CN112686508B - Method for judging and solving failure behavior of distillation device - Google Patents
Method for judging and solving failure behavior of distillation device Download PDFInfo
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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 corrosion prevention control measures such as the compiled technology corrosion prevention standard, the equipment corrosion prevention guide basis and the like so as to determine the feasible execution 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 oil deterioration, large production load change, continuous extension of operation period and the like, and avoids large accidents and losses caused by corrosion of equipment and pipelines as the focus of oil refining and chemical engineering 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 and pipelines is prolonged by a material upgrading mode, so that the adaptability of the equipment and the 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 and pipeline materials, operating temperature and material medium, and judging the corrosion failure risk for the equipment and pipeline materials for I times;
s2: and (3) corrosion risk value accounting: a general consideration of corrosion failure in distillation plant equipment is classified as RoC Thinning ，RoC Cracking of ，RoC Metallurgical variants ，RoC Failure case And separately accounting for the corrosion occurrence degreeRisk value, total corrosion risk value RoC for the entire circuit according to the following formula General (1) Carrying out I times of accounting:
in the formula: RoC General assembly For the total corrosion risk value of the whole loop,
in order to sum up the values of the corrosion risk for thinning,
for the summation of the values of the risk of cracking corrosion,
for the summation of metallurgical variant corrosion risk values,
summing the corrosion risk values of the failure cases;
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 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 equipment and pipelines of each processing unit or system of the distillation device by combining the result of the check calculation and evaluation to complete I-time verification;
s5: on the basis of judging results, evaluating accounting and I-time verification of the corrosion failure behaviors, providing corresponding corrosion material upgrading suggestions for each processing unit or system, evaluating the failure effect of process anticorrosion measures in the aspects of process operation, injection agent selection and injection method, and providing process anticorrosion 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 programmed technology anticorrosion standard and the anticorrosion control measure according to the equipment anticorrosion guidance so as to determine the feasible execution and continuously optimize.
Preferably, in the corrosion risk value calculation of S2, taking the corrosion risk calculation process of the overhead low-temperature system of a certain distillation plant as an example, the following steps are included:
s21: based on a low-temperature dew point corrosion mechanism, a 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, a corrosion failure factor judgment value is determined by adopting carbon steel or 0Cr13 easily thinned equipment and pipelines through a corrosion thinning mechanism, and a corrosion failure factor judgment value is determined by adopting stainless steel 316 equipment and pipelines to the corresponding equipment and 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 RoC General assembly The 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 in S2, the weight of the production technical factors, the selection and manufacturing quality of the equipment and pipeline materials suitable for use under the processing raw materials of the distillation apparatus, the weight influence factor of the internal structure, the weight factor of the fluctuation of the process conditions of the apparatus, and the material characteristic factor in the designated corrosion loop are taken into consideration as the basis for determining the judgment value of the corrosion failure factor.
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 corrosion failure weights of the device material and the medium environment thereof are ranked, the corrosion weight factor values thereof are calculated, and the size of the weight occupied by a certain corrosion mechanism in the corrosion failure is determined, so as to determine the possibility of the corrosion failure damage form occurrence of a certain specific portion.
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 and the 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 materials, medium environments 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 influencing the implementation effect of the scheme cannot be determined in the traditional corrosion control scheme is optimized, and the method has practical application value.
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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 corrosion failure behavior influence factors of the equipment and the 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 and pipeline materials which are suitable for being selected under the processing raw materials of the distillation device, the manufacturing quality, the internal structure and the like, 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 which are crossed by a plurality of corrosion mechanisms and respectively account for the specific corrosion mechanisms, the corrosion failure factors such as equipment materials, medium environments 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 and 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 and pipeline materials, operating temperature and material medium, 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 and pipelines such as carbon steel or 0Cr13 and the like through a corrosion thinning mechanism, and corrosion failure factor judgment is carried out on corresponding equipment and pipelines by adopting stainless steel 316 materials; and (4) accounting the corrosion failure risk value of each corrosion failure risk, and determining a corrosion failure factor judgment value according to the table 1.
Total corrosion risk RoC General assembly The risk value is obtained by carrying out weighted average treatment 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, wherein 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 and pipelines 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 invention, 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 the key corrosion weak part on the overall stable operation of the distillation device is effectively identified, a corresponding full-loop solution is provided and the circulation optimization is carried out, and the method has strong actual executability and guidance 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 the equipment material, the medium environment and the like, and the corrosion damage degree, the corrosion actual occurrence case and other factors to judge, calculate, simulate, evaluate and audit the failure risk in the corrosion loop diagram, 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 influencing the implementation effect of the scheme cannot be determined in the traditional corrosion control scheme is optimized, 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 judging and solving the failure behavior of a distillation device is characterized by comprising 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 through judgment classification and failure risk value accounting, evaluation and audit, 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 and pipeline materials, operating temperature and material medium, and judging the corrosion failure risk for the equipment and pipeline materials for I times;
s2: and (3) corrosion risk value accounting: classifying the combined considerations of corrosion failure of distillation plant equipment and pipelines including
RoC Thinning ，RoC Cracking of ，RoC Variation of metallurgy ，RoC Failure case And respectively calculating the corrosion risk value for each corrosion occurrence degree, and according to the following formula, the total corrosion risk value RoC of the whole loop General assembly And (3) performing I-time accounting:
in the formula: RoC General assembly For the total corrosion risk value of the entire circuit,
in order to sum up the values of the risk of thinning corrosion,
for the summation of the values of the risk of cracking corrosion,
for the summation of metallurgical variant corrosion risk values,
summing the corrosion risk values of the failure cases;
alpha is a thinning corrosion failure factor judging value, beta is a cracking corrosion failure factor judging value, and gamma is a metallurgical variation corrosion failure factor judging value;
s3: and (4) judging the corrosion failure risk for II times: building a laboratory simulation device according to the operating temperature and 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 equipment and pipelines of each processing unit or system of the distillation device by combining the result of the check calculation and evaluation to complete I-time verification;
s5: on the basis of judging results, evaluating accounting and I-time verification of the corrosion failure behaviors, providing corresponding corrosion material upgrading suggestions for each processing unit or system, evaluating the failure effect of process anticorrosion measures in the aspects of process operation, injection agent selection and injection method, and providing process anticorrosion 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: auditing and revising the value scheme: and (4) auditing and revising the value scheme of the programmed technology anticorrosion standard and the anticorrosion control measure according to the equipment anticorrosion guidance so as to determine the feasible execution and continuously optimize.
2. The method for determining and solving the failure behavior of the distillation plant according to claim 1, wherein the corrosion risk value accounting of S2 is applied to the corrosion risk accounting of the tower top cryogenic system of the distillation plant, and comprises 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 low-temperature system, a corrosion failure factor determination value is determined by adopting carbon steel or easily thinned equipment and pipelines of 0Cr13 through a corrosion thinning mechanism, and a corrosion failure factor determination value is determined by adopting stainless steel 316 equipment and pipelines to corresponding equipment and 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 the product of the weight of the corrosion influence factors;
s24: total corrosion risk RoC General assembly The risk value is obtained after weighted average processing is carried out on all possible corrosion risks according to categories, and the corrosion weight factor value obtained by calculation in the corrosion failure weight grade and the occurrence condition of the corrosion failure case are comprehensively calculated.
3. The method as claimed in claim 2, wherein the corrosion risk value calculation in S2 takes into account the weight of production technical factors, the selection and manufacturing quality of equipment and pipeline materials suitable for use under the processing material of the distillation apparatus, the weight influence factor of internal structure, the weight factor of fluctuation of process conditions of the apparatus, and the material characteristic factor in the designated corrosion loop as the basis for determining the judgment value of the corrosion failure factor.
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 corrosion risk value calculation of S2, for corrosion mechanisms that are crossed, the corrosion damage forms of specific corrosion mechanisms are calculated respectively, the corrosion failure weights of equipment materials, media and environment thereof are ranked, the corrosion weight factor values are calculated, and the probability of occurrence of the corrosion failure damage forms of a specific part is determined by determining the weight of a corrosion mechanism in the corrosion failure.
6. The method as claimed in claim 5, wherein the corrosion risk value of S2 is calculated by calculating the corrosion risk of the corrosion loop according to the damage consequences and the corrosion case failure risk, and the method is suitable for determining the corrosion failure risk of the equipment and the pipeline in all corrosion loop diagrams of the distillation plant.
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| CN108204941B (en) * | 2016-12-20 | 2021-08-03 | 中国石油天然气股份有限公司 | Method for predicting internal corrosion degree of pipeline before production |
| CN109670663A (en) * | 2017-10-17 | 2019-04-23 | 中国石油化工股份有限公司 | Petrochemical plant corrosion protection integrated technique method |
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| US4998208A (en) * | 1987-03-16 | 1991-03-05 | The Standard Oil Company | Piping corrosion monitoring system calculating risk-level safety factor producing an inspection schedule |
| JP2005091027A (en) * | 2003-09-12 | 2005-04-07 | Babcock Hitachi Kk | Method for diagnosing easiness to cause alkali stress corrosion cracking and alkali corrosion damage |
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