CN112686508A - Method for judging and solving failure behavior of distillation device - Google Patents
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Abstract
The invention relates to a method for judging and solving failure behaviors of a distillation device, and belongs to the technical field of corrosion of oil refining enterprises. The invention comprises the following steps: s1: judging the corrosion failure risk for the first time; s2: calculating a corrosion risk value; s3: judging the corrosion failure risk for II times; s4: verifying the corrosion failure risk for the first time; s5: determining a corrosion failure factor; s6: evaluating and solving a full loop; s7: review and revision of the value scheme: checking and revising a value scheme of the anticorrosion control measures such as the programmed technology anticorrosion standard, the equipment anticorrosion guide basis and the like to determine the feasible executability and continuously optimize; by grading each influence factor of the corrosion damage mechanism, judging the value of the corrosion failure factor and carrying out corrosion risk value accounting on each corrosion failure risk, the problem that the implementation effect of the main influence factor influence scheme cannot be determined in the traditional corrosion control scheme is optimized, and the method has practical application value.
Description
Technical Field
The invention relates to a method for judging and solving failure behaviors of a distillation device, and belongs to the technical field of corrosion of oil refining enterprises.
Background
Statistically, 31.1% of the major chemical accidents are caused by equipment corrosion, and of the losses due to corrosion, about 25% of the corrosion losses can be avoided by various corrosion protection measures. Along with the increase of the exploitation difficulty of petroleum resources, the proportion of high-sulfur and high-acid crude oil in crude oil processed by an oil refining chemical device is continuously increased, and the risk of corrosion accidents is continuously increased. The distillation device takes crude oil as a primary processing raw material, how to deal with the influences of poor oil quality, large production load change, continuous extension of operation period and the like, and avoids the major accidents and losses caused by corrosion problems of equipment and pipelines as the focus of oil refining chemical enterprises.
At present, the oil refining device generally adopts a material adaptability assessment mode to theoretically calculate the corrosion rate of a high-temperature part, and the residual service life of equipment/pipelines is prolonged by a material upgrading mode, so that the adaptability of the equipment/pipelines to the degradation of processed crude oil is improved. How to provide a whole-loop optimization scheme comprising material corrosion prevention, process corrosion prevention, corrosion monitoring and detection and the like is a continuous optimization direction of a corrosion control scheme of an oil refining chemical device.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a method for judging and solving the failure behavior of the distillation device, which is an important method for realizing comprehensive and effective corrosion prevention by respectively judging, accounting, simulating, evaluating and auditing the failure risks of a plurality of corrosion loops in the distillation device in a mode of grading each influence factor of a corrosion damage mechanism, judging the value of a corrosion failure factor and accounting each corrosion failure risk value and establishing a corrosion failure risk judgment model corresponding to the distillation device.
The method for judging and solving the failure behavior of the distillation device comprises the following steps: the method comprises the following steps of judging corrosion failure risks according to the process flow characteristics of each processing unit of the distillation device, and forming a full-flow solution of the distillation device by judging classification and performing accounting, evaluation and audit on failure risk values, wherein the method comprises the following specific steps:
s1: the corrosion failure risk is judged for I times: considering the existing corrosion mechanism, establishing a corrosion loop chart comprising equipment/pipeline materials, operation temperature and material medium, and judging the corrosion failure risk for the corrosion loop chart for I times;
s2: and (3) corrosion risk value accounting: a general consideration of corrosion failure in distillation plant equipment is classified as RoCThinning，RoCCracking of，RoCVariation of metallurgy，RoCFailure caseAnd calculating corrosion risk value for each corrosion occurrence degree respectively, and summing RoC for the whole loop according to the following formulaGeneral assemblyCarrying out I times of accounting:
in the formula: RoCGeneral assemblyIn order to be a total risk of corrosion,
in order to reduce the risk of corrosion,
in order to risk the corrosion by cracking,
in order to avoid the risk of metallurgical variation corrosion,
corrosion risk for failure case;
alpha is a thinning corrosion failure factor judgment value, beta is a cracking corrosion failure factor judgment value, and gamma is a metallurgical variation corrosion failure factor judgment value;
s3: and (4) judging the corrosion failure risk for II times: building a laboratory simulation device according to the operating temperature and the corrosion medium characteristics of a specific distillation device, carrying out laboratory simulation on the simulation result of the equipment corrosion failure behavior mathematical model, correcting the judgment value of the corrosion failure factor, and evaluating and calculating the result for the second time;
s4: the corrosion failure risk is verified for I times: performing on-site detection and rechecking on the equipment/pipelines of each processing unit/system of the distillation device by combining the result of the check calculation and evaluation to complete I-time verification;
s5: determination of corrosion failure factor determination value: on the basis of judging results of the corrosion failure behaviors, evaluating accounting and verifying for the first time, providing corresponding corrosion material upgrading suggestions for each processing unit/system, evaluating the failure effect of process anti-corrosion measures in the aspects of process operation, injection agent selection and injection method, and providing process anti-corrosion optimization measures;
s6: full loop evaluation and resolution: determining a full-loop evaluation and solution method of the whole distillation device including process corrosion prevention optimization, corrosion monitoring and detection and equipment material corrosion resistance;
s7: review and revision of the value scheme: and (4) auditing and revising the value scheme of the anticorrosion control measures such as the programmed technology anticorrosion standard, the equipment anticorrosion guide basis and the like so as to determine the feasible executability and continuously optimize.
Preferably, the corrosion risk value accounting of S2, taking the corrosion risk accounting process of the overhead low-temperature system of a certain distillation plant as an example, includes the following steps:
s21: based on a low-temperature dew point corrosion mechanism, tower top equipment material selection and a process agent injection execution scheme, a corrosion failure risk value is calculated for corrosion risks such as a thinning damage mechanism, a cracking damage mechanism, a metallurgical variation damage mechanism and a failure case corrosion risk;
s22: in the tower top system, the judgment value of the corrosion failure factor is determined by adopting carbon steel or easily thinned equipment/pipelines such as 0Cr13 and the like through a corrosion thinning mechanism, and the judgment value of the corrosion failure factor is determined by adopting stainless steel 316 equipment/pipelines to the corresponding equipment/pipelines through a corrosion cracking damage mechanism;
s23: each corrosion failure risk calculates a corrosion failure risk value according to the characteristics of the corrosion failure risk, and a corrosion failure factor judgment value is determined according to a judgment table;
s24: total corrosion risk RoCGeneral assemblyThe risk value is obtained by carrying out weighted average processing on all possible corrosion risks according to categories, and the corrosion weight factor value and the corrosion failure case occurrence condition obtained by calculation in a corrosion judgment table are comprehensively calculated.
Preferably, in the calculation of the corrosion risk value of S2, the weight of the production technical factor, the selection of the equipment/pipeline material and the manufacturing quality suitable for use under the processing raw material of the distillation apparatus, the weight influence factor of the internal structure, the weight factor of the process condition fluctuation of the apparatus, and the material characteristic factor in the designated corrosion loop are taken into consideration as the basis for determining the corrosion failure factor determination value.
Preferably, in the corrosion risk value accounting of S2, the weights of the corrosion influencing factors are arranged from large to small, the corrosion failure weight is increased or decreased according to the actual situation, and the grades are divided by a theoretical corrosion rate calculation model in the execution process.
Preferably, in the corrosion risk value accounting of S2, for a plurality of corrosion mechanisms that cross each other according to the corrosion occurrence mechanism, the corrosion damage forms of the specific corrosion mechanisms are respectively accounted, the equipment material and the medium-environment corrosion failure weight thereof are ranked, the corrosion weight factor value thereof is calculated, and the possibility of occurrence of the corrosion failure damage form of a specific portion is determined by determining the weight of a certain corrosion mechanism in the corrosion failure.
Preferably, in the corrosion risk value calculation of S2, the corrosion risk of the corrosion loop is calculated according to the damage consequences and the corrosion case failure risk of the corrosion loop concerning the corrosion thinning, corrosion cracking and metallurgical variation in the corrosion loop diagram, and is suitable for determining the corrosion failure risk of the equipment/pipeline in all the corrosion loop diagrams of the distillation apparatus.
The invention has the beneficial effects that: aiming at a specific corrosion failure behavior mode of the distillation device, the method grades influence factors of each corrosion mechanism in the same corrosion loop of the same device to realize the judgment of a corrosion factor weight value, carries out accounting on corrosion failure risks according to the corrosion failure damage degree, comprehensively considers influence factors such as equipment material, medium-environment and the like, judges, accounts, simulates, evaluates and audits the failure risks in a corrosion loop diagram of the device according to the corrosion failure damage degree and the corrosion actual occurrence case, establishes a corrosion failure risk judgment model corresponding to the distillation device, and is an important method for realizing comprehensive and effective corrosion prevention; the problem that the main influence factors cannot be determined to influence the implementation effect of the scheme in the traditional corrosion control scheme is solved, and the method has practical application value.
Drawings
FIG. 1 is a schematic flow diagram of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1:
as shown in fig. 1, the method for determining and solving the failure behavior of the distillation apparatus according to the present invention comprises the following steps:
s1: the corrosion failure risk is judged for I times: and calling basic data of the distillation device, identifying the corrosion failure behavior of the device, drawing a corrosion loop diagram, establishing the corrosion loop diagram, and judging the effectiveness of the influence factors of the corrosion failure behavior of the equipment/pipeline for the first time by evaluating the material quality of the equipment, the process operation temperature, the corrosion key parameters, the anticorrosion measures and the like.
S2: the comprehensive consideration factors of the corrosion failure of the distillation device equipment are classified, wherein the comprehensive consideration factors comprise RoC thinning, RoC cracking, RoC metallurgical variation and RoC failure cases, the corrosion risk is calculated according to each corrosion occurrence degree, and the total corrosion risk value of the whole loop is calculated for the first time according to the following formula.
The steps comprise: considering the weight of the production technical factors, the weight influence factors of the selection of the equipment/pipeline material and the manufacturing quality, the internal structure and the like which are suitable for being selected under the processing raw materials of the distillation device, the weight factors of the fluctuation of the process working conditions of the device, the material characteristic factors in the specified corrosion loop and the like as the judgment values of the corrosion failure factors;
TABLE 1 weight factor decision Table
The A, B, C, D … … grades are arranged from large to small according to the weight of the influence factors on the corrosion (70%, 60%, 50%, 40%, 30% and 10% … …), the corrosion failure factors in the judgment table 1 can be increased or decreased according to actual conditions, and the grades can be divided through a theoretical corrosion rate calculation model in the execution process. According to the corrosion generation mechanism, for the corrosion damage forms of a plurality of corrosion mechanisms which are crossed and respectively account for the specific corrosion mechanisms, the corrosion failure factors such as equipment materials, medium-environment and the like are graded, the corrosion weight factor values are calculated, the weight occupied by a certain corrosion mechanism in the corrosion failure is determined, the possibility of the corrosion failure damage form generation of a certain specific part is determined, and the cracking form caused at the part has comparability because the corrosion failure weights in the same corrosion loop diagram are graded uniformly in the corresponding corrosion mechanisms; calculating the corrosion risk of the corrosion loop according to the damage result, the corrosion case and the like of the corrosion thinning, the corrosion cracking and the metallurgical variation related to the corrosion loop diagram, and being suitable for judging the corrosion failure risk of equipment/pipelines in all corrosion loop diagrams of the distillation device;
s3: carrying out laboratory simulation on the simulation result of the equipment corrosion failure behavior mathematical model, correcting the judgment value of the corrosion failure factor, and evaluating and accounting the result for the second time;
s4: performing on-site detection and rechecking by combining the result of the accounting evaluation and the conditions of process operation, equipment pipeline inspection, corrosion monitoring and detection and the like in recent years to finish I-time verification;
s5: on the basis of judging results of the corrosion failure behaviors, evaluating and accounting and I-time verification, corrosion material upgrading suggestions and process corrosion prevention optimization measures are provided; determining a full-loop evaluation and solution method of the distillation device, including process corrosion prevention optimization, corrosion monitoring and detection and equipment material corrosion resistance;
s6: full loop evaluation and resolution: and after the fifth step, checking and revising the value scheme of the corrosion prevention control measures such as the programmed technology corrosion prevention standard, the equipment corrosion prevention guidance basis and the like so as to determine the feasible execution and continuously optimize.
Example 2:
taking the corrosion risk accounting process of a tower top low-temperature system of a certain distillation device as an example, a process explanation is carried out on a judgment failure behavior judgment mode of judgment, accounting, simulation, evaluation and auditing;
s1: according to a low-temperature condensing system at the top of a certain fractionating device, considering possible corrosion mechanisms, establishing a corrosion loop chart comprising equipment/pipeline materials, operating temperature and material media, and judging the corrosion failure risk for the corrosion loop chart for I times;
s2: starting from a low-temperature dew point corrosion mechanism, tower top equipment material selection and a process agent injection execution scheme, accounting the total corrosion risk for corrosion risks such as a thinning damage mechanism, a cracking damage mechanism, a metallurgical variation damage mechanism and a failure case corrosion risk; in the tower top system, corrosion failure factor value judgment is carried out by adopting easily thinned equipment/pipelines such as carbon steel or 0Cr13 and the like through a corrosion thinning mechanism, and corrosion failure factor judgment is carried out by adopting stainless steel 316 equipment/pipelines to corresponding equipment/pipelines through a corrosion cracking damage mechanism; and (4) carrying out corrosion failure risk value accounting on each corrosion failure risk, and determining a corrosion failure factor judgment value according to the table 1.
Total corrosion risk RoCGeneral assemblyThe method is characterized in that all possible corrosion risks are subjected to weighted average treatment according to categories to obtain risk values, corrosion weight factor values obtained by calculation in a corrosion judgment table and corrosion failure case occurrence conditions are comprehensively calculated, and the calculation formula is as follows:
s3: building a laboratory simulation device according to the operating temperature and the corrosion medium characteristics of a specific distillation device, carrying out laboratory simulation on the simulation result of the equipment corrosion failure behavior mathematical model, correcting the judgment value of the corrosion failure factor, and evaluating and calculating the result for the second time;
s4: performing on-site detection and rechecking on the tower top low-temperature system equipment/pipeline by combining the result of the check calculation evaluation to complete I-time verification;
s5: on the basis of judging results of the corrosion failure behaviors, evaluating accounting and verifying for the first time, providing a corrosion material upgrading suggestion, evaluating the failure effect of process anticorrosion measures from the aspects of process operation, injection agent selection, injection method and the like, and providing process anticorrosion optimization measures; determining a full loop evaluation and solution method including process corrosion prevention optimization, corrosion monitoring and detection and equipment material corrosion resistance of a distillation plant tower top low-temperature system;
s6: full loop evaluation and resolution: after S5, the value scheme is reviewed and revised for the programmed process corrosion protection standards and equipment corrosion protection guidance bases and other corrosion protection control measures to determine the feasibility and the continuous optimization.
According to the method, the corrosion mechanism of the distillation device is used as basic data for failure behavior judgment, the weight factor of corrosion failure risk is determined, the influence of key corrosion weak parts on the overall stable operation of the distillation device is effectively identified, a corresponding full-loop solution is provided and is circularly optimized, and the method has strong actual executability and guiding value.
Aiming at a specific corrosion failure behavior mode of a distillation device, the invention grades influence factors of each corrosion mechanism in the same corrosion loop of the same device, realizes judgment of a corrosion factor weight value, and carries out accounting on corrosion failure risks according to the corrosion failure damage degree; the method comprehensively considers the influence factors such as equipment material, medium-environment and the like, the corrosion damage degree and the corrosion actual occurrence case, and determines, accounts, simulates, evaluates and audits the failure risk in the corrosion loop diagram, establishes a corrosion failure risk determination model corresponding to the distillation device, and is an important method for realizing comprehensive and effective corrosion prevention. The problem that the main influence factors cannot be determined to influence the implementation effect of the scheme in the traditional corrosion control scheme is solved, and the method has practical application value.
The invention can be widely applied to corrosion occasions of oil refining enterprises.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (6)
1. A method for determining and addressing failure behavior of a distillation apparatus, comprising the steps of: the method comprises the following steps of judging corrosion failure risks according to the process flow characteristics of each processing unit of the distillation device, and forming a full-flow solution of the distillation device by judging classification and performing accounting, evaluation and audit on failure risk values, wherein the method comprises the following specific steps:
s1: the corrosion failure risk is judged for I times: considering the existing corrosion mechanism, establishing a corrosion loop chart comprising equipment/pipeline materials, operation temperature and material medium, and judging the corrosion failure risk for the corrosion loop chart for I times;
s2: and (3) corrosion risk value accounting: a general consideration of corrosion failure in distillation plant equipment is classified as RoCThinning，RoCCracking of，RoCVariation of metallurgy，RoCFailure caseAnd calculating corrosion risk value for each corrosion occurrence degree respectively, and summing RoC for the whole loop according to the following formulaGeneral assemblyCarrying out I times of accounting:
in the formula: RoCGeneral assemblyIn order to be a total risk of corrosion,
in order to reduce the risk of corrosion,
in order to risk the corrosion by cracking,
in order to avoid the risk of metallurgical variation corrosion,
corrosion risk for failure case;
alpha is a thinning corrosion failure factor judgment value, beta is a cracking corrosion failure factor judgment value, and gamma is a metallurgical variation corrosion failure factor judgment value;
s3: and (4) judging the corrosion failure risk for II times: building a laboratory simulation device according to the operating temperature and the corrosion medium characteristics of a specific distillation device, carrying out laboratory simulation on the simulation result of the equipment corrosion failure behavior mathematical model, correcting the judgment value of the corrosion failure factor, and evaluating and calculating the result for the second time;
s4: the corrosion failure risk is verified for I times: performing on-site detection and rechecking on the equipment/pipelines of each processing unit/system of the distillation device by combining the result of the check calculation and evaluation to complete I-time verification;
s5: determination of corrosion failure factor determination value: on the basis of judging results of the corrosion failure behaviors, evaluating accounting and verifying for the first time, providing corresponding corrosion material upgrading suggestions for each processing unit/system, evaluating the failure effect of process anti-corrosion measures in the aspects of process operation, injection agent selection and injection method, and providing process anti-corrosion optimization measures;
s6: full loop evaluation and resolution: determining a full-loop evaluation and solution method of the whole distillation device including process corrosion prevention optimization, corrosion monitoring and detection and equipment material corrosion resistance;
s7: review and revision of the value scheme: and (4) auditing and revising the value scheme of the anticorrosion control measures such as the programmed technology anticorrosion standard, the equipment anticorrosion guide basis and the like so as to determine the feasible executability and continuously optimize.
2. The method for determining and solving the failure behavior of the distillation apparatus according to claim 1, wherein the corrosion risk value accounting of S2 includes the following steps, taking the corrosion risk accounting process of the tower top cryogenic system of a certain distillation apparatus as an example:
s21: based on a low-temperature dew point corrosion mechanism, tower top equipment material selection and a process agent injection execution scheme, a corrosion failure risk value is calculated for corrosion risks such as a thinning damage mechanism, a cracking damage mechanism, a metallurgical variation damage mechanism and a failure case corrosion risk;
s22: in the tower top system, the judgment value of the corrosion failure factor is determined by adopting carbon steel or easily thinned equipment/pipelines such as 0Cr13 and the like through a corrosion thinning mechanism, and the judgment value of the corrosion failure factor is determined by adopting stainless steel 316 equipment/pipelines to the corresponding equipment/pipelines through a corrosion cracking damage mechanism;
s23: each corrosion failure risk calculates a corrosion failure risk value according to the characteristics of the corrosion failure risk, and a corrosion failure factor judgment value is determined according to a judgment table;
s24: total corrosion risk RoCGeneral assemblyThe risk value is obtained by carrying out weighted average processing on all possible corrosion risks according to categories, and the corrosion weight factor value and the corrosion failure case occurrence condition obtained by calculation in a corrosion judgment table are comprehensively calculated.
3. The method as claimed in claim 2, wherein the corrosion risk value calculation of S2 is based on the determination of the corrosion failure factor determination value by considering the weight of the production technical factors, the selection of the material and the manufacturing quality of the equipment/pipeline that is suitable for use under the raw material of the distillation apparatus, the weight influence factor of the internal structure, the weight factor of the fluctuation of the process condition of the apparatus, and the material characteristic factor in the designated corrosion loop.
4. The method for judging and solving the failure behavior of the distillation apparatus according to claim 1 or 3, wherein the corrosion risk values of S2 are arranged from large to small according to the weight of the corrosion influencing factors, the weight of the corrosion failure is increased or decreased according to the actual situation, and the grades of the corrosion failure are classified through a theoretical corrosion rate calculation model during the execution.
5. The method as claimed in claim 4, wherein in the calculation of the corrosion risk value of S2, for corrosion damage forms of specific corrosion mechanisms that exist alternately according to corrosion mechanisms, the corrosion risk value is calculated, the corrosion damage forms of the specific corrosion mechanisms are calculated, the equipment material and the medium-environment corrosion failure weight are ranked, the corrosion weight factor value is calculated, and the possibility of occurrence of the corrosion damage form of a specific part is determined by determining the weight of a corrosion mechanism in the corrosion failure.
6. The method for determining and solving the failure behavior of the distillation apparatus as claimed in claim 5, wherein the corrosion risk value of S2 is calculated according to the corrosion thinning, corrosion cracking, metallurgical variation and damage consequences involved in the corrosion loop diagram, and the corrosion case failure risk, and is suitable for determining the corrosion failure risk of the equipment/pipeline in all corrosion loop diagrams of the distillation apparatus.
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