CN110991115A - Method for evaluating service life of key pressure-bearing component of thermal power over-service unit - Google Patents
Method for evaluating service life of key pressure-bearing component of thermal power over-service unit Download PDFInfo
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Abstract
The invention relates to a method for evaluating the service life of a key pressure-bearing component of a thermal power over-service unit, which comprises the following steps of ① inducing basic operation factors of the unit, ② answering the pressure-bearing component to be evaluated in service life and key problems of the unit in which the pressure-bearing component is positioned according to the basic operation factors induced in the step ①, ③ evaluating the residual service life of the pressure-bearing component according to the answer condition in the step ②, wherein the service life evaluation in the step ③ comprises first-level evaluation, second-level evaluation and third-level evaluation.
Description
Technical Field
The invention belongs to the technical field of continuous demonstration of operation licenses of thermal power generating units, and particularly relates to a service life prolonging evaluation method for a key pressure-bearing component of a thermal power over-service unit.
Background
Since thermal power plant components are designed for conventional strength rather than limited life, it is generally not possible to give an accurate design life of the plant components, for pressure-bearing components, i.e. the wall thickness of the component is determined by its pressure, temperature, allowable stress and geometry of the material. The design life of the thermal power generating unit is generally 30 years, and the power generating unit with the running time of more than 30 years is an overdimensioned power generating unit. The operation time of many units worldwide exceeds 30 years and can still normally operate, which indicates that the potential life of the thermal power generating unit is far longer than the design life of the thermal power generating unit.
The pressure-bearing member of thermal power generating unit is under high temperature, high-pressure operating mode mostly, and main damage mechanism includes: creep, fatigue, creep-fatigue interaction, corrosion, wear, mechanical damage, and the like. The most of domestic units are peak shaving operation units, including frequent starting, stopping and load change, so that the most main damage mechanism of key pressure-bearing components of the units is creep deformation, fatigue and creep deformation-fatigue interaction. With the fact that a subcritical unit put into production at early stage in China has been operated for 30 years or more than 30 years, the aging of a key pressure-bearing part is increasingly serious, the critical unit is operated for an extended period only by daily inspection and maintenance, scientific service life assessment is not made, and the risk is high. Therefore, a method for evaluating the service life of the key pressure-bearing component of the thermal power unit in extended service needs to be provided, so that the problems that the service life evaluation method of the key pressure-bearing component is uncertain and unspecified in the process of continuing and demonstrating the operation license of the domestic thermal power unit are solved, and the service life of the thermal power unit (equipment) component is more comprehensive, reasonable and economical.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a method for evaluating the service life of a key pressure-bearing member of a thermal power over-service unit.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a service life prolonging evaluation method for a key pressure-bearing member of a thermal power over-service unit comprises the following steps of ① summarizing basic operation factors of the unit, ② answering the key problems of the pressure-bearing member to be subjected to service life evaluation and the unit where the pressure-bearing member is located according to the basic operation factors summarized in the step ①, ③ evaluating the residual service life of the pressure-bearing member according to the answer condition in the step ②, and the service life evaluation in the step ③ comprises first-level evaluation, second-level evaluation and third-level evaluation.
Preferably, the basic operation factors in the step ① include the number of times of unit operation, hot start, warm start and cold start, unit load record, accident history and accident analysis report, maintenance and replacement record, structural material composition check of pressure-bearing member, size check of pressure-bearing member, steam temperature record of unit operation, and unit design parameters.
The key questions answered in step ② preferably include whether the unit has been operated in excess of design parameters, whether suitable design parameters will be exceeded during extended life, whether there is a margin of safety in the original design or material selection of the unit, whether there is an excessive history of the accident, and whether the steam temperature record will be satisfactory for assessing high temperature operating components.
Preferably, the first level of assessment in step ③ includes the steps of:
a1, drawing a steam temperature distribution diagram, and performing accounting to obtain normal metal temperature;
a2, calculating the working stress of the pressure-bearing member according to the design and normal operation parameters of the pressure-bearing member;
a3, calculating the life loss coefficient and the residual life of the pressure-bearing member;
a4, when the residual life is longer than the extended life of the design project, setting the inspection interval and keeping the accurate operation record; otherwise, the second grade evaluation is carried out.
Preferably, the second level of assessment in step ③ includes the steps of:
b1, carefully and macroscopically inspecting the pressure-bearing component, and observing whether the root of the pipe hole belt or the welding seam has cracks or not, wherein a third-level evaluation is required if the cracks are found;
b2, adopting a thermocouple to measure and monitor the temperature of the pressure-bearing member in real time on site, and measuring the on-site real-time operation pressure of the pressure-bearing member to obtain representative data;
b3, calculating the working stress of the pressure-bearing member according to the real-time measurement data;
b4, calculating the life loss coefficient and the residual life of the pressure-bearing member;
b5, when the residual life is longer than the extended life of the design project, setting the inspection interval and keeping the accurate operation record; otherwise, the third-level evaluation is carried out.
Preferably, the third level of assessment in step ③ includes the steps of:
c1, carrying out detailed inspection by adopting a nondestructive testing method, and measuring the sizes of all crack defects;
c2, sampling by using a trepanning, and measuring the material performance of the pressure-bearing component;
c3, evaluating microstructures such as laminating and electron microscopy of key parts of the pressure-bearing component;
c4, measuring the temperature, pressure, size and strain of the pressure bearing member;
c5, carrying out finite element instantaneous or steady state thermal analysis and structural stress analysis to obtain an accurate working stress field of the component;
c6, carrying out fatigue, creep and fracture mechanics analysis according to the relation between the fatigue crack propagation rate da/dN of the component and the stress intensity factor amplitude delta K of the crack tip
Determining crack propagation to correspondencesThe number of cycles N required for critical dimension under operating conditions; according to the relation between the creep crack propagation rate da/dt of the part and the stress intensity factor K of the crack tip
Determining the time t required by the crack to expand to the critical dimension under the corresponding working condition; resulting in the remaining life of the component, wherein: a, m is a constant related to material performance, an environmental medium and the geometry of a sample; b and n are creep material constants;
c7, when the residual life is longer than the prolonged life of the design project, setting a check interval and keeping accurate operation record; otherwise, the maintenance or replacement is determined.
Preferably, the working stress calculation in steps a2 and b3 uses the following method:
firstly, the internal pressure stress is calculated by adopting the following formula for the cylinder pressure-bearing component:
wherein: p is the rated working pressure, DoIs the outside diameter of the pipe, SmFor the pipe wall thickness, α is the additional wall thickness considering corrosion, abrasion and mechanical strength, and Y is the correction coefficient of the temperature to the formula for calculating the pipe wall thickness;
secondly, aiming at the elbow/elbow pressure-bearing part, the internal pressure stress is calculated by adopting the following formula:
wherein: e is the out-of-roundness of the elbow/bend, DnomIs the nominal outer diameter of the pipe, Domax，DominMaximum and minimum outside diameters of the pipe, P is the calculated pressure, DO，DiThe outer diameter and the inner diameter of the pipeline are shown, S is the minimum wall thickness, v is the Poisson ratio, and E is the elastic modulus of the material;
thirdly, calculating the cyclic thermal stress by adopting the following formula:
e is the elastic modulus of the material, α is the linear expansion coefficient of the material, delta T is the temperature difference between the inner wall and the outer wall, v is the Poisson ratio, f is the structural coefficient related to the inner wall and the outer wall;
and fourthly, calculating the working stress by adopting finite elements aiming at the unconventional pressure-bearing part.
Preferably, the life loss coefficient calculation in steps a3 and b4 adopts the following method: combining Larson-Miller parameter curves LMP (sigma) ═ T (C + log T) of high temperature bearing member materials according to actual operating stressesiR) Where LMP (σ) is a function of operating stress, T is operating temperature, T isiRMinimum break time, material C parameter; the corresponding minimum fracture time t is calculatediRAdding the losses under different operating conditions to obtain the total life loss of the high-temperature pressure-bearing equipment, and calculating the minimum fracture time t under different service temperatures i according to the manual dataiRThen calculating the life loss coefficient
Wherein: t is tiFor an operating temperature of the operating time at i, tiRIs the minimum break time at operating temperature i.
Preferably, the remaining life calculation method in steps a3 and b4 is as follows: rL＝(1-LFE)tiR(ii) a Wherein: rLThe remaining life.
Due to the implementation of the technical scheme, compared with the prior art, the invention has the following advantages:
the method for evaluating the service life of the key pressure-bearing component of the thermal power extended service unit can be used for evaluating the service life of the key pressure-bearing component of the thermal power extended service unit, solves the problem that the service life evaluation method of the key pressure-bearing component continuously demonstrated by the operation license of the thermal power unit in China is uncertain and unspecified, and enables the service life of the component of the thermal power unit (equipment) to be more comprehensive, reasonable and economical.
Drawings
FIG. 1 is a flow chart for life extension assessment of a pressure containing member of the present invention.
Detailed Description
The invention is described in further detail below with reference to the figures and specific examples.
Referring to fig. 1, the method for evaluating the service life of the key pressure-bearing member of the thermal power over-service unit comprises the following steps of ① summarizing basic operation factors of the unit, ② answering key problems of the pressure-bearing member to be subjected to service life evaluation and the unit where the pressure-bearing member is located according to the basic operation factors summarized in the step ①, ③ evaluating the residual service life of the pressure-bearing member according to the answer condition in the step ②, and the service life evaluation in the step ③ comprises first-level evaluation, second-level evaluation and third-level evaluation.
Specifically, the basic operation factors in step ① include, but are not limited to, unit operation hours, hot start, warm start, and cold start times, unit load records, accident history and accident analysis reports, maintenance work, maintenance and replacement records, pressure-bearing member structural material composition verification, pressure-bearing member dimension verification, unit operation steam temperature records, unit design parameters, and the like.
The key questions answered in step ② include whether the unit is operating above design parameters (temperature/pressure, etc.), whether it will operate above appropriate design parameters during extended life (peak shaver operation, etc.), whether there is a margin of safety in the original design or material selection of the unit, whether there is an excessive history of accidents, whether the steam temperature record will satisfy the assessment of high temperature operating components.
Further, the first level of assessment in step ③ includes the steps of:
a1, drawing a steam temperature distribution diagram, and performing accounting to obtain normal metal temperature;
a2, calculating the working stress of the pressure-bearing member according to the design and normal operation parameters of the pressure-bearing member;
a3, calculating the life loss coefficient and the residual life of the pressure-bearing member;
a4, when the residual life is longer than the extended life of the design project, setting the inspection interval and keeping the accurate operation record; otherwise, the second grade evaluation is carried out.
Preferably, the second level of assessment in step ③ includes the steps of:
b1, carefully and macroscopically inspecting the pressure-bearing component, and observing whether the root of the pipe hole belt or the welding seam has cracks or not, wherein a third-level evaluation is required if the cracks are found;
b2, adopting a thermocouple to measure and monitor the temperature of the pressure-bearing member in real time on site, and measuring the on-site real-time operation pressure of the pressure-bearing member to obtain representative data;
b3, calculating the working stress of the pressure-bearing member according to the real-time measurement data;
b4, calculating the life loss coefficient and the residual life of the pressure-bearing member;
b5, when the residual life is longer than the extended life of the design project, setting the inspection interval and keeping the accurate operation record; otherwise, the third-level evaluation is carried out.
The working stress calculation in steps a2 and b3 uses the following method:
firstly, the internal pressure stress is calculated by adopting the following formula for the cylinder pressure-bearing component:
wherein: p is the rated working pressure, DoIs the outside diameter of the pipe, SmFor the pipe wall thickness, α is the additional wall thickness considering corrosion, abrasion and mechanical strength, and Y is the correction coefficient of the temperature to the formula for calculating the pipe wall thickness;
secondly, aiming at the elbow/elbow pressure-bearing part, the internal pressure stress is calculated by adopting the following formula:
wherein: e is the out-of-roundness of the elbow/bend, DnomIs the nominal outer diameter of the pipe, Domax，DominMaximum and minimum outside diameters of the pipe, P is the calculated pressure, DO，DiThe outer diameter and the inner diameter of the pipeline are shown, S is the minimum wall thickness, v is the Poisson ratio, and E is the elastic modulus of the material;
thirdly, calculating the cyclic thermal stress by adopting the following formula:
e is the elastic modulus of the material, α is the linear expansion coefficient of the material, delta T is the temperature difference between the inner wall and the outer wall, v is the Poisson ratio, f is the structural coefficient related to the inner wall and the outer wall;
and fourthly, calculating the working stress by adopting finite elements aiming at the unconventional pressure-bearing part.
In addition, the life loss coefficient calculation in steps a3 and b4 adopts the following method: combining Larson-Miller parameter curves LMP (sigma) ═ T (c + log T) of high temperature bearing member materials according to actual operating stressesiR) Where LMP (σ) is a function of operating stress, T is operating temperature, T isiRMinimum break time, material C parameter; the corresponding minimum fracture time t is approximately calculatediRAdding the losses under different operating conditions to obtain the total life loss of the high-temperature pressure-bearing equipment, and calculating the minimum fracture time t under different service temperatures i according to the manual dataiRThen calculating the life loss coefficient
Wherein: t is tiFor an operating temperature of the operating time at i, tiRIs the minimum break time at operating temperature i.
The remaining life calculation method in steps a3 and b4 is as follows: rL＝(1-LFE)tiR(ii) a Wherein: rLThe remaining life.
The third level of assessment in step ③ includes the steps of:
c1, carrying out detailed inspection by adopting a nondestructive testing method, and measuring the sizes of all crack defects;
c2, sampling by using a trepanning, and measuring the material performance of the pressure-bearing component;
c3, evaluating microstructures such as laminating and electron microscopy of key parts of the pressure-bearing component;
c4, measuring the temperature, pressure, size and strain of the pressure bearing member;
c5, carrying out finite element instantaneous or steady state thermal analysis and structural stress analysis to obtain an accurate working stress field of the component;
c6, carrying out fatigue, creep and fracture mechanics analysis according to the relation between the fatigue crack propagation rate da/dN of the component and the stress intensity factor amplitude delta K of the crack tip
Determining the cycle number N required by the crack to expand to the critical dimension under the corresponding working condition; according to the relation between the creep crack propagation rate da/dt of the part and the stress intensity factor K of the crack tip
Determining the time t required by the crack to expand to the critical dimension under the corresponding working condition; resulting in the remaining life of the component, wherein: a, m is a constant related to material performance, an environmental medium and the geometry of a sample; b and n are creep material constants;
c7, when the residual life is longer than the prolonged life of the design project, setting a check interval and keeping accurate operation record; otherwise, the maintenance or replacement is determined.
And establishing life prolonging measures for supervising operation, modification, grade improvement or replacement and the like according to the evaluation result of the residual life of the part, specifically comprising a periodic inspection and re-evaluation schedule during the future life prolonging operation, a maintenance or replacement equipment part list (expense, delivery time, recommended manufacturer, replacement probability and the like), a spare part storage level and the like.
In conclusion, the method for evaluating the service life of the key pressure-bearing component of the thermal power unit in extended service can be used for evaluating the service life of the key pressure-bearing component of the thermal power unit in extended service, solves the problem that the service life evaluation method of the key pressure-bearing component continuously demonstrated by the operation license of the domestic thermal power unit is uncertain and unspecified at present, and enables the service life of the components of the thermal power unit (equipment) to be more comprehensive, reasonable and economical.
The above embodiments are merely illustrative of the technical concept and features of the present invention, and the purpose thereof is to enable those skilled in the art to understand the content of the present invention and implement the invention, and not to limit the scope of the invention, and all equivalent changes or modifications made according to the spirit of the present invention should be covered by the scope of the present invention.
Claims (9)
1. A service life prolonging evaluation method for a key pressure-bearing member of a thermal power over-service unit is characterized by comprising the following steps of ① inducing basic operation factors of the unit, ② answering the pressure-bearing member to be subjected to service life evaluation and key problems of the unit where the pressure-bearing member is located according to the basic operation factors induced in the step ①, ③ evaluating the residual service life of the pressure-bearing member according to the answer condition in the step ②, and the service life evaluation in the step ③ comprises first-level evaluation, second-level evaluation and third-level evaluation.
2. The method for evaluating the service life of the key pressure-bearing member of the thermal power over-service unit according to claim 1 is characterized in that basic operation factors in step ① include unit operation hours, times of hot start, warm start and cold start, unit load record, accident history and accident analysis report, maintenance and replacement record, structural material component checking of the pressure-bearing member, size checking of the pressure-bearing member, steam temperature record of unit operation and unit design parameters.
3. The method for evaluating the service life of the key pressure-bearing component of the thermal power unit in extended service according to claim 1, wherein the key questions answered in step ② include whether the unit is operated beyond design parameters, whether the unit is operated beyond suitable design parameters during the extended service life, whether the original design or material selection of the unit has safety margins, whether the accident history is excessive, and whether the steam temperature record can meet the evaluation of high-temperature operation components.
4. The method for evaluating the service life of the key pressure-bearing member of the thermal power plant over-service unit according to claim 1, wherein the first-level evaluation in the step ③ comprises the following steps:
a1, drawing a steam temperature distribution diagram, and performing accounting to obtain normal metal temperature;
a2, calculating the working stress of the pressure-bearing member according to the design and normal operation parameters of the pressure-bearing member;
a3, calculating the life loss coefficient and the residual life of the pressure-bearing member;
a4, when the residual life is longer than the extended life of the design project, setting the inspection interval and keeping the accurate operation record; otherwise, the second grade evaluation is carried out.
5. The method for evaluating the service life of the key pressure-bearing member of the thermal power plant over-service unit according to claim 1, wherein the second-stage evaluation in the step ③ comprises the following steps:
b1, carefully and macroscopically inspecting the pressure-bearing component, and observing whether the root of the pipe hole belt or the welding seam has cracks or not, wherein a third-level evaluation is required if the cracks are found;
b2, adopting a thermocouple to measure and monitor the temperature of the pressure-bearing member in real time on site, and measuring the on-site real-time operation pressure of the pressure-bearing member to obtain representative data;
b3, calculating the working stress of the pressure-bearing member according to the real-time measurement data;
b4, calculating the life loss coefficient and the residual life of the pressure-bearing member;
b5, when the residual life is longer than the extended life of the design project, setting the inspection interval and keeping the accurate operation record; otherwise, the third-level evaluation is carried out.
6. The method for evaluating the service life of the key pressure-bearing member of the thermal power plant over-service unit according to claim 1, wherein the third-level evaluation in the step ③ comprises the following steps:
c1, carrying out detailed inspection by adopting a nondestructive testing method, and measuring the sizes of all crack defects;
c2, sampling by using a trepanning, and measuring the material performance of the pressure-bearing component;
c3, evaluating microstructures such as laminating and electron microscopy of key parts of the pressure-bearing component;
c4, measuring the temperature, pressure, size and strain of the pressure bearing member;
c5, carrying out finite element instantaneous or steady state thermal analysis and structural stress analysis to obtain an accurate working stress field of the component;
c6, carrying out fatigue, creep and fracture mechanics analysis according to the relation between the fatigue crack propagation rate da/dN of the component and the stress intensity factor amplitude delta K of the crack tip
Determining the cycle number N required by the crack to expand to the critical dimension under the corresponding working condition; according to the relation between the creep crack propagation rate da/dt of the part and the stress intensity factor K of the crack tip
Determining the time t required by the crack to expand to the critical dimension under the corresponding working condition; resulting in the remaining life of the component, wherein: a, m is a constant related to material performance, an environmental medium and the geometry of a sample; b and n are creep material constants;
c7, when the residual life is longer than the prolonged life of the design project, setting a check interval and keeping accurate operation record; otherwise, the maintenance or replacement is determined.
7. The method for evaluating the service life of the key pressure-bearing member of the thermal power extended service unit according to claim 1, wherein the method comprises the following steps: the working stress calculation in steps a2 and b3 uses the following method:
firstly, the internal pressure stress is calculated by adopting the following formula for the cylinder pressure-bearing component:
wherein: p is the rated working pressure, DoIs the outside diameter of the pipe, SmFor the pipe wall thickness, α is the additional wall thickness considering corrosion, abrasion and mechanical strength, and Y is the correction coefficient of the temperature to the formula for calculating the pipe wall thickness;
secondly, aiming at the elbow/elbow pressure-bearing part, the internal pressure stress is calculated by adopting the following formula:
wherein: e is the out-of-roundness of the elbow/bend, DnomIs the nominal outer diameter of the pipe, Domax，DominMaximum and minimum outside diameters of the pipe, P is the calculated pressure, DO，DiThe outer diameter and the inner diameter of the pipeline are shown, S is the minimum wall thickness, v is the Poisson ratio, and E is the elastic modulus of the material;
thirdly, calculating the cyclic thermal stress by adopting the following formula:
e is the elastic modulus of the material, α is the linear expansion coefficient of the material, delta T is the temperature difference between the inner wall and the outer wall, v is the Poisson ratio, f is the structural coefficient related to the inner wall and the outer wall;
and fourthly, calculating the working stress by adopting finite elements aiming at the unconventional pressure-bearing part.
8. The method for evaluating the service life of the key pressure-bearing member of the thermal power extended service unit according to claim 1, wherein the method comprises the following steps: the life loss coefficient calculation in steps a3 and b4 adopts the following method: combining Larson-Miller parameter curves LMP (sigma) T (C + logt) of high temperature bearing member material according to actual working stressiR) Where LMP (σ) is a function of operating stress, T is operating temperature, T isiRMinimum break time, material C parameter; the corresponding minimum fracture time t is calculatediRAdding the losses under different operating conditions to obtain the total life loss of the high-temperature pressure-bearing equipment, and calculating the minimum fracture time t under different service temperatures i according to the manual dataiRThen calculating the life loss coefficient
Wherein: t is tiFor an operating temperature of the operating time at i, tiRIs the minimum break time at operating temperature i.
9. The method for evaluating the service life of the key pressure-bearing member of the thermal power extended service unit according to claim 1, wherein the method comprises the following steps: the remaining life calculation method in steps a3 and b4 is as follows: rL＝(1-LFE)tiR(ii) a Wherein: rLThe remaining life.
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| CN113836660A (en) * | 2021-09-24 | 2021-12-24 | 苏州热工研究院有限公司 | Method suitable for evaluating service life of thermal power turbine rotor in extended service |
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| CN112347583A (en) * | 2020-11-08 | 2021-02-09 | 西南石油大学 | Method for calculating limit internal pressure of double-defect-contained bent pipe of booster station |
| CN112347583B (en) * | 2020-11-08 | 2022-01-28 | 西南石油大学 | Method for calculating limit internal pressure of double-defect-contained bent pipe of booster station |
| CN112415170A (en) * | 2020-11-13 | 2021-02-26 | 吉林省电力科学研究院有限公司 | Method for evaluating service life of main steam pipeline of large heat supply unit |
| CN112417733A (en) * | 2020-11-25 | 2021-02-26 | 长江勘测规划设计研究有限责任公司 | Comprehensive evaluation method for remaining life of over-service water turbine generator set |
| CN113158352A (en) * | 2020-11-25 | 2021-07-23 | 长江勘测规划设计研究有限责任公司 | Method for evaluating remaining service life of water turbine generator set based on key components |
| CN112417733B (en) * | 2020-11-25 | 2022-11-01 | 长江勘测规划设计研究有限责任公司 | Comprehensive evaluation method for remaining life of over-service water turbine generator set |
| CN113836660A (en) * | 2021-09-24 | 2021-12-24 | 苏州热工研究院有限公司 | Method suitable for evaluating service life of thermal power turbine rotor in extended service |
| CN113836660B (en) * | 2021-09-24 | 2023-05-30 | 苏州热工研究院有限公司 | Assessment method suitable for service life of rotor of thermal power out-of-service steam turbine |
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