits, see Fig. 6 (c).Obviously, this machinery score is under the continuous action of fretting wear, and outer wall surface is progressively worn thinning, and damage is serious, finally the Cracking Failure because of fatigue.
From this it can be concluded that the heat-transfer pipe that this machinery score cut is mechanical damage and fretting wear causes lost efficacy.
Embodiment 4 : the Inactivation shape of foreign matters from being blocked and analysis
When the heat-transfer pipe of certain sea water heat exchanger is made regular check on, find that many defect pipes are blocked by some not clear foreign bodies.According to the micro-zone analysis to different cut shapes, clearly identify the rubber lining fragment etc. that these foreign bodies are silt, shell and neighbouring hydroecium respectively.These tampers seriously exacerbate the sea water local scour wear effects to tube wall, define distinctive cut feature, only they are strictly made a distinction, and solve countermeasure and have specific aim, and control measures just can be effectively.
1) sedimentation: this cut feature typically has a plurality of parallel extruding streak and fold, and has multiple narrow bar cut along streak direction simultaneously, and cut circumferential surface is smooth, sees Fig. 7 (a).Obviously, this is that caused by the compound action by the abrasive wear produced containing sediment seawater after in sedimentation pipe and impact wear, its total wear extent can use formula (1) to represent.Obviously, the index times (V of its erosive wear effect and pipe maritime interior waters mean flow raten) there is the biggest association.The tube wall of silt blocking is under the selectivity abrasive wear of sea water and the compound action of erosive wear, and wall thickness reduction is accelerated, and is finally worn.
We =Ww + kVn (1)
Wherein, We、Ww、kVnBeing respectively total wear extent, abrasive wear amount and erosive wear amount, V is seawater velocity, and n is the material constant more than 2.2, and k is physical parameter.
2) shell jam: through micro-zone analysis, the cut pattern that shell jam causes exactly likes the shape of a hoof and edge is uneven, inner wall surface has irregular washes away vestige, sees Fig. 7 (b).This is owing to soft shell is softer and yielding so that inside pipe wall is by there being the orientation impact wear effect at certain inclination angle.Owing to inside pipe wall is stopped by shell, at this fault location, current there occurs that sudden change turns to, and occurs in that the erosive wear effect caused by the impact jet flow oriented, and its wear extent is shown in formula (2).According to the principle that pipe same cross section flow is equal, the impact jet flow speed that its current produce is greater than the mean flow rate of pipe maritime interior waters, and produced constant impingement abrasive action is very big, thus the inside pipe wall stopped by this kind of foreign body is quickly washed worn-off and falls.
We =ke Vm (2)
Wherein, VmBeing effluxvelocity at foreign body, m is the constant relevant with angle and foreign body shape, and ke is physical parameter.
3) rubber strip blocking: the scouring patterns that rubber strip blocking causes has two kinds: if rubber strip crimps in pipe and blocks major part cross section, its erosive wear behavior is as shell, concentrated wear amount as the formula (2), i.e. based on impact wear (Fig. 7 (c));If rubber strip is fully extended, its erosive wear behavior as silt, concentrated wear effect such as formula (1), i.e. there is the complex effect of abrasive wear and erosive wear, thus the concentrated wear effect caused after both superpositions be the most serious.
From this it can be concluded that the heat-transfer pipe that above series of cut pattern is foreign matters from being blocked to be caused lost efficacy.
Embodiment 5 : acid / The Inactivation shape of alkali alternating corrosion and analysis
In certain large-scale heat exchanger running, part carbon steel heat-transfer pipe leaks, shown in cut pattern such as Fig. 8 (a).Finding after using the detection of the means such as chromatography of ions, inductively coupled plasma atomic emission, the chemical analysis of heat-transfer pipe shell side fresh water (FW) medium the most frequently occurs with pH value significantly to change.Confirm in conjunction with after three-dimensional Stereo microscope, scanning electron microscope, energy spectrum analysis, cut is to be become big caused by the coin shape micropore disjunctor in Fig. 8 (b), these micropores itself then produce under acid/base alternating corrosion effect, there is the characters and appearances of point corrosion pit and micro/nano level needle-like caustic embrittlement corrosion product simultaneously, see Fig. 8 (c).
From this it can be concluded that the heat-transfer pipe that such cut is acid/base alternating corrosion effect to be caused lost efficacy.
Embodiment 6 : the Inactivation shape of spot corrosion and analysis
Certain large-scale heat exchanger is when regular maintenance, it was observed that part stainless steel heat-transfer pipe outer wall has point corrosion pit (Fig. 9 (a)), is clearly distinguished from inner wall smooth surface, sees Fig. 9 (b).Use scanning electron microscope and energy spectrum analysis that the point corrosion pit as shown in Fig. 9 (c) is carried out micro-zone analysis discovery, there is in hole higher concentration chloride ion, and design conditions should be free from this harmful ion.After utilizing ion chromatography, determine that chloride ion is accidentally to introduce during heat-transfer pipe alkali cleaning operation, thus finally cause spot corrosion to lose efficacy.
From this it can be concluded that the heat-transfer pipe spot corrosion that such cut is halide ion (predominantly chlorine) to be caused was lost efficacy.

Claims (1)

1. the failure comprehensive decision method of a great generating equipment, it is characterised in that specifically comprise the following steps that
(1): using wholeness strategy to be analyzed the failure site of great generating equipment, the analysis to failure site considers eight aspect influence factors, including material, designs, manufactures, installs, checks, operates, safeguards and environment;Emphasis checks processing and the duty status of failure site, includes: whether to use Advanced, if having corrosion vestige, if having foreign matters from being blocked, and whether have local mechanical score;Analysis to failure site uses any one method in grand microscopic appearance, chemical valence state, surface-element, phase structure, group composition or hot property;
(2): use comprehensive characterization method, failure site carrying out cut micro-zone analysis and macroscopic view test, wherein cut micro-zone analysis refers to the sign after amplification is more than 500 times to cut surface microscopic feature;The integrating step (1) analysis result to failure site, classifies to failure cause, and sets up the judging principle and method of failure cause;
Described failure cause be divided into following in any one:
(A) if cut ovalize, fascia edge is the most recessed, and inwall and neighbouring surface are the most smooth, then judge that its failure cause is hydrogen blister;
(B) if forming some quasi-circular pits, diameter is between 1.5 ~ 2.5mm, deep for hole shape, shallow for coin shape, and distribution spacing has certain rule, then judge that its failure cause is for mechanical micro-pits;
(C) if being blocked by silt, cut outer wall surface is without wear trace, and cut inwall then has a plurality of parallel narrow bar extruding streak, and because local plastic large deformation produces fold;If by shell jam, cut edge is uneven, in the shape of a hoof, has erosive wear form;If being blocked by rubber strip, the cut such as shell jam when it occurs curling and blocks major part cross section, when it is fully extended, cut blocks with silt;Judge that its failure cause is foreign matters from being blocked;
(3): on the basis of step (2), use one or more characterization methods in three-dimensional stereomicroscope, scanning electron microscope, energy spectrum analysis, infrared spectrum, Raman spectrum, atomic absorption spectrum, inductively coupled plasma atomic emission, secondary ion mass spectrum, chromatography of ions, x-ray photoelectron power spectrum, X-ray diffraction analysis, x-ray fluorescence analysis, thermogravimetic analysis (TGA) or differential scanning calorimetric analysis further, failure site is carried out comprehensive study, the rapid discrimination technology of foundation failure mechanism under corrosive wear, erosive wear, compound etching complex operating mode;
Specific implementation method be following in any one: use scanning electron microscope, x-ray photoelectron power spectrum, secondary ion mass spectrum and four kinds of characterizing methods of X-ray diffraction analysis, the micro-raman spectra of failure site cut inside and outside wall edge surface and material composition thereof, protium content, classes of compounds, phase structure are comprehensively analyzed, if finally found that the existence of titantium hydride crystalline phase, then can define the material failure mechanism of hydrogen blister and hydrogen embrittlement;
Use macroscopic view test that foreign body is analyzed, and combine three-dimensional stereomicroscope and the scanning electron microscope grand microscopic appearance observed result to cut, if finding, cut inwall has a plurality of parallel narrow bar extruding streak and generation fold or cut edge is uneven and in the shape of a hoof, then determines the material failure that foreign matters from being blocked causes;
Use the micro-zone analysis method that scanning electron microscope combines with energy spectrum analysis, if fester in discovery material wear surface generation local, micro-pits, and deposit the mix powder being made up of titanium oxide or ferrum oxide dissimilar metal oxide, then can determine that failure cause is fretting wear;
Use inductively coupled plasma atomic emission, chromatography of ions, three-dimensional stereomicroscope, scanning electron microscope, the multiple characterizing method of energy spectrum analysis, if detecting, processing medium composition is widely varied frequently, and coin shape corrosion micropore, point corrosion pit, the micro/nano level needle-like corrosion product on cut surface, then can define the brand-new failure mechanism of acid/base alternating corrosion;
Use scanning electron microscope and two kinds of analysis means of energy spectrum analysis, if the halogen ion of high level in observing failure site surface and the multiple spot corrosion form of section and point corrosion pit, then can determine that out the partial mulching that operation maintenance misoperation causes.
CN201410003155.0A 2014-01-06 2014-01-06 A kind of failure comprehensive decision method of great generating equipment Expired - Fee Related CN103698150B (en)

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