CN110082493A - 一种高温导汽管的蠕变寿命现场快速无损评估方法 - Google Patents

一种高温导汽管的蠕变寿命现场快速无损评估方法 Download PDF

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CN110082493A
CN110082493A CN201910349926.4A CN201910349926A CN110082493A CN 110082493 A CN110082493 A CN 110082493A CN 201910349926 A CN201910349926 A CN 201910349926A CN 110082493 A CN110082493 A CN 110082493A
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郑坊平
张红军
殷尊
吕一楠
林琳
孟永乐
高磊
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Xian Thermal Power Research Institute Co Ltd
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    • G01N2291/02—Indexing codes associated with the analysed material
    • G01N2291/028—Material parameters
    • G01N2291/0289—Internal structure, e.g. defects, grain size, texture

Abstract

本发明公开了一种高温导汽管的蠕变寿命现场快速无损评估方法，包括以下步骤：1)获取导汽管的设计参数及服役时间；2)确认导汽管的理化性能是否符合标准要求；3)确认导汽管是否存在表面缺陷及内部缺陷；4)当导汽管的理化性能符合标准要求且导汽管不存在表面缺陷、内部缺陷时，则转至步骤5)；当导汽管的理化性能不符合标准要求或导汽管存在表面缺陷、内部缺陷时，则需更换导汽管或消缺合格后再转至5)；5)采用内壁氧化层厚度超声测量设备测量导汽管的内壁氧化层及金属层的厚度，计算高温导汽管的蠕变寿命tr，该方法能够实现导汽管的蠕变寿命现场快速无损评估。

Description

一种高温导汽管的蠕变寿命现场快速无损评估方法
技术领域
本发明属于蠕变寿命评估技术领域，涉及一种高温导汽管的蠕变寿命现场快速无损评估方法。
背景技术
高温导汽管由于承受着一定的压力且服役温度在蠕变温度范围内，其损伤的主要形式是高温蠕变。在原始状态一定的情况下，影响导汽管蠕变寿命的主要因素为温度、应力和已服役时间，其中温度为导汽管服役的当量温度，应力为导汽管的实际周向应力，时间为已累计服役时间。
累计服役时间超过20年(约15万小时)的12Cr1MoV、P22等材料的导汽管均面临着组织性能衰退、蠕变寿命损耗等问题；高温高压导汽管在长期服役中因材质蠕变损伤造成开裂、爆管的非停事故时有发生；如果能够正确预测导汽管的蠕变寿命，就可以有效防止因导汽管材质蠕变损伤导致的非停事故发生。
传统的高温高压导汽管蠕变寿命评估方法，无论是等温线外推法还是θ函数法，均需要通过割取管样、蠕变持久试验进行，这除了会占用机组正常检修的宝贵工期，还会产生检修费、高温长时试验费，更不利的是试验需耗时长达2年之久才能出来评估结果。
因此，有必要开发一种导汽管蠕变寿命现场快速无损评估方法，在机组停机检修期间，现场通过无损的检验评估手段快速得到导汽管的蠕变寿命，为电厂决策是否需要更换导汽管或采取运行措施提供技术依据。
发明内容
本发明的目的在于克服上述现有技术的缺点，提供了一种高温导汽管的蠕变寿命现场快速无损评估方法，该方法能够实现导汽管的蠕变寿命现场快速无损评估。
为达到上述目的，本发明所述的高温导汽管的蠕变寿命现场快速无损评估方法包括以下步骤：
1)获取导汽管的设计参数及服役时间；
2)通过对导汽管进行光谱成分分析、硬度试验及金相检验，确认导汽管的理化性能是否符合标准要求；
3)通过对导汽管进行外观检查、磁粉检测及超声检测，确认导汽管是否存在表面缺陷及内部缺陷；
4)当导汽管的理化性能符合标准要求且导汽管不存在表面缺陷、内部缺陷时，则转至步骤5)；当导汽管的理化性能不符合标准要求或导汽管存在表面缺陷、内部缺陷时，则需更换导汽管或消缺合格后再转至5)；
5)采用内壁氧化层厚度超声测量设备测量导汽管的内壁氧化层及金属层的厚度，计算高温导汽管的蠕变寿命tr，其中，
其中，x为导汽管的内壁氧化层厚度，t为导汽管的累计服役时间，a、b、C0、C1、C2、C3及C4为与导汽管材料相关的参数，δ为导汽管金属层的厚度，Dw为导汽管的外径，P为导汽管的蒸汽压力，σ为导汽管的内压应力，T为导汽管的当量温度。
内壁氧化层厚度超声测量设备包括超声脉冲发生接收器、示波器及高频探头。
本发明具有以下有益效果：
本发明所述的高温导汽管的蠕变寿命现场快速无损评估方法在具体操作时，通过对导汽管进行光谱成分分析、硬度试验及金相检验，确认导汽管的理化性能是否符合标准要求；通过对导汽管进行外观检查、磁粉检测及超声检测，确认导汽管是否存在表面缺陷及内部缺陷，以确定导汽管是否存在超标缺陷，当导汽管无超标缺陷时，则利用内壁氧化层厚度超声测量设备测量导汽管的内壁氧化层及金属层的厚度，并以此计算高温导汽管的蠕变寿命，需要说明的是，本发明无需进行割管取样，节省割管及焊接恢复导汽管的工期，且无需进行高温长时间试验，评估效率较高。
附图说明
图1为本发明的流程图；
图2为本发明中内壁氧化层厚度超声测量设备的结构示意图；
图3为实施例一中锅炉导汽管的显微组织图；
图4为实施例二中汽轮机高压导汽管的显微组织图。
具体实施方式
下面结合附图对本发明做进一步详细描述：
参考图1，本发明所述的高温导汽管的蠕变寿命现场快速无损评估方法包括以下步骤：
1)获取导汽管的设计参数及服役时间；
2)通过对导汽管进行光谱成分分析、硬度试验及金相检验，确认导汽管的理化性能是否符合标准要求；
3)通过对导汽管进行外观检查、磁粉检测及超声检测，确认导汽管是否存在表面缺陷及内部缺陷；
4)当导汽管的理化性能符合标准要求且导汽管不存在表面缺陷、内部缺陷时，则转至步骤5)；当导汽管的理化性能不符合标准要求或导汽管存在表面缺陷、内部缺陷时，则需更换导汽管或消缺合格后再转至5)；
5)采用内壁氧化层厚度超声测量设备测量导汽管的内壁氧化层及金属层的厚度，计算高温导汽管的蠕变寿命tr，其中，
其中，x为导汽管的内壁氧化层厚度，t为导汽管的累计服役时间，a、b、C0、C1、C2、C3及C4为与导汽管材料相关的参数，δ为导汽管金属层的厚度，Dw为导汽管的外径，P为导汽管的蒸汽压力，σ为导汽管的内压应力，T为导汽管的当量温度。
参考图2，内壁氧化层厚度超声测量设备包括超声脉冲发生接收器、示波器及高频探头。
实施例一
对某发电厂锅炉导汽管的蠕变寿命进行现场快速评估，具体实施步骤及结果如下：
1)查阅技术资料知，导汽管的材料为12Cr1MoV，规格为Φ159×14mm，额定蒸汽压力及温度分别为9.81MPa及540℃，已累计服役时间为235400h；
2)经外观检查，未见缺陷和异常；经光谱成分分析，结果符合标准要求，经多点硬度试验，实测硬度最小值为120HBHLD，已略低于标准要求下限值，硬度最小值部位经金相检验，显微组织为铁素体加碳化物，球化4级，已完全球化，金相组织照片如图3所示；
3)经磁粉检测，发现外壁存在长约20mm、深约0.5mm的线性缺陷，现场打磨消除，经超声检测，未发现超标缺陷；
4)对多点进行内壁氧化层及金属层厚度测量，实测内壁氧化层厚度最大值为0.73mm，金属层厚度最小值为11.88mm；
5)当量温度评估结果为579℃，内压应力计算结果为60.7MPa；
6)汽管的蠕变寿命评估结果为约4.8万小时。
考虑到本次检修工期不充足，电厂计划在下一年的检修期间进行该导汽管更换。
实施例二
对某发电厂汽轮机高压导汽管的蠕变寿命进行现场快速评估，具体实施步骤及结果如下：
1)查阅技术资料知，汽轮机高压导汽管的材料为12Cr1MoV，规格为Φ159×20mm，额定蒸汽压力及温度分别为13.7MPa及545℃，已累计服役时间为188600h；
2)经外观检查，未见缺陷和异常；经光谱成分分析，结果符合标准要求；经多点硬度试验，实测硬度最小值为128HBHLD，已略低于标准要求下限值；硬度最小值部位经金相检验，显微组织为铁素体加贝氏体加碳化物，球化3～4级，已中度球化～完全球化，金相组织照片如图4所示；
3)经磁粉检测，未见缺陷和异常；经超声检测，未发现超标缺陷；
4)对多点进行内壁氧化层和金属层厚度测量，实测内壁氧化层厚度最大值为0.37mm，金属层厚度最小值为17.04mm；
5)当量温度评估结果为558℃，内压应力计算结果为57.1MPa；
6)导汽管的蠕变寿命评估结果为大于10万小时。
该导汽管不用更换，可以继续正常运行两个大修期。

Claims (2)

1.一种高温导汽管的蠕变寿命现场快速无损评估方法，其特征在于，包括以下步骤：
1)获取导汽管的设计参数及服役时间；
2)通过对导汽管进行光谱成分分析、硬度试验及金相检验，确认导汽管的理化性能是否符合标准要求；
3)通过对导汽管进行外观检查、磁粉检测及超声检测，确认导汽管是否存在表面缺陷及内部缺陷；
4)当导汽管的理化性能符合标准要求且导汽管不存在表面缺陷、内部缺陷时，则转至步骤5)；当导汽管的理化性能不符合标准要求或导汽管存在表面缺陷、内部缺陷时，则需更换导汽管或消缺合格后再转至5)；
5)采用内壁氧化层厚度超声测量设备测量导汽管的内壁氧化层及金属层的厚度，计算高温导汽管的蠕变寿命tr，其中，
其中，x为导汽管的内壁氧化层厚度，t为导汽管的累计服役时间，a、b、C0、C1、C2、C3及C4为与导汽管材料相关的参数，δ为导汽管金属层的厚度，Dw为导汽管的外径，P为导汽管的蒸汽压力，σ为导汽管的内压应力，T为导汽管的当量温度。
2.根据权利要求1所述的高温导汽管的蠕变寿命现场快速无损评估方法，其特征在于，内壁氧化层厚度超声测量设备包括超声脉冲发生接收器、示波器及高频探头。
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