CN111684453A - Maintenance management menu determining method and equipment maintenance management method - Google Patents
Maintenance management menu determining method and equipment maintenance management method Download PDFInfo
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Abstract
A maintenance management menu determination method according to at least one embodiment of the present invention is a maintenance management menu determination method for a device, including the steps of: predicting a remaining life of a part to be serviced, which is in contact with the fluid in the apparatus, based on a result of a flaw detection inspection of the part; when the predicted remaining life is shorter than an allowable period, re-predicting the remaining life when an input factor value used for evaluating the remaining life of the part to be serviced is changed by a life extension measure for the part to be serviced; and drawing up a maintenance management menu for the equipment including the service life extension measure when it is confirmed that the remaining service life after the re-prediction is longer than the allowable period.
Description
Technical Field
The present disclosure relates to a maintenance menu determination method and a maintenance management method for a device.
Background
For example, in a pipe of a boiler used for a long time in a high-temperature and high-pressure environment, creep damage may occur in a welded portion between the pipes. Since creep damage progresses, it is necessary to evaluate the remaining life in accordance with the degree of progress of creep damage and to repair the welded portion at a proper timing. Therefore, the degree of progression of creep damage in the welded portion is measured to evaluate the remaining life (see patent document 1).
Prior art documents
Patent document
Patent document 1: japanese patent No. 5086615
Disclosure of Invention
Problems to be solved by the invention
In the method of evaluating the remaining life disclosed in patent document 1, when it is determined that the estimated remaining life is equal to or shorter than a predetermined time, that is, for example, equal to or shorter than a time corresponding to a period until the next inspection, the possibility of breakage of the inspection object before the next inspection is high, and some measures are required.
However, for example, in the case of replacing the inspection object, if the replacement item is not immediately available, the equipment has to be stopped again for replacement of the inspection object before the next inspection after the equipment is once operated. Therefore, costs related to the shutdown of the equipment after the operation and the re-operation after the replacement of the inspection object, and loss of benefits related to the shutdown of the equipment after the operation are generated. As described above, it is sometimes required to extend the remaining life of the inspection object by a predetermined period (for example, an allowable period).
In view of the above circumstances, an object of at least one embodiment of the present invention is to extend the life of a maintenance target portion of equipment by a predetermined period.
Means for solving the problems
(1) A maintenance management menu determination method according to at least one embodiment of the present invention is a maintenance management menu determination method for a device, including the steps of:
predicting a remaining life of a part to be serviced, which is in contact with the fluid in the apparatus, based on a result of a flaw detection inspection of the part;
when the predicted remaining life is shorter than an allowable period, re-predicting the remaining life when an input factor value used for evaluating the remaining life of the part to be serviced is changed by a life extension measure for the part to be serviced; and
if it is confirmed that the remaining life after the re-prediction is longer than the allowable period, a maintenance management menu for the equipment is created, the maintenance management menu including the life extension measure.
According to the method of the above (1), since the maintenance management menu including the life extension measure is created after confirming that the remaining life after the adoption of the life extension measure is longer than the allowable period, the remaining life of the part to be maintained can be made longer than the allowable period.
(2) In some embodiments, based on the method of (1), the service life extension countermeasure includes at least one of an operation condition alleviation countermeasure for reducing a load on the maintenance target portion by changing an operation condition of the equipment, and a local countermeasure to be performed on the maintenance target portion.
According to the method of the above (2), by taking measures for mitigating the operating conditions, it is possible to reduce the load on the maintenance target site at a plurality of sites within the range in which the influence of the change in the operating conditions of the facility is spread. Further, by performing local countermeasures for the maintenance target portion, the range of influence spread due to the implementation of the countermeasures can be limited.
(3) In some embodiments, based on the method (2), the step of predicting the remaining lifetime further includes the steps of: the input factor value changed by the operation condition relaxation measure or the local measure is obtained, and the remaining life is re-predicted based on the obtained input factor value.
According to the method of the above (3), since the input factor value changed by the operation condition mitigation countermeasure or the local countermeasure is obtained, the obtained input factor value becomes a proper value, and the accuracy of the remaining lifetime to be re-predicted based on the obtained input factor value is improved.
(4) In some embodiments, based on the method (2) or (3), the lifetime extension measure is a measure in which the operation condition mitigation measure and the local measure are combined.
According to the method of the above (4), by combining the operation condition mitigating measures with the local measures, the amount of change in the operation conditions of the plant can be suppressed, the influence on the operation of the plant can be suppressed, and the local measures can be simplified.
(5) In some embodiments, based on the method of (4) above, the lifetime extension measure is a combination of the operating condition mitigating measure and the local measure selected so that a sum of a loss of interest and an increase in cost is reduced from a case where the operating condition mitigating measure and the local measure are separately implemented.
For example, in the countermeasure for mitigating the operating condition, the operating condition of the plant is changed, and therefore, the operating efficiency of the plant may be lowered, and a loss of profit may occur. In general, the larger the range of change in the operating conditions of the plant, the lower the operating efficiency of the plant and the more the loss of profit tends to increase. In addition, in the local countermeasure, the cost required for the countermeasure tends to increase as the effect of the countermeasure is generally improved. Therefore, for example, by combining the operation condition mitigating measures with the local measures, although a loss of interest due to a change in the operation conditions of the plant occurs, an increase in cost due to implementation of the local measures can be suppressed. In other words, by combining the operation condition mitigating measures with the local measures, the cost for implementing the local measures is incurred, but the loss of interest due to the change in the operation conditions of the plant can be reduced. Therefore, according to the method of (5), the sum of the loss of interest and the increase in cost can be suppressed by appropriately selecting and combining the operation condition mitigating measures and the local measures.
(6) In some embodiments, in any one of the methods (2) to (5), the operation condition mitigating measure includes at least one of a measure for reducing a temperature of a fluid in contact with the part to be serviced and a measure for reducing a pressure of the fluid.
According to the method of the above (6), since the load acting on the part to be serviced can be reduced, the remaining life of the part to be serviced can be extended.
(7) In some embodiments, in the method according to any one of (2) to (6), the local countermeasure includes at least one of local cooling for locally cooling the maintenance target portion, a stress relaxation countermeasure for relaxing stress in the maintenance target portion, and a damage recovery countermeasure for recovering damage to the maintenance target portion.
According to the method of the above (7), the remaining life of the part to be serviced can be extended by at least one of the local cooling, the stress relaxation countermeasure, and the damage recovery countermeasure.
(8) In some embodiments, in the method according to any one of the above (2) to (7), the local countermeasure includes at least one of reinforcement of the maintenance target portion and a change in a limiting condition of the maintenance target portion as a stress relaxation countermeasure for relaxing stress at the maintenance target portion.
According to the method of the above (8), the stress on the part to be serviced is relaxed by at least one of the reinforcement of the part to be serviced and the change of the regulation condition of the part to be serviced, and the remaining life of the part to be serviced can be extended.
(9) In some embodiments, in the method according to any one of the above (2) to (8), the local countermeasure includes at least repair welding of the maintenance target portion as a damage recovery countermeasure for recovering the damage of the maintenance target portion.
According to the method of the above (9), the damage of the part to be serviced is recovered by the damage recovery measure including at least repair welding of the part to be serviced, whereby the remaining life of the part to be serviced can be extended.
(10) In some embodiments, based on any one of the methods (1) to (9), in the step of creating the maintenance management menu, when a plurality of the life extension measures capable of extending the remaining life by the allowable period exist, an amount of money is converted for an influence when at least one of the plurality of life extension measures is applied, and the maintenance management menu is determined in consideration of a result of the amount of money conversion.
According to the method of (10), the remaining life of the part to be serviced can be made longer than the allowable period while suppressing economic loss due to implementation of the life extension measures.
(11) In some embodiments, based on any one of the methods (1) to (10), in the step of predicting the remaining life again, the remaining life is predicted again on the basis of at least one of the re-estimation of the allowable period and the re-estimation of the input factor value.
According to the method of the above (11), by predicting the remaining lifetime after at least one of the re-estimation of the allowable period and the re-estimation of the input factor value is performed, for example, if the period required to be extended by the lifetime extension countermeasure can be shortened, the extent of change of the operating conditions of the equipment due to the operating condition alleviation countermeasure can be suppressed, and the local countermeasure to be performed on the maintenance target portion can be simplified.
(12) In several embodiments, based on any one of the methods (1) to (11) above,
the apparatus is a power generation apparatus and,
the fluid is steam.
According to the method of the above (12), as described in the above (1), since the maintenance management menu including the life extension measure is created after it is confirmed that the remaining life after the adoption of the life extension measure is longer than the allowable period, the remaining life of the part to be maintained in contact with the steam in the power generation facility can be made longer than the allowable period.
(13) A maintenance management method for a facility according to at least one embodiment of the present invention includes the steps of:
determining a maintenance management menu of the equipment by using the maintenance management menu determination method of any one of (1) to (12) above;
performing maintenance management of the maintenance target part according to the maintenance management menu; and
the maintenance target portion is monitored after the maintenance management.
According to the method of (13) above, the remaining life of the part to be serviced can be made longer than the allowable period by taking the life extension measure, and the state of the part to be serviced during the subsequent operation period of the apparatus can be grasped.
(14) In some embodiments, based on the method of (13), in the step of monitoring the site to be serviced, items that affect the input factor value used when the remaining life is to be re-predicted are monitored, and whether or not the items are out of an allowable range that should be satisfied in order to make the remaining life after the re-prediction longer than the allowable period is determined.
According to the method of (14), since it is possible to determine whether or not the remaining life of the part to be serviced can be shortened compared to the allowable period, measures for extending the life can be additionally taken as necessary, and it is possible to further cope with the situation that the remaining life is longer than the allowable period.
(15) In some embodiments, based on the method (14), the method further includes:
predicting a new remaining life when the input factor value is changed by a new life extension measure for the part to be serviced, when it is determined that the value of the item deviates from the allowable range in the step of monitoring the part to be serviced; and
if it is confirmed that the new remaining life is longer than the allowable period, a maintenance management menu for the equipment is created, which includes the new measure for prolonging the life.
According to the method of (15) above, since the maintenance management menu including the new life extension measure is created after it is confirmed that the new remaining life after the adoption of the new life extension measure is longer than the allowable period, the remaining life of the part to be maintained can be made longer than the allowable period.
Effects of the invention
According to at least one embodiment of the present invention, the service life of the maintenance target portion of the equipment can be extended by a predetermined period.
Drawings
Fig. 1 is a diagram showing steps in a maintenance management method for a facility using a maintenance management menu determination method according to some embodiments.
Fig. 2 is a graph in which the horizontal axis represents the temperature of the part to be maintained and the vertical axis represents the stress of the part to be maintained.
Fig. 3 is a table for explaining a combination pattern of the life prolonging measures and the amount of temperature drop.
Detailed Description
Several embodiments of the present invention will be described below with reference to the drawings. However, the dimensions, materials, shapes, relative arrangements, and the like of the constituent members described as the embodiments and shown in the drawings are not intended to limit the scope of the present invention to these, and are merely illustrative examples.
For example, a relative or absolute arrangement expression such as "in a certain direction", "along a certain direction", "parallel", "orthogonal", "central", "concentric", or "coaxial" indicates not only such an arrangement strictly, but also a state in which the arrangement is relatively displaced with a tolerance or an angle or a distance to the extent that the same function can be obtained.
For example, expressions indicating states in which objects are equal, such as "identical", "equal", and "homogeneous", indicate not only states in which the objects are exactly equal but also states in which there are tolerances or differences in the degree to which the same function can be obtained.
For example, the expression "square shape" or "cylindrical shape" means not only a shape such as a square shape or a cylindrical shape in a geometrically strict sense but also a shape including a concave and convex portion or a chamfered portion within a range in which the same effect can be obtained.
On the other hand, the expressions "provided with", "having", "including", or "having" one constituent element are not exclusive expressions excluding the presence of other constituent elements.
First, an outline of a maintenance menu determination method and a maintenance management method of a facility according to some embodiments will be described with reference to fig. 1.
Fig. 1 is a diagram showing steps in a maintenance management method for a facility using a maintenance management menu determination method according to some embodiments. The maintenance management method of the equipment of some embodiments includes: a step S1 of selecting a part to be maintained; a step S2 of performing an inspection of the part to be serviced; step S3 of determining a maintenance management menu; a step S7 of performing maintenance management of the maintenance target site; and a step S8 of monitoring the part to be maintained.
The maintenance management menu determining method of some embodiments includes a step S3 of determining a maintenance management menu.
The maintenance menu determination method and the facility maintenance management method according to some embodiments are suitable for maintenance management of a metal member used for a long time in an environment where a high temperature and a large load are applied, and are suitable for maintenance management of a welded portion such as a steam pipe connecting a boiler and a steam turbine in a thermal power plant, for example.
The welded portion of the steam pipe or the like includes a heat-affected portion by welding. The heat-affected zone generates the following creep damage. That is, in the heat-affected zone, creep voids are generated due to long-term use at high temperatures. The number of creep voids increases due to long-term use, and adjacent creep voids are connected to each other to become cracks. Then, cracks gradually grow, and eventually the welded portion penetrates in the thickness direction, thereby causing leakage of the internal fluid. Therefore, in operation of boilers and the like, maintenance of welded portions such as steam pipes needs to be performed accurately.
Hereinafter, the outline of each step in the maintenance management method of the facility according to some embodiments will be described.
In the maintenance management method for a facility according to some embodiments, the steps do not have to be performed in the order shown in fig. 1, and as described later, there may be steps that are not performed, steps that are performed in a different order from the order shown in fig. 1, or steps that are performed repeatedly.
(step S1 of selecting a part to be serviced)
Step S1 of selecting a site to be serviced is a step of selecting a site to be serviced from among welded portions of a plurality of steam pipes or the like existing in the facility.
(step S2 of inspecting the site to be serviced)
Step S2 of performing the inspection of the site to be serviced is a step of performing a flaw detection inspection on the site to be serviced selected in step S1 of selecting the site to be serviced. The flaw detection performed in step S2 for performing the inspection of the part to be maintained may be performed by, for example, a phased array method, UT method, aperture synthesis method, high-frequency UT method, or ultrasonic noise method. Here, the high-frequency UT method refers to flaw detection using ultrasonic waves having a frequency of 20MHz or higher.
Step S2 of performing the inspection of the site to be serviced is performed, for example, when the apparatus is stopped, such as a periodic inspection of the apparatus. In the following description, step S2 of performing the inspection of the site to be serviced is a step performed at the time of the regular inspection of the equipment, and a case of performing the regular inspection at the time point of performing step S2 of performing the inspection of the site to be serviced is referred to as the present regular inspection. The next scheduled periodic inspection of the present periodic inspection is referred to as a next periodic inspection, and the periodic inspection performed next to the next periodic inspection is referred to as a next periodic inspection.
(step S3 of deciding maintenance management Menu)
The step S3 of determining the maintenance management menu includes a step S4 of predicting the remaining life of the part to be maintained, which will be described later, a step S5 of predicting the remaining life, and a step S6 of preparing the maintenance management menu.
(step S4 for predicting the remaining Life of the part to be serviced)
Step S4 of predicting the remaining life of the part to be serviced is a step of predicting the remaining life of the part to be serviced based on the result of the inspection of the part to be serviced performed in step S2 of performing the inspection of the part to be serviced.
The remaining life is the time from the current time point to the time point at which the maintenance target portion is broken due to creep damage.
The prediction of the remaining life may be performed by, for example, crack progression calculation, FEM, evaluation of damage mechanics, a hole simulation method, a tissue simulation method, or the like.
(step S5 of predicting remaining Life)
The step S5 of predicting the remaining life is performed when the remaining life predicted by the step S4 of predicting the remaining life of the part to be serviced is shorter than the allowable period or has a margin less than the allowable period. Here, the allowable period is a period from a time point when the remaining life of the part to be serviced is expected to be exceeded, for example, a period until a periodic inspection next or later.
In step S5 of predicting the remaining life again, the input factor value used for the remaining life evaluation (prediction of remaining life) of the maintenance target part is re-estimated, and the remaining life is predicted again. In step S5 of predicting the remaining life, the allowable period may be re-estimated.
In the re-estimation of the input factor value, the input factor value may be re-estimated by re-estimating the margin that the input factor value has to the security side.
As an example of the case where the input factor value is reestimated by reestimating the margin to the safe side that the input factor value has, for example, in the case where the input factor used when the remaining life is first predicted is the design value of the equipment relating to the maintenance target site, it is conceivable to use the actual measurement value as the reestimated input factor value.
That is, the design value is often redundant and is often set to a value too much stricter than the actual value. For example, it is conceivable that the design values of the stress and the temperature acting on the maintenance target site are larger than those of the stress and the temperature actually acting on the maintenance target site.
Therefore, by using the actual measurement value as the input factor value after the re-estimation, it is expected that the remaining lifetime after the re-estimation is longer than the allowable period.
Instead of using the actual measurement value, an estimated value may be used as the input factor value after the re-estimation. For example, when it is difficult to measure the actual measurement value, the estimated value of the site to be maintained may be calculated from the operating conditions of the equipment, the actual measurement value in the vicinity of the site to be maintained, and the like. For example, if the site to be serviced is a welded portion of a steam pipe, the temperature and pressure of the steam flowing through the steam pipe are obtained from the operation data of the equipment, and the values of the temperature and stress of the site to be serviced can be estimated.
In the reestimation of the input factor value, it is conceivable to change the input factor value by a service life extension measure of the maintenance target portion, which will be described later. That is, it is assumed that a measure (life extension measure) for changing the input factor value so as to extend the remaining life is implemented to change the input factor value. In step S6 of preparing a maintenance management menu, which will be described later, step S5 of predicting the remaining life may be performed in the process of considering the life extension countermeasure for the maintenance target site, and the remaining life may be predicted again using the input factor value after the change based on the life extension countermeasure.
As an example of the case of the re-estimation allowable period, for example, in the case where the allowable period before the re-estimation is, for example, four years, which is a period until the next periodic inspection in the periodic inspection performed every two years, it is conceivable that the allowable period after the re-estimation is two years, which is a period until the next periodic inspection. In addition, depending on the case, a period up to a time different from the time of performing the periodic inspection, such as a temporary device stop, may be set as the re-estimated allowable period.
In step S5 of predicting the remaining life, either or both of the input factor value and the allowable period may be reestimated.
That is, in some embodiments, in the step S5 of predicting the remaining life again, the remaining life is predicted again after at least one of the re-estimation of the allowable period and the re-estimation of the input factor value is performed. By predicting the remaining lifetime after at least one of the re-estimation of the allowable period and the re-estimation of the input factor value, for example, if the period required to be extended by the lifetime extension measure can be shortened, the extent of change of the operating condition of the equipment due to the operating condition relaxation measure can be suppressed, and the local measure to be performed on the part to be maintained can be simplified.
(step S6 of drawing up maintenance management menu)
Step S6 of preparing a maintenance menu is a step of preparing a maintenance menu for the equipment including the measures for prolonging the life. For example, in step S6 of preparing a maintenance management menu, if the remaining life after the re-prediction in step S5 of re-predicting the remaining life is shorter than the allowable period, a life extension measure is prepared. Specifically, the lifetime extension measures are planned as follows.
Fig. 2 is a graph in which the horizontal axis represents the temperature of the part to be serviced and the vertical axis represents the stress of the part to be serviced.
In the graph of fig. 2, a solid line plot P0 represents the temperature and stress applied to the part to be serviced during the operation of the equipment, and is a plot before the input factor value is reestimated in step S5 of predicting the remaining life.
In the graph of fig. 2, a broken-line plot P1 represents the temperature and stress applied to the part to be serviced during the operation of the equipment, and is a plot obtained after the input factor value is reestimated in step S5 of predicting the remaining life.
In the graph of fig. 2, the solid line is an equal lifetime line L0 indicating conditions of temperature and stress in which the remaining lifetime of the part to be serviced is equal to the allowable period. The equal lifetime line L0 is the equal lifetime line before the input factor value and the allowable period are reestimated in step S5 of predicting the remaining lifetime.
In the graph of fig. 2, a broken line L1 is an equal life line L1 indicating conditions of temperature and stress that make the remaining life of the part to be serviced equal to the allowable period. The equal lifetime line L1 is the equal lifetime line after the input factor value and the allowable period are reestimated in step S5 of predicting the remaining lifetime.
The broken line L2 in the graph of fig. 2 will be described later.
When the equipment is re-operated after the current periodic inspection, if the temperature and stress acting on the part to be serviced are those of the region corresponding to the left side of the equal lifetime line L0, the remaining lifetime of the part to be serviced is longer than the allowable period before the re-estimation, and if the temperature and stress are those of the region corresponding to the right side of the equal lifetime line L0, the remaining lifetime of the part to be serviced is shorter than the allowable period before the re-estimation. Similarly, when the equipment is re-operated after the current periodic inspection, if the temperature and stress acting on the part to be serviced are those of the region corresponding to the left side of the equal lifetime line L1, the remaining lifetime of the part to be serviced is longer than the allowable period after the re-estimation, and if the temperature and stress are those of the region corresponding to the right side of the equal lifetime line L1, the remaining lifetime of the part to be serviced is shorter than the allowable period after the re-estimation.
When the remaining lifetime after the re-prediction is shorter than the allowable period in the step S5 of re-predicting the remaining lifetime, the broken-line plot P1 is located in the region on the right side of the equal lifetime line L1 as shown in fig. 2. Therefore, when the apparatus is re-operated after the present periodic inspection, at least one of the temperature and the stress of the part to be serviced is changed so that the condition of the temperature and the stress of the part to be serviced is located at least in the region on the left side of the equal lifetime line L1, whereby the remaining lifetime of the part to be serviced can be made longer than the allowable period.
As a measure (life extension measure) for changing at least one of the temperature and the stress of the maintenance target portion, which is the input factor value, so as to extend the remaining life, the following measures can be cited.
(1) Operation condition relaxation countermeasure
The operation condition mitigating measures are measures for prolonging the life by changing the operation conditions of the equipment to reduce the load on the maintenance target portion.
For example, if the site to be serviced is a welded portion of the steam pipe, the temperature of the site to be serviced can be reduced by reducing the temperature of the steam flowing through the steam pipe, as shown by a broken line plot P2, for example.
Further, for example, if the site to be serviced is a welded portion of the steam pipe, the pressure of the steam flowing through the steam pipe is reduced, so that the stress of the site to be serviced can be reduced, for example, as shown by a dotted line plot P3.
Further, for example, if the site to be serviced is a welded portion of the steam pipe, the temperature and the pressure of the steam flowing through the steam pipe are reduced, and thus, for example, as shown by a dotted line plot P4, the temperature and the stress of the site to be serviced can be reduced.
In the operation condition mitigation measures, since the operation conditions of the plant are changed as described above, the load on the maintenance target site at a plurality of sites within the range affected by the change in the operation conditions of the plant can be reduced, and the remaining life can be extended.
Further, since the operation condition mitigating measures include at least one of measures for reducing the temperature of the fluid with which the maintenance target portion is in contact and measures for reducing the pressure of the fluid, the load acting on the maintenance target portion can be reduced, and the remaining life of the maintenance target portion can be extended.
In the countermeasure for mitigating the operating condition, it is necessary to consider a case where the operating condition of the plant is changed as described above, and therefore, the operation of the plant is affected. For example, it is necessary to consider a case where the operating efficiency of the plant may be reduced by reducing the temperature and pressure of the steam.
(2) Local countermeasure for maintenance target part
The local countermeasure to be taken for the maintenance target portion is a life extension countermeasure to be taken locally for the maintenance target portion. In the following description, the case of local countermeasures performed on the maintenance target site is also referred to as local countermeasures.
Examples of the local measures include a stress relaxation measure for relaxing stress in the part to be serviced, a local cooling for locally cooling the part to be serviced, and a damage recovery measure for recovering damage to the part to be serviced.
(2-1) stress relaxation countermeasure
The stress relaxation measures are measures for relaxing the stress of the part to be maintained by at least one of reinforcing the part to be maintained and changing the restriction conditions of the part to be maintained.
The reinforcement of the part to be serviced is, for example, a measure to wind a metal wire, which is heat-resistant and has the same linear expansion coefficient as that of the pipe, around the part to be serviced of the pipe and its surrounding area in a state where a pressing force is applied to the pipe. By reinforcing the part to be treated, for example, as shown by a dotted line plot P3, the stress acting on the part to be treated can be reduced.
Further, the maintenance target site may be reinforced by increasing the thickness of the maintenance target site by performing build-up welding on the maintenance target site.
The change of the restriction condition of the maintenance target site is a measure to reduce the stress applied to the maintenance target site during the operation of the equipment, and to apply a restriction force to the pipe from, for example, a support structure of the pipe including the maintenance target site. For example, if the site to be serviced is a circumferential weld portion connecting pipes, a pressing force in the pipe axial direction is applied to the pipes so as to compress the circumferential weld portion in the pipe axial direction of the pipes. By changing the restriction conditions for the site to be serviced, for example, as shown by a dotted line plot P3, the stress acting on the site to be serviced can be reduced.
As described above, in some embodiments, at least one of the reinforcement of the part to be serviced and the change of the regulation condition of the part to be serviced is included as the stress relaxation measure, and therefore, the stress of the part to be serviced can be relaxed by at least one of the reinforcement of the part to be serviced and the change of the regulation condition of the part to be serviced, and the remaining life of the part to be serviced can be extended.
(2-2) local Cooling
The local cooling is a measure for reducing the temperature of the part to be maintained by locally cooling the part to be maintained.
For example, if the part to be serviced is a welded part of a steam pipe, the temperature of the part to be serviced can be reduced by blowing steam or air having a temperature lower than the temperature of the steam flowing through the steam pipe to the periphery of the part to be serviced. As a result, the temperature acting on the site to be maintained can be reduced, as shown by a broken line plot P5, for example. When local cooling is performed, the temperature around the part to be serviced decreases and the periphery of the part to be serviced contracts, and therefore the stress acting on the part to be serviced may increase compared to before the local cooling is performed. Therefore, it is necessary to set the temperature decrease amount of the site to be maintained in consideration of the change in the stress acting on the site to be maintained.
(2-3) Damage recovery countermeasure
The damage recovery measures are measures for recovering damage to the maintenance target portion by, for example, repair welding the maintenance target portion.
As a measure for the damage recovery, for example, a creep hole or a crack in the part to be repaired may be pressure-bonded/repaired by thermal stress by heating the part to be repaired while thermal expansion of the part to be repaired is restricted.
By taking measures against the damage restoration in this way, the position of the equal lifetime line is shifted as shown by the equal lifetime line L2 indicated by the broken line L2, for example.
As described above, in some embodiments, the local countermeasure includes at least repair welding of the maintenance target portion as a damage recovery countermeasure for recovering the damage of the maintenance target portion. Therefore, the damage of the part to be repaired is recovered by the damage recovery measures including at least the repair welding of the part to be repaired, and the remaining life of the part to be repaired can be extended.
As described above, in some embodiments, the local countermeasure includes at least one of local cooling for locally cooling the part to be serviced, a stress relaxation countermeasure for relaxing stress in the part to be serviced, and a damage recovery countermeasure for recovering damage to the part to be serviced. Thereby, the remaining life of the maintenance target portion can be extended by at least one of the local cooling, the stress relaxation measures, and the damage recovery measures.
(calculation of input factor value)
Since the input factor value is changed by the above-described each operation condition mitigation countermeasure or the local countermeasure, the changed input factor value is obtained as follows, for example.
For example, when the temperature of steam flowing through a steam pipe is changed as an operation condition of a plant, if the steam pipe is kept warm with a large flow rate of steam, the temperature of a maintenance target portion of the pipe can be regarded as being equal to the temperature of the steam.
For example, the following can be considered: in the case of a pipe in which the maintenance target portion is present, such as a branch pipe, the flow rate of steam is smaller than that of the main pipe through which steam flows, or in the case of a pipe which is not kept warm, the temperature of the maintenance target portion is not regarded as equal to the temperature of steam flowing through the main pipe. In such a case, if the temperature of the maintenance target site cannot be directly measured, it is necessary to estimate the temperature of the maintenance target site by some method. For example, if the temperature of the branch pipe or the temperature of the steam flowing through the branch pipe can be obtained on the downstream side of the maintenance target portion of the branch pipe, the temperature of the maintenance target portion may be estimated by interpolation based on the obtained temperature and the temperature of the steam flowing through the main pipe.
In estimating the temperature of the maintenance target site, it is desirable to consider heat radiation or heat absorption of the piping around the maintenance target site.
In the case where the pressure of the steam flowing through the steam pipe is changed as the operation condition of the plant, the stress of the part to be maintained may be estimated by taking into consideration the shape of the pipe including the part to be maintained, the pressure loss of the steam, the support state of the pipe, and the like, with reference to the above-described pressure value as the operation condition.
For example, when the local countermeasure is implemented, the temperature or stress of the maintenance target portion may be estimated by estimating the degree of temperature reduction or stress reduction expected due to the local countermeasure.
Since the input factor value is changed by the above-described operation condition mitigation measures or the local measures, in step S6 of creating the maintenance management menu, the process returns to step S5 of re-predicting the remaining life in the process of creating the maintenance management menu, and the remaining life is re-predicted based on the changed input factor value obtained as described above.
That is, the step S5 of predicting the remaining life includes the steps of: and a step of obtaining an input factor value changed by the operation condition relaxation measure or the local measure, and predicting the remaining life based on the obtained input factor value.
In this way, since the input factor value changed by the operation condition mitigation measures or the local measures is obtained, the obtained input factor value becomes a proper factor value, and the accuracy of the remaining life after the re-prediction based on the obtained input factor value is improved.
In some embodiments, as described above, the process of listing the life extension measure candidates in step S6 of creating the maintenance management menu, re-predicting the remaining life in step S5 of performing the life extension measure candidates, and determining whether the re-predicted remaining life is longer than the allowable period is repeated as appropriate. In step S6 of creating the maintenance management menu, a life extension countermeasure for confirming that the remaining life after the re-prediction is longer than the allowable period is created as a life extension countermeasure to be implemented.
As described above, the maintenance menu determining method according to some embodiments is a method for determining a maintenance menu of a device, and includes step S4 of predicting the remaining life of a maintenance target portion in contact with a fluid in the device based on a result of a flaw detection inspection of the maintenance target portion. The maintenance management menu determining method according to some embodiments includes step S5 of predicting the remaining life when the input factor value used for the evaluation of the remaining life of the part to be maintained is changed by the life extension measure for the part to be maintained, if the predicted remaining life is shorter than the allowable period in step S5. The maintenance management menu determining method of some embodiments includes the following steps: and a step of drawing up a maintenance management menu for the equipment including the measures for prolonging the service life when it is confirmed that the predicted remaining service life is longer than the allowable period.
In this way, the remaining life of the part to be serviced can be made longer than the allowable period by creating a maintenance management menu including the life extension measures after confirming that the remaining life after the adoption of the life extension measures is longer than the allowable period.
In addition, if the plant is a power generation plant and the fluid flowing through the pipe is steam, the remaining life of the part to be serviced in contact with the steam in the power generation plant can be made longer than the allowable period by creating a service management menu including the life extension measures after confirming that the remaining life after the adoption of the life extension measures is longer than the allowable period as described above.
The life extension countermeasure to be implemented may be one of the plurality of life extension countermeasures described above, or a combination of a plurality of life extension countermeasures may be implemented.
For example, as a result of the examination with reference to fig. 2, when it is determined that the temperature of the part to be serviced needs to be lowered by T ° c in order to make the remaining life longer than the allowable period, the temperature of the part to be serviced may be lowered by T ° c by one of the above-described plurality of measures for prolonging the life. Further, the temperature of the site to be serviced may be lowered by T1 ℃ by one of the above-described measures for prolonging the service life, lowered by T2 ℃ by the other measures, and the sum of the lowered temperatures T1 and T2 may be T ℃ or higher. The same applies to the reduction of stress in the maintenance target portion.
When a plurality of life extension measures are combined, the measures for reducing the steam temperature and the measures for reducing the steam pressure, which are measures for alleviating the operating conditions, may be combined as described above. In addition, when a plurality of life extension countermeasures are combined, a plurality of countermeasures may be combined with each other by a local countermeasure such as a combination of a stress relaxation countermeasure and a local cooling countermeasure.
In addition, when a plurality of life extension countermeasures are combined, the operation condition mitigating countermeasures and the local countermeasures may be combined. By combining the operation condition mitigating measures with the local measures, the amount of change in the operation conditions of the plant can be suppressed, the influence on the operation of the plant can be suppressed, and the local measures can be simplified.
It is conceivable that a loss of interest occurs and a cost increases each time the life extension measure is implemented. Therefore, it is desirable to calculate in advance how much the loss of interest and the increase in cost are due to the implementation of the life extension measures.
For example, if the temperature and pressure of the steam are reduced by the operation condition mitigating measures to lower the operation efficiency of the plant, a loss of interest occurs in which the degree of reduction in the operation efficiency and the period of implementation of the operation condition mitigating measures are included in the parameters.
In addition, for example, in order to perform a local countermeasure, a cost for implementing the countermeasure is incurred. The cost includes the cost of a mechanical material or the like necessary for preparing the countermeasure, and the construction cost for implementing the countermeasure. Further, if the period of time during which the equipment is stopped is extended for implementing this countermeasure, a loss of interest in the equipment due to the extended period of time during which the equipment is stopped occurs.
In the step S6 of creating the maintenance management menu, when a plurality of life extension measures can be provided in which the remaining life can be extended beyond the allowable period, the influence of applying at least one of the plurality of life extension measures is converted into a money amount in consideration of the above point, and the maintenance management menu is determined in consideration of the result of the money amount conversion. This makes it possible to suppress economic loss due to implementation of the life extension measure and to make the remaining life of the part to be serviced longer than the allowable period.
For example, the lifetime extension countermeasure may be a combination of the operating condition mitigating countermeasure and the local countermeasure selected so that the sum of the profit loss and the added cost is reduced from the case where the operating condition mitigating countermeasure and the local countermeasure are separately implemented.
That is, for example, in the countermeasure for mitigating the operating condition, the operating condition of the plant is changed, and therefore, as described above, the operating efficiency of the plant may be reduced, and the loss of profit may occur. In general, the larger the range of change in the operating conditions of the plant, the lower the operating efficiency of the plant and the more the loss of profit tends to increase. In addition, in the local countermeasure, the cost required for the countermeasure tends to increase as the effect of the countermeasure is generally improved. Therefore, for example, by combining the operation condition mitigating measures with the local measures, although a loss of interest due to a change in the operation conditions of the plant occurs, an increase in cost due to implementation of the local measures can be suppressed. In other words, by combining the operation condition mitigating measures with the local measures, the cost for implementing the local measures is incurred, but the loss of interest due to the change in the operation conditions of the plant can be reduced. Therefore, by appropriately selecting and combining the operation condition mitigating measures and the local measures, the sum of the loss of interest and the increase in cost can be suppressed.
The combination of the operation condition mitigating measures and the local measures is effective particularly when the life prolonging measures are required for a plurality of portions.
For example, consider a case where three sites are found in a portion having a shorter remaining life than the allowable period. Here, in the case of dealing with the temperature decrease in the operation condition relaxation measure in these three portions, it is determined that the temperature decrease of-100 ℃ is required in the position a, the temperature decrease of-50 ℃ is required in the position B, and the temperature decrease of-30 ℃ is required in the position C. As measures for prolonging the lifetime, the following methods (1) to (3) can be adopted.
The method (1) is a method of lowering the steam temperature as the operation condition of the plant. In the method (1), the amount of decrease in the steam temperature is assumed to be limited to-50 ℃. In the method (1), the loss of interest corresponding to the amount of decrease in the temperature of the steam continues to occur during the period of time in which the method (1) is carried out.
The method (2) is a first method of locally lowering the temperature. In the method (2), the amount of decrease in temperature is assumed to be limited to-50 ℃. In method (2), although the amount of temperature decrease is small compared to method (3) described later, the initial cost is low, and the maintenance cost for continuing to carry out method (2) can be ignored.
The method (3) is a second method of locally lowering the temperature. In the method (3), the amount of decrease in temperature is assumed to be limited to-100 ℃. In method (3), although the amount of temperature decrease is large as compared with method (2) described above, the initial cost is high, and the maintenance cost for continuing to carry out method (3) can be ignored.
Under these conditions, a table obtained by summarizing the combination pattern of the life prolonging measures and the amount of temperature drop is shown in fig. 3. Mode 1 in fig. 3 is a case where the method (1) is effectively used to the maximum, mode 3 is a case where the method (1) is not used, and mode (2) is a case in between. The method (1) is a change in the operating conditions of the plant, and is effective for all the positions a to C. The methods (2) and (3) are local countermeasures, and have an effect only on each position where the countermeasures are implemented.
Specifically, in mode 1, the temperature at each of the positions a to C was lowered by 50 ℃ by the method (1), and the temperature at the position a was lowered by 50 ℃ again by the method (2). Thus, the temperature was decreased by 100 ℃ at the position A and by 50 ℃ at the positions B and C, respectively.
In mode 2, the temperature at each of the positions a to C was lowered by 30 ℃ by the method (1), the temperature at the position B was lowered by 20 ℃ by the method (2), and the temperature at the position a was lowered by 70 ℃ by the method (3). Thus, the temperature drops by 100 ℃ at position A, by 50 ℃ at position B and by 30 ℃ at position C.
In pattern 3, the temperature at location B was decreased by 50 ℃ by method (2), the temperature at location C was decreased by 30 ℃ by method (2), and the temperature at location a was decreased by 100 ℃ by method (3). Thus, the temperature drops by 100 ℃ at position A, by 50 ℃ at position B and by 30 ℃ at position C.
As to which combination pattern is good, the profit loss by the method (1) and the added costs by the methods (2) and (3) are added for each pattern, and the addition results are compared to determine the optimum combination pattern.
(about monitoring contents)
In order to secure the remaining life extended by the life extension countermeasure prepared as described above, the device is monitored in step S8 in which the maintenance target site is monitored as necessary. As described above, the monitoring items and the monitoring methods are suitable for the proposed life extension measures among the monitoring items and the monitoring methods listed below for the purpose of securing the remaining life extended by the life extension measures.
Therefore, in step S6 of creating a maintenance management menu, a monitoring item and a monitoring method suitable for the created life extension countermeasure are selected.
The monitoring includes monitoring performed during operation of the plant and monitoring performed when the plant is stopped.
In monitoring performed during operation of the equipment, the monitoring items include temperature, pressure, deformation (strain), progress of cracks, and the like of the site to be maintained.
Examples of the method of monitoring the temperature include temperature measurement by a thermocouple, a radiation thermometer, an infrared camera, or the like, and temperature measurement by an optical fiber. The temperature measurement by the optical fiber is a temperature measurement using the temperature dependence of the raman scattered light intensity in the optical fiber.
The pressure monitoring method may use, for example, a pressure gauge provided in the apparatus.
Examples of the method of monitoring the deformation (strain) include measurement by a strain gauge, measurement by a laser speckle strain gauge, displacement gauge side by an image correlation method, creep button, measurement by a laser distance meter, and displacement measurement by an optical fiber displacement meter. Here, the creep button is a method of specifying a measurement point in advance in order to measure a creep strain generated during operation. The button represents the shape of the measurement point. Specifically, the method includes providing protrusions on both sides of a welding line, measuring a distance between the protrusions in advance as an initial value, and tracking a change in the distance over time.
Examples of the method of monitoring the progress of the crack include detection of acoustic emission, a potential difference method of detecting a change in resistance value due to the progress of the crack, a method of detecting a change in magnetic properties due to the progress of the crack, and measurement of strain.
In the monitoring performed during the stop of the equipment, the temperature, deformation (strain), crack progression, and the like of the part to be maintained can be used as the monitoring items.
Examples of the method of monitoring the temperature include a method of estimating the temperature history by observing the structure of the part to be maintained by the replication method, a method of estimating the temperature history from a small amount of the sample obtained, a method of estimating the temperature history by observing the aged structure, and a method of estimating the temperature history from the state of formation of the vapor scale or the state of formation of the precipitates.
The method of monitoring the deformation (strain) is as described above.
As a method of monitoring the progress of cracks, for example, if the surface of the part to be maintained is a surface, there are a magnetic particle inspection, a penetrant inspection, an inspection by an MT transfer method, an eddy current inspection, and the like. In addition, if the part is inside the part to be maintained, ultrasonic inspection by the conventional UT method, ultrasonic inspection by the TOFD method, ultrasonic inspection by guided waves, ultrasonic inspection by the phased array method, ultrasonic inspection by the open pore synthesis method, ultrasonic inspection by the high frequency UT method, ultrasonic inspection by the ultrasonic noise method, radiation inspection, and the like can be cited.
(step S7 for maintenance management of the site to be maintained)
Step S7 of performing maintenance management of the maintenance target site is a step of performing maintenance management of the maintenance target site in accordance with the maintenance management menu determined in step S3 of determining the maintenance management menu, that is, the maintenance management menu including the life extension countermeasure set in step S6 of setting up the maintenance management menu.
(step S8 of monitoring the site to be serviced)
Step S8 of monitoring the site to be serviced is a step of monitoring the site to be serviced after the maintenance management performed in step S7 of performing the maintenance management of the site to be serviced.
In the monitoring performed in step S8 of monitoring the site to be serviced, the site to be serviced is monitored by the monitoring item and the monitoring method selected in step S6 of preparing a maintenance management menu.
That is, in step S8 of monitoring the part to be serviced, items that affect the input factor value used when the remaining life is to be re-predicted are monitored, and it is determined whether or not the items are out of the allowable range of the monitoring items that should be satisfied in order to make the re-predicted remaining life longer than the allowable period.
Accordingly, it is possible to determine whether or not the remaining life of the part to be serviced can be shortened with respect to the allowable period, and therefore, a life extension measure or the like can be additionally implemented as necessary, and it is possible to further cope with the situation where the remaining life of the part to be serviced is longer than the allowable period.
As described above, the maintenance management method for a facility according to some embodiments includes: step S3 of determining a maintenance management menu of the equipment; step S7 of performing maintenance management of the maintenance target part according to the maintenance management menu; and a step S8 of monitoring the maintenance target site after maintenance management.
Thus, by implementing the life extension measure, the remaining life of the part to be serviced can be made longer than the allowable period, and the state of the part to be serviced during the subsequent operation period of the apparatus can be grasped.
When it is determined that the value of the monitoring item is out of the allowable range, the above-described step S5 of predicting the remaining life and the step S6 of creating the maintenance management menu are executed again to create a new measure for prolonging the life.
That is, in some embodiments, the method includes step S5, where step S5 is a step of predicting a new remaining life when the input factor value is changed by the new life extension measure for the part to be serviced, that is, a step of predicting the remaining life again, when it is determined that the value of the monitoring item is out of the allowable range in the step of monitoring the part to be serviced. Further, some embodiments include step S6, where step S6 is a step of creating a maintenance management menu for the equipment including the new measure for prolonging the life, that is, creating a maintenance management menu, when it is confirmed that the new remaining life is longer than the allowable period.
In this way, after confirming that the new remaining life after the adoption of the new life extension measure is longer than the allowable period, the maintenance management menu including the new life extension measure is created, so that the remaining life of the part to be maintained can be made longer than the allowable period.
The present invention is not limited to the above-described embodiments, and includes a mode in which the above-described embodiments are modified, and a mode in which these modes are appropriately combined.
For example, in the above-described embodiments, the maintenance target section is the welded section of the multi-system steam pipes connecting the boiler and the steam turbine in the thermal power plant, but the welded section to be maintained is not limited to a part of the boiler, and the maintenance menu determination method and the maintenance management method for the plant according to the present invention can be applied to various welded sections exposed to high temperature and high pressure or other sections than the welded section.
Description of the reference symbols
L0, L1, L2, etc.
Claims (15)
1. A maintenance management menu decision method for a device, comprising the steps of:
predicting a remaining life of a part to be serviced, which is in contact with the fluid in the apparatus, based on a result of a flaw detection inspection of the part;
when the predicted remaining life is shorter than an allowable period, re-predicting the remaining life when an input factor value used for evaluating the remaining life of the part to be serviced is changed by a life extension measure for the part to be serviced; and
if it is confirmed that the remaining life after the re-prediction is longer than the allowable period, a maintenance management menu for the equipment is created, the maintenance management menu including the life extension measure.
2. The maintenance management menu decision method according to claim 1,
the service life extension countermeasure includes at least one of an operation condition relaxation countermeasure for reducing a load on the maintenance target portion by changing an operation condition of the equipment, and a local countermeasure to be performed for the maintenance target portion.
3. The maintenance management menu decision method according to claim 2,
the step of predicting the remaining life further comprises the steps of: the input factor value changed by the operation condition relaxation measure or the local measure is obtained, and the remaining life is re-predicted based on the obtained input factor value.
4. A service management menu decision method according to claim 2 or 3,
the life extension countermeasure is a combination of the operating condition mitigating countermeasure and the local countermeasure.
5. The maintenance management menu decision method according to claim 4,
the lifetime extension measure is a combination of the operating condition mitigating measure and the local measure selected so that a sum of a loss of interest and an increase cost is reduced from a case where the operating condition mitigating measure and the local measure are separately implemented.
6. The maintenance management menu decision method according to any one of claims 2 to 5,
the operation condition mitigating measures include at least one of measures for reducing the temperature of the fluid in contact with the maintenance target portion and measures for reducing the pressure of the fluid.
7. The maintenance management menu decision method according to any one of claims 2 to 6,
the local countermeasure includes at least one of local cooling for locally cooling the maintenance target portion, a stress relaxation countermeasure for relaxing stress in the maintenance target portion, and a damage recovery countermeasure for recovering damage to the maintenance target portion.
8. The maintenance management menu decision method according to any one of claims 2 to 7,
the local countermeasure includes at least one of reinforcement of the maintenance target portion and change of a restriction condition of the maintenance target portion as a stress relaxation countermeasure for relaxing stress of the maintenance target portion.
9. The maintenance management menu decision method according to any one of claims 2 to 8,
the local countermeasure includes at least repair welding of the maintenance target portion as a damage recovery countermeasure for recovering damage of the maintenance target portion.
10. The maintenance management menu decision method according to any one of claims 1 to 9,
in the step of creating the maintenance menu, when there are a plurality of the life extension measures capable of extending the remaining life by the allowable period, a money amount is converted for an influence when at least one of the plurality of the life extension measures is applied, and the maintenance menu is determined in consideration of a result of the money amount conversion.
11. The maintenance management menu decision method according to any one of claims 1 to 10,
in the step of predicting the remaining life, the remaining life is predicted again on the basis of at least one of the re-estimation of the allowable period and the re-estimation of the input factor value.
12. The maintenance management menu decision method according to any one of claims 1 to 11,
the apparatus is a power generation apparatus and,
the fluid is steam.
13. A method for maintaining and managing a facility, comprising the steps of:
determining a maintenance menu of the equipment by using the maintenance menu determination method according to any one of claims 1 to 12;
performing maintenance management of the maintenance target part according to the maintenance management menu; and
the maintenance target portion is monitored after the maintenance management.
14. A method of managing maintenance of an apparatus according to claim 13,
in the step of monitoring the part to be serviced, an item that affects the input factor value used when the remaining life is re-predicted is monitored, and it is determined whether or not the item deviates from an allowable range that should be satisfied in order to make the re-predicted remaining life longer than the allowable period.
15. A method of managing maintenance of an apparatus according to claim 14, further comprising the steps of:
predicting a new remaining life when the input factor value is changed by a new life extension measure for the part to be serviced, when it is determined that the value of the item deviates from the allowable range in the step of monitoring the part to be serviced; and
if it is confirmed that the new remaining life is longer than the allowable period, a maintenance management menu for the equipment is created, which includes the new measure for prolonging the life.
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|---|---|---|---|
| JP2018-031795 | 2018-02-26 | ||
| JP2018031795A JP7218091B2 (en) | 2018-02-26 | 2018-02-26 | Plant maintenance management method |
| PCT/JP2019/006965 WO2019163979A1 (en) | 2018-02-26 | 2019-02-25 | Maintenance management menu determination method and plant maintenance management method |
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| CN111684453A true CN111684453A (en) | 2020-09-18 |
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| JP (1) | JP7218091B2 (en) |
| CN (1) | CN111684453A (en) |
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| WO (1) | WO2019163979A1 (en) |
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| TWI711996B (en) | 2020-12-01 |
| JP2019148440A (en) | 2019-09-05 |
| WO2019163979A1 (en) | 2019-08-29 |
| JP7218091B2 (en) | 2023-02-06 |
| TW201939417A (en) | 2019-10-01 |
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