CN112597642A - High-temperature container state evaluation method based on metal detection - Google Patents
High-temperature container state evaluation method based on metal detection Download PDFInfo
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Abstract
A high-temperature header state evaluation method based on metal detection comprises the following steps; 1) defining an evaluation object and basic information; 2) clearly evaluating the specific stage of the full life cycle of the object; 3) calculating a state correction factor CS(ii) a 4) Defining detailed evaluation points; 5) preparing and implementing a metal inspection scheme; 6) obtaining a metal inspection result; 7) evaluation of evaluation Point statusEstimating; 8) and evaluating the state of the evaluation object. The invention can help thermal power plant technicians to make maintenance strategies better.
Description
Technical Field
The invention relates to the technical field of state evaluation of high-temperature equipment of a thermal power plant, in particular to a high-temperature container state evaluation method based on metal inspection.
Background
The high temperature collection case is the important part of thermal power factory boiler system, and in recent years, along with the change of external environment, various large-scale high parameter thermal power generating unit are inessentially compelled to become the peak shaver group, and this makes the high temperature collection case be in more abominable operating mode condition in the operation process, receives the influence of heat exchange change load effect more easily. Especially the collection case barrel belongs to thick wall equipment, has fairly high temperature difference stress, and the inside and outside wall temperature difference of collection case barrel distributes along wall thickness linearity, and thickness is big more, and the difference in temperature is big more, and stress is big more. Since the high temperature header is located outside the boiler, there is a risk of causing significant personal safety and economic loss if a leakage accident occurs to the drum, and thus it is necessary to accurately evaluate the state of the high temperature header.
For the high-temperature header, the stress and strength analysis of the high-temperature header has been reported in the literature, such as the stress and strength analysis of the high-temperature superheater outlet header made of SA335-P91 steel, the hot working process 2016(12), and the fatigue-creep life analysis of the high-temperature header has also been reported in the literature, such as the fatigue-creep life analysis of the pressed part based on european standard EN12952, the university of Chongqing science 2016 (11). Whether stress and strength analysis or fatigue-creep life analysis is performed, various conditions are required: the assessment personnel are required to have abundant basic knowledge, mechanics calculation knowledge, life assessment knowledge and experience of the metal materials; collecting complete design data and design data; collecting complete operation history data; complete and comprehensive metal inspection related data needs to be collected; comprehensive laboratory analysis data on samples of the same material are required as a reference group and the like. These conditions determine that the development of stress and strength analysis, fatigue-creep life analysis, etc. is limited to specialized technical organizations and personnel, and the collection of these basic data and data, complete and comprehensive metal inspection, and laboratory analysis result in increased maintenance and labor costs for the plant.
Therefore, a universal method is required to be explored, assessment personnel do not need to have abundant basic knowledge, mechanical calculation knowledge, service life assessment knowledge and experience of metal materials, extra test cost is not required to be borne, and the state of the high-temperature header can be assessed only by obtaining existing metal inspection data, so that the technical personnel of the thermal power plant can be directly helped to make maintenance strategies.
Disclosure of Invention
In order to overcome the technical problems, the invention aims to provide a high-temperature header state evaluation method based on metal inspection, which helps thermal power plant technicians to make a maintenance strategy better.
In order to achieve the purpose, the technical scheme adopted by the invention and the beneficial effects of the invention are as follows:
a high-temperature header state evaluation method based on metal detection comprises the following steps;
1) the high-temperature collection box is taken as an evaluation object, and basic information of the high-temperature collection box is determined;
2) defining the specific stage of the full life cycle of the high-temperature header;
3) calculating a state correction factor CS；
4) Defining detailed evaluation points;
5) preparing and implementing a metal inspection scheme;
6) obtaining a metal inspection result;
7) evaluating the dot state;
8) and (4) evaluating the state of the high-temperature header.
The basic information of the step 1) comprises a design drawing, a design diameter, a design wall thickness and a design material;
the step 2) comprises the following specific operation steps:
determining which stage of the early stage, the middle stage, the final stage and the final stage of the full life cycle the high-temperature header is in;
| each stage of the life cycle | Time ranges of the stages of the full life cycle |
| Early stage | (0,0.2Lc] |
| Middle stage | (0.2Lc～0.7Lc] |
| End stage | (0.7Lc～0.9Lc] |
| End stage | (0.9Lc～Lc] |
Wherein L iscTo design life, a 300000 unit hours of operation are typically defined.
The specific operation steps in the step 3) are as follows:
determining the corresponding state correction factor C based on the stage of the clear evaluation object in the step 2)S；
| Each stage of the life cycle | State factor CS |
| Early stage | 1+1c |
| Middle stage | 1 |
| End stage | 1+2c |
| End stage | 1+5c |
Defining c as a correction factor, and determining the actual value according to the following table according to the design and manufacturing data collected in step 1).
| Several cases of the value of the correction factor c | Value of correction factor c |
| No abnormality is found at the design and manufacturing stage | 0.01 |
| With few exceptions at the design and manufacturing stage, but without affecting normal use | 0.02 |
| The defect of more abnormalities in the design and manufacturing stage and the defect of normal after repair | 0.05 |
The specific operation steps in the step 4) are as follows:
all evaluation points of the subject are evaluated explicitly and divided into two broad categories: the base metal type evaluation points and the weld type evaluation points are respectively distinguished by the following corner marks bm and wd.
The step 5) comprises the following specific operation steps:
and (2) comprehensively considering the maintenance plan, time and cost, and selecting and implementing a proper project designation metal inspection scheme from the macroscopic inspection, the rough bulging inspection, the spectral inspection, the wall thickness measurement, the hardness inspection, the scale measurement, the metallographic inspection and the nondestructive inspection (comprising ultrasonic waves, magnetic powder, penetration and rays) aiming at all the evaluation points determined in the step 1).
The specific operation steps in the step 6) are as follows:
acquiring all metal inspection results of the evaluation points according to the metal inspection items determined in the step 5), classifying the state parameters into three categories according to the metal inspection results, and confirming the state parameters corresponding to all the metal inspection items of the evaluation points;
the step 7) comprises the following specific operation steps:
performing state evaluation on the single evaluation point according to the metal inspection result obtained in the step 6), and defining the state of the single evaluation point as CjThe evaluation model is shown as formula (1);
if Max{CPqi-j,CPgi-j,CPmi-j}＝1,
else if Max{CPqi-j,CPgi-j,CPmi-j}≠1
Cj＝1
(1)
state C of evaluation pointjThe value of (A) normally falls within [0,1 ]]Within the interval, if CjThe value is 0, the state of the evaluation point is optimal, when CjWhen the value of (a) is changed from 0 to 1, the state of the evaluation point becomes worse and worse;
weight Q of the three types of state parameters in the formula (1)qi、QgiAnd QmiGiving the rule of formula (2);
the specific operation steps in the step 8) are as follows:
counting all the evaluation points obtained in the step 7) according to the classification of the base metal evaluation points and the welding seam evaluation points, counting the number n of the base metal evaluation points and the number m of the welding seam evaluation points, and then carrying out overall evaluation on the state C of an evaluation object, wherein an evaluation model is shown as a formula (11);
if the value of the state C of the evaluation object is 0, the state of the evaluation object is considered to be optimal, and when the value of P is changed from 0 to 1, the state of the evaluation object gradually becomes worse; when the C value is more than 0.5, the state of an evaluation object is general, and the state of some evaluation points is poor, so that the attention of technicians is required; when the C value is larger than 0.75, the state of an evaluation object is poor, and the state of most evaluation points is poor; particularly, at the end stage and the final stage of the full life cycle, if the evaluation is continuously carried out for multiple times and the state C value of the evaluation object is gradually increased, the poor state of the evaluation object is also verified, and the enterprise should be ready for the whole replacement of the evaluation object.
The evaluation object is a high-temperature header, and the evaluation point is selected from a base material and a welding line of the high-temperature header.
The first type state parameters in the step 6): macroscopic State parameter CPq1-jFrom the result MR of a macroscopic examinationq1-j: { no defect found, and out-of-standard defect found } is defined as shown in equation (3):
the first type state parameters in the step 6): composition state parameter CPq2-jFrom the results of the spectroscopic examination MRq2-j: { pass, fail } definition, as shown in equation (4):
the second type state parameters in the step 6): tissue state parameter CPg1-jFrom the results of the metallographic examination MRg1-j: { level 1, level 2, level 3, level 4, level 5 } definition, as shown in equation (5):
the second type state parameters in the step 6): lossless State parameter CPg2-jMR by nondestructive examination of ultrasonic wave, magnetic powder, penetration, and rayg2-j: { stage I, stage II, stage III, stage IV } definition, as shown in equation (6):
the third type state parameters in the step 6): rough state parameter CPm1-jMR from the results of dilatory examinationm1-jAs defined by formula (7):
in the formula (7), D0Designed diameter in mm;
the third type state parameters in the step 6): wall thickness State parameter CPm2-jFrom the results of the wall thickness examination MRm2-jAs defined by formula (8):
the third type state parameters in the step 6): hardness State parameter CPm3-jFrom the results of the hardness test MRm3-jAs defined by formula (9):
the third type state parameters in the step 6): oxidation state parameter CPm4-jMR measured from the oxide scalem4-jDefinition, as shown in formula (10):
the invention has the beneficial effects that:
according to the method, the condition of the high-temperature header can be evaluated only by acquiring the existing metal inspection data without the need that an evaluator has abundant basic knowledge, mechanics calculation knowledge, life evaluation knowledge and experience of metal materials and bearing extra test cost, so that the thermal power plant technician is directly helped to make a maintenance strategy.
Drawings
FIG. 1 is a schematic diagram of a state estimation process according to the present invention.
Detailed Description
The invention is further described in the following with reference to the accompanying drawings and examples.
As shown in fig. 1:
1) specifying evaluation target and basic information
Firstly, the high-temperature header is definitely evaluated, and whether the high-temperature header is a high-temperature superheater outlet header or a high-temperature reheater outlet header can be evaluated by the method.
In addition, information such as design drawings, design diameters, design wall thicknesses, and design materials of the evaluation target needs to be collected and specified.
2) Specifying a particular phase of the full life cycle at which the object is evaluated
The state of the evaluation object has a certain relation with the specific stage of the full life cycle, and the equipment state is not good due to design and manufacturing defects and hidden danger left after installation in the early stage of the full life cycle. With the continuous familiarity of the operators with the unit, after the middle stage of the whole life cycle, the evaluation object reaches the optimal state and can last for a long time. When the end stage of the full life cycle is entered, the state of the evaluation object is gradually deteriorated under the influence of the long-term peak shaving operation of the unit. When the final stage of the full life cycle is entered, the material is aged gradually and quickly under the high-temperature and high-pressure service condition for a long time, and the state of an evaluation object is degraded rapidly.
It is unambiguously assessed which of the early, mid, end and final stages of the full life cycle the subject is in.
Wherein L iscTo design life, a 300000 unit hours of operation are typically defined.
3) Calculating a state correction factor CS
Based on2) Determining the corresponding state correction factor C of the stage in which the specific evaluation object is locatedS。
| Each stage of the life cycle | State factor CS |
| Early stage | 1+1c |
| Middle stage | 1 |
| End stage | 1+2c |
| End stage | 1+5c |
Defining c as a correction factor, and determining the actual value according to the following table based on the design and manufacturing data collected in 1).
| Several cases of the value of the correction factor c | Value of correction factor c |
| No abnormality is found at the design and manufacturing stage | 0.01 |
| With few exceptions at the design and manufacturing stage, but without affecting normal use | 0.02 |
| The defect of more abnormalities in the design and manufacturing stage and the defect of normal after repair | 0.05 |
If all indexes in the design and manufacturing data are normal and no major problems are found, the value of c is 0.01, otherwise, the evaluation personnel can adjust according to the problems found in the design and manufacturing stages and the actual conditions of the components.
4) Unambiguous detailed evaluation points
In order to know the actual state of an evaluation object in detail, it is generally suggested to select multiple positions (parent metal and welding seam) for the evaluation object to be inspected, and since the inspection points will eventually participate in state evaluation, they are also called evaluation points, and the evaluation points are divided into two categories: the base metal type evaluation points and the weld type evaluation points are respectively distinguished by the following corner marks bm and wd.
5) Making metal testing plan and implementing
And (2) comprehensively considering the maintenance plan, time and cost, and selecting and implementing a proper project designation metal inspection scheme from macroscopic inspection, rough inspection, spectral inspection, wall thickness measurement, hardness inspection, scale measurement, metallographic inspection and nondestructive inspection (comprising ultrasonic waves, magnetic powder, permeation and rays) aiming at all the evaluation points determined in the step 1).
6) Obtaining a metal test result
Obtaining all metal inspection results of the evaluation points according to the metal inspection items determined in the step 5), dividing the state parameters into three categories according to the metal inspection results, and confirming the state parameters corresponding to all the metal inspection items of the evaluation points, wherein the table is shown in the following.
7) Evaluation point state evaluation
Performing state evaluation on the single evaluation point according to the metal inspection result obtained in the step 6), wherein the state of the single evaluation point is defined as CjThe evaluation model is shown as formula (1), when the three types of state parameters CPqi-j、CPgi-jOr CPmi-jIn which one or more parameter values are 1, defines the state C of the evaluation pointjTaking the value 1, otherwise, defining the state C of the evaluation pointjIs a three-class state parameter CPqi-j、CPgi-jOr CPmi-jIs weighted and multiplied by a state correction factor CS。
State C of evaluation pointjThe value of (A) normally falls within [0,1 ]]Within the interval, if CjThe value is 0, the state of the evaluation point is optimal, when CjThe state of the evaluation point becomes worse and worse when the value of (a) is changed from 0 to 1.
Comprehensively considering the importance of various metal inspection items and the implementation frequency, result accuracy and other factors, and weighting Q for the three types of state parameters in the formula (1)qi、QgiAnd QmiGives the rule of equation (2).
The evaluation methods of three types of state parameters of a single evaluation point are given below.
7.1) evaluation of the first State parameters
7.1.1) evaluation of the macroscopic State parameters corresponding to the macroscopic examination
Result of macroscopic examination MRq1-jTypically one of the sets { no defect found, out-of-standard defect } corresponding to the macro state parameter CPq1-jIs as defined in formula (3).
7.1.2) evaluation of the corresponding component State parameters for the spectroscopic examination
Results of the spectroscopic examination MRq2-jGenerally, the result is { pass, fail }, and the pass or fail conclusion is obtained by comparing with the national standard or the industry standard whether the result meets the requirement, and the corresponding component state parameter CPq2-jIs as defined in formula (4).
7.2) evaluation of the second type of State parameters
7.2.1) evaluation of the corresponding structural State parameters by metallographic examination
Results of metallographic examination MRg1-jGenerally, the metal material is { grade 1, grade 2, grade 3, grade 4, grade 5 }, different metal materials have different industry standard guiding grades, and corresponding organization state parameters CPg1-jIs as defined in formula (5).
7.2.2) non-destructive evaluation of corresponding non-destructive State parameters for non-destructive examination
The nondestructive testing items can be divided into ultrasonic, magnetic powder, penetration and ray tests, and all test results MRg2-jGenerally, the parameters are { I level, II level, III level and IV level }, if a plurality of nondestructive testing items are implemented, the nondestructive testing result with the highest grade is selected as the nondestructive testing result, and the corresponding nondestructive state parameter CP is selectedg2-jDefinition of (1)As shown in equation (6).
7.3) evaluation of the third State parameters
7.3.1) evaluation of the parameters of the dilatant state corresponding to the dilatant examination
The evaluation object can gradually generate outer diameter creep expansion when running under high temperature condition for a long time, when the creep expansion is serious, the evaluation object can be in a poor state, therefore, the evaluation object needs to be subjected to rough swelling inspection at the end stage and the final stage of the whole life cycle of the evaluation object, and the MR of the rough swelling inspection resultm1-jCorresponding swell-state parameter CPm1-jIs as defined in formula (7).
In the formula (7), D0For design diameter, in mm.
7.3.2) evaluation of the wall thickness State parameters corresponding to the wall thickness check
The evaluation object is subjected to erosion and corrosion of steam in the high-temperature operation process to generate high-temperature oxidation, and the process consumes the base metal of the evaluation object, so that the evaluation object is thin in wall thickness, bears larger stress and has a worse state. Results of wall thickness examination MRm2-jCorresponding wall thickness state parameter CPm2-jIs as defined in formula (8).
In the formula (8), d0For design wall thickness, units are mm.
7.3.3) evaluation of the hardness State parameters corresponding to the hardness test
The evaluation object gradually undergoes an aging phenomenon when operated under high temperature conditions, thereby causing a gradual decrease in hardness, which changes the state of the evaluation objectPoor, may result in failure. Results of hardness examination MRm3-jCorresponding hardness state parameter CPm3-jIs as defined in formula (9).
7.3.4) evaluation of the Oxidation State parameters for the measurement of the oxide skin
The evaluation object is in contact with high-temperature high-pressure steam to generate high-temperature oxidation, and the formed inner wall oxidation layer increases the heat transfer resistance between the evaluation object and the high-temperature high-pressure steam, so that the actual use temperature of the metal of the evaluation object is increased along with the operation time, the thickness of the metal reflects the aging degree of the evaluation object to a certain extent, and the thicker the oxide skin, the worse the state of the evaluation object. Results of scale measurement MRm4-jCorresponding oxidation state parameter CPm4-jIs as defined in formula (10).
8) Evaluation object state evaluation
And (4) counting all the evaluation points obtained in the step (7) according to the classification of the base metal evaluation points and the welding seam evaluation points, counting the number n of the base metal evaluation points and the number m of the welding seam evaluation points, and then carrying out overall evaluation on the state C of the evaluation object, wherein an evaluation model is shown as a formula (11).
The state C of the evaluation object is considered to be the best state when the value of C is 0, and the state of the evaluation object gradually deteriorates when the value of P changes from 0 to 1. When the C value is greater than 0.5, the state of the evaluation target is general, and some evaluation points are poor in state, which is of interest to technicians. When the C value is greater than 0.75, the evaluation object state is poor, and the state of most evaluation points is poor. Particularly, at the end stage and the final stage of the full life cycle, if the evaluation is continuously carried out for multiple times and the state C value of the evaluation object is gradually increased, the poor state of the evaluation object is also verified, and the enterprise should be ready for the whole replacement of the evaluation object.
By adopting the technical scheme to evaluate and obtain the state of the high-temperature header, the method not only can help the technical personnel in the thermal power plant to know the actual state of the high-temperature header, but also can predict the change trend of the state of the high-temperature header through multiple state evaluation results aiming at the same evaluation point, can also evaluate the overall state of the high-temperature header by integrating the state results of all the evaluation points, and has important significance for making a maintenance plan and replacing strategies.
Claims (10)
1. A high-temperature header state evaluation method based on metal detection is characterized by comprising the following steps;
1) the high-temperature collection box is taken as an evaluation object, and basic information of the high-temperature collection box is determined;
2) defining the specific stage of the full life cycle of the high-temperature header;
3) calculating a state correction factor CS；
4) Defining detailed evaluation points;
5) preparing and implementing a metal inspection scheme;
6) obtaining a metal inspection result;
7) evaluating the dot state;
8) and (4) evaluating the state of the high-temperature header.
2. The metal inspection-based high-temperature header state evaluation method according to claim 1, wherein the basic information of step 1) includes design drawings, design diameters, design wall thicknesses and design materials;
the evaluation object is a high-temperature header, and the evaluation point is selected from a base material and a welding line of the high-temperature header.
3. The metal inspection-based high-temperature header state evaluation method according to claim 1, wherein the step 2) comprises the following specific operation steps:
determining which stage of the early stage, the middle stage, the final stage and the final stage of the full life cycle the high-temperature header is in;
wherein L iscTo design life, a 300000 unit hours of operation are typically defined.
4. The method for evaluating the state of the high-temperature header based on metal detection as claimed in claim 1, wherein the specific operation steps in the step 3) are as follows:
determining the corresponding state correction factor C based on the stage of the clear evaluation object in the step 2)S；
Defining c as a correction factor, and determining the actual value according to the following table according to the design and manufacturing data collected in the step 1);
5. The method for evaluating the state of the high-temperature header based on metal detection as claimed in claim 1, wherein the specific operation steps of the step 4) are as follows:
all evaluation points of the subject are evaluated explicitly and divided into two broad categories: the base metal type evaluation points and the weld type evaluation points are respectively distinguished by the following corner marks bm and wd.
6. The method for evaluating the state of the high-temperature header based on metal detection as claimed in claim 1, wherein the step 5) comprises the following specific operation steps:
comprehensively considering the maintenance plan, time and cost, and selecting and implementing a proper project designation metal inspection scheme from the macroscopic inspection, the rough bulging inspection, the spectral inspection, the wall thickness measurement, the hardness inspection, the scale measurement, the metallographic inspection and the nondestructive inspection aiming at all the evaluation points determined in the step 1).
7. The method for evaluating the state of the high-temperature header based on metal detection as claimed in claim 1, wherein the specific operation steps of the step 6) are as follows:
acquiring all metal inspection results of the evaluation points according to the metal inspection items determined in the step 5), classifying the state parameters into three categories according to the metal inspection results, and confirming the state parameters corresponding to all the metal inspection items of the evaluation points;
8. the method for evaluating the state of the high-temperature header based on metal detection as claimed in claim 1, wherein the step 7) comprises the following specific operation steps:
performing state evaluation on the single evaluation point according to the metal inspection result obtained in the step 6), and defining the state of the single evaluation point as CjThe evaluation model is shown as formula (1);
if Max{CPqi-j,CPgi-j,CPmi-j}＝1,
else if Max{CPqi-j,CPgi-j,CPmi-j}≠1
Cj＝1
(1)
state C of evaluation pointjThe value of (A) normally falls within [0,1 ]]Within the interval, if CjThe value is 0, the state of the evaluation point is optimal, when CjWhen the value of (a) is changed from 0 to 1, the state of the evaluation point becomes worse and worse;
weight Q of the three types of state parameters in the formula (1)qi、QgiAnd QmiGiving the rule of formula (2);
9. the method for evaluating the state of the high-temperature header based on metal detection as claimed in claim 1, wherein the specific operation steps in the step 8) are as follows:
counting all the evaluation points obtained in the step 7) according to the classification of the base metal evaluation points and the welding seam evaluation points, counting the number n of the base metal evaluation points and the number m of the welding seam evaluation points, and then carrying out overall evaluation on the state C of an evaluation object, wherein an evaluation model is shown as a formula (11);
if the value of the state C of the evaluation object is 0, the state of the evaluation object is considered to be optimal, and when the value of P is changed from 0 to 1, the state of the evaluation object gradually becomes worse; when the C value is more than 0.5, the state of an evaluation object is general, and the state of some evaluation points is poor, so that the attention of technicians is required; when the C value is larger than 0.75, the state of an evaluation object is poor, and the state of most evaluation points is poor; particularly, at the end stage and the final stage of the full life cycle, if the evaluation is continuously carried out for multiple times and the state C value of the evaluation object is gradually increased, the poor state of the evaluation object is also verified, and the enterprise should be ready for the whole replacement of the evaluation object.
10. A high-temperature header condition evaluation method based on metal inspection according to claim 1, wherein in step 6), the first type condition parameters: macroscopic State parameter CPq1-jFrom the result MR of a macroscopic examinationq1-j: { no defect found, and out-of-standard defect found } is defined as shown in equation (3):
the first type state parameters in the step 6): composition state parameter CPq2-jFrom the results of the spectroscopic examination MRq2-j: { pass, fail } definition, as shown in equation (4):
the second type state parameters in the step 6): tissue state parameter CPg1-jFrom the results of the metallographic examination MRg1-j: { level 1, level 2, level 3, level 4, level 5 } definition, as shown in equation (5):
the second type state parameters in the step 6): lossless State parameter CPg2-jThe result MR is detected by ultrasonic, magnetic powder, penetration and ray without damageg2-j: { stage I, stage II, stage III, stage IV } definition, as shown in equation (6):
the third type state parameters in the step 6): rough state parameter CPm1-jMR from the results of dilatory examinationm1-jAs defined by formula (7):
in the formula (7), D0Designed diameter in mm;
the third type state parameters in the step 6): wall thickness State parameter CPm2-jFrom the results of the wall thickness examination MRm2-jAs defined by formula (8):
the third type state parameters in the step 6): hardness State parameter CPm3-jFrom the results of the hardness test MRm3-jAs defined by formula (9):
the third type state parameters in the step 6): oxidation state parameter CPm4-jMR measured from the oxide scalem4-jDefinition, as shown in formula (10):
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