CN113210800A - Method for repairing defects of weld overlay on inner wall of PTA (pure terephthalic acid) reactor - Google Patents
Method for repairing defects of weld overlay on inner wall of PTA (pure terephthalic acid) reactor Download PDFInfo
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- CN113210800A CN113210800A CN202110482275.3A CN202110482275A CN113210800A CN 113210800 A CN113210800 A CN 113210800A CN 202110482275 A CN202110482275 A CN 202110482275A CN 113210800 A CN113210800 A CN 113210800A
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- 230000007547 defect Effects 0.000 title claims abstract description 39
- 238000000034 method Methods 0.000 title claims abstract description 38
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 title description 24
- 238000003466 welding Methods 0.000 claims abstract description 78
- 230000007797 corrosion Effects 0.000 claims abstract description 27
- 238000005260 corrosion Methods 0.000 claims abstract description 27
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 19
- 239000010959 steel Substances 0.000 claims abstract description 19
- 238000005498 polishing Methods 0.000 claims abstract description 14
- 230000008439 repair process Effects 0.000 claims abstract description 13
- 238000005553 drilling Methods 0.000 claims abstract description 4
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 12
- 229910000856 hastalloy Inorganic materials 0.000 claims description 10
- 238000001514 detection method Methods 0.000 claims description 8
- 229910052786 argon Inorganic materials 0.000 claims description 6
- 238000005485 electric heating Methods 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 230000008569 process Effects 0.000 claims description 5
- 238000004140 cleaning Methods 0.000 claims description 4
- 230000002950 deficient Effects 0.000 claims description 4
- 229910000365 copper sulfate Inorganic materials 0.000 claims description 2
- ARUVKPQLZAKDPS-UHFFFAOYSA-L copper(II) sulfate Chemical compound [Cu+2].[O-][S+2]([O-])([O-])[O-] ARUVKPQLZAKDPS-UHFFFAOYSA-L 0.000 claims description 2
- 230000007704 transition Effects 0.000 claims description 2
- 238000012423 maintenance Methods 0.000 abstract description 7
- 239000000463 material Substances 0.000 abstract description 7
- 238000010276 construction Methods 0.000 abstract description 3
- 239000000956 alloy Substances 0.000 description 6
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000243 solution Substances 0.000 description 5
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 4
- 229910001220 stainless steel Inorganic materials 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 238000007689 inspection Methods 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 2
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 2
- 229920000742 Cotton Polymers 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 239000000460 chlorine Substances 0.000 description 2
- 229910052801 chlorine Inorganic materials 0.000 description 2
- OSVXSBDYLRYLIG-UHFFFAOYSA-N dioxidochlorine(.) Chemical compound O=Cl=O OSVXSBDYLRYLIG-UHFFFAOYSA-N 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- WQYVRQLZKVEZGA-UHFFFAOYSA-N hypochlorite Chemical compound Cl[O-] WQYVRQLZKVEZGA-UHFFFAOYSA-N 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000001590 oxidative effect Effects 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000004155 Chlorine dioxide Substances 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- HMDDXIMCDZRSNE-UHFFFAOYSA-N [C].[Si] Chemical compound [C].[Si] HMDDXIMCDZRSNE-UHFFFAOYSA-N 0.000 description 1
- 239000003929 acidic solution Substances 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 229910000963 austenitic stainless steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000003763 carbonization Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 150000001805 chlorine compounds Chemical class 0.000 description 1
- 235000019398 chlorine dioxide Nutrition 0.000 description 1
- 239000012459 cleaning agent Substances 0.000 description 1
- 239000010960 cold rolled steel Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000005984 hydrogenation reaction Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 238000007778 shielded metal arc welding Methods 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/235—Preliminary treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
Abstract
The invention discloses a method for repairing defects of a build-up welding layer on the inner wall of a PTA reactor, which comprises the following steps: repairing pits in the corrosion area; welding a layer of flitch on the corroded area; drilling two rows of plug welding holes on each pasting board at intervals; assembling the flitch on the inner wall of the pipe wall and welding; polishing the welding part, welding the connection part of the flitch, and finally welding the connection two ends of the flitch and the cylinder wall; according to the method, the dense corrosion defect of the inner wall of the PTA reactor is repaired, the flitch is used, the steel plate can be purchased in advance, the maintenance construction period is short, the repair quality can be effectively ensured, a large amount of manpower and material resources are saved, and the maintenance period is greatly shortened.
Description
Technical Field
The invention relates to a method for repairing defects of a build-up welding layer on the inner wall of a PTA reactor, and belongs to the technical field of repair of build-up welding layers on the inner wall of a pressure vessel.
Background
The PTA reactor is a plant for producing PTA (purified terephthalic acid), and CTA (crude terephthalic acid) is purified into PTA (purified terephthalic acid) mainly by a hydrogenation reduction method. When a PTA reactor of a petrochemical company is used for parking inspection after a period of time, the concentrated point corrosion defects of a plurality of 347 stainless steel overlaying layers below a manhole are found, the PTA reactor is in a pit shape, and the deepest part is about 4.5 mm. The partial corrosion pits are connected together to form a pitting corrosion zone which is distributed along the circumferential direction of the inner wall.
After analysis, the main reason is considered to be that the Br-is contacted for a long time under the acidic working environment for a long time, particularly under the high temperature. Br-has stronger activity, it can be strongly adsorbed on the surface of steel to destroy passive film on the surface of steel, and Br-is further concentrated in the etching hole, and the pitting corrosion can be developed into deep place. The acidic solution also aggravates the corrosion of Br "to the inner surfaces of the reactor. Meanwhile, under the conditions of high temperature and high pressure, the acetic acid containing Br-is more and more corrosive, so that the pitting corrosion condition is more serious, and the corrosion rate of the stainless steel containing molybdenum element is improved.
The petrochemical industry container often stops the time of overhauing very limited, if adopt the mode of large tracts of land surfacing of polishing to carry out defect repair, need spend a large amount of time, influence user normal use, each item cost of maintenance is also very expensive simultaneously.
Disclosure of Invention
The invention aims to provide a method for repairing defects of a build-up welding layer on the inner wall of a PTA reactor, which aims to solve the defects that in the prior art, repair needs to take a lot of time and the repair cost is very high.
A method for repairing defects of a weld overlay on an inner wall of a PTA reactor, the method comprising:
repairing pits in the corrosion area;
welding a layer of flitch on the corroded area;
drilling two rows of plug welding holes on each pasting board at intervals;
assembling the flitch on the inner wall of the pipe wall and welding;
and polishing the welding part, welding the connection part of the flitch, and finally welding the connection part of the flitch and the cylinder wall to connect two ends.
Further, the thickness of the flitch is 4mm-6 mm.
Furthermore, the flitch plate is made of a Hastelloy C-276 steel plate.
Furthermore, a single-side 30-degree V-shaped groove is formed in the periphery of the flitch.
Further, the two rows of plug welding holes are alternated to form a zigzag shape.
Furthermore, the welding is carried out by adopting an ERNiCrMo-4 argon arc welding wire with the diameter of phi 2.4.
Further, the method also comprises the detection/inspection of the raw overlay layer, and the specific inspection steps are as follows:
measuring and recording the thickness of the overlaying layer with the surface defect area by adopting a UT thickness measuring mode;
carrying out 100% UT detection on a defective area according to NB/T47013.3-2015 from the side of the overlaying layer, and marking and recording a defective part;
the PT/UT residue was cleaned.
Further, the PT/UT residue cleaning method comprises the following steps:
removing defects by adopting a polishing method;
the bottom of the area where the defects are removed by polishing is smooth and transited with the edge of the original surfacing layer smoothly;
the depth of the defect removal site was measured and recorded.
Further, when the depth of the defect removal part is more than or equal to 6.0mm, a copper sulfate solution is coated on the corresponding area, whether the polishing of the area reaches the base layer parent metal or not is confirmed, and special identification and recording are carried out on the defect part reaching the base layer parent metal.
Further, when the depth of the defect removal part is less than or equal to 6.0mm, an external electric heating crawler belt is switched on to preheat the part to be repaired and the part nearby the part to be repaired to be more than or equal to 150 ℃;
and after the temperature is reached, the external electric heating crawler is powered off, the transition layer is subjected to surfacing by adopting ER309L welding wire argon arc welding, the temperature is observed at any time in the repair welding process, the welding is stopped when the temperature is lower than 100 ℃, and the external electric heating crawler is electrified and preheated again to be more than or equal to 150 ℃.
Compared with the prior art, the invention has the following beneficial effects: according to the method, the dense corrosion defect of the inner wall of the PTA reactor is repaired, the flitch is used, the steel plate can be purchased in advance, the maintenance construction period is short, the repair quality can be effectively ensured, a large amount of manpower and material resources are saved, and the maintenance period is greatly shortened.
Drawings
FIG. 1 is a PTA reactor wall defect;
FIG. 2 is a defect distribution of the inner wall;
FIG. 3 is the reactor inner wall after patch repair.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further described with the specific embodiments.
As shown in fig. 1-3, a method for repairing defects of a weld overlay on an inner wall of a PTA reactor is disclosed, the method comprising:
repairing pits in the corrosion area;
welding a layer of flitch on the corroded area;
drilling two rows of plug welding holes on each pasting board at intervals;
assembling the flitch on the inner wall of the pipe wall and welding;
polishing the welding part, welding the connection part of the flitch, and finally welding the connection two ends of the flitch and the cylinder wall;
firstly, the flitch is selected, and in order to prevent pitting corrosion, an alloy material which is resistant to local corrosion damage can be selected. Wherein, two materials are widely used, 904L stainless steel and C-276 Hastelloy, and the technical proposal adopts the C-276 Hastelloy material for maintenance; the C-276 hastelloy belongs to a nickel-based alloy, has extremely low silicon-carbon content, and has excellent corrosion resistance to most corrosive media in an oxidation state and a reduction state. Has excellent pitting corrosion resistance, crevice corrosion resistance and stress corrosion resistance, mainly resists moisture and chlorine, various oxidizing chlorides, chloride solution, sulfuric acid and oxidizing salt, and has good corrosion resistance in low-temperature and medium-temperature hydrochloric acid. Meanwhile, the C-276 alloy is one of only a few materials which are resistant to corrosion of moist chlorine, hypochlorite and chlorine dioxide solution, and has obvious corrosion resistance to high-concentration chloride solution, so that the C-276 alloy is widely applied to severe corrosion environments such as PTA equipment. The welding performance of the C-276 alloy is similar to that of common austenitic stainless steel, and the weldability is good, so that the welding quality can be ensured only by operating according to the correct welding method and process requirements.
In the embodiment, the thickness of the flitch plate is 4mm-6mm of a C-276 hastelloy plate. The C-276 hastelloy plate is a cold-rolled steel plate subjected to solution annealing. In order to keep good attaching degree of the attaching plate, welding points are reasonably arranged, and the sealing welding at the periphery of the attaching plate needs to be tight without any gap; the method has the advantages that the steel plate can be purchased in advance, and the maintenance construction period is short.
And a layer of C-276 hastelloy steel plate with the thickness of 4mm is attached to the surface area of the corrosion resistant layer which is about 1000 mm-5000 mm below the manhole adapter pipe of the device N6.
The Hastelloy C-276 steel plate is purchased in advance, and the material and the performance meet the requirements of the C-276 Hastelloy steel plate in the ASTM B575 standard. Size: 4 sheets of-4X 2400X 8000 mm; weight: 2734.08 Kg.
After the steel plate is fed, whether the surface has visible defects is checked. And (3) carrying out 100% PT detection on the steel plate, wherein the grade I is qualified, any crack is not allowed to exist, and the technical grade is grade C.
The PT residue was cleaned.
Cutting the steel plate into 90 pieces of-4X 200X 4000mm by a shearing method; 4X 150X 4000mm,1 piece. A single-side 30-degree V-shaped groove is arranged on the periphery. The residual steel plate is used as the residual material.
Two rows of phi 10 through holes are drilled in each steel plate at intervals of 100 mm. The two rows of through holes are alternately zigzag-shaped.
Each steel plate is bent and formed according to the internal diameter phi 5800mm of the cylinder body, and the steel plates are completely attached to the inner wall of the cylinder body when the steel plates are assembled with the inner wall of the cylinder body.
The steel plate is assembled to the inner wall of the can as shown. Before assembly, oil stains on the inner wall of the cylinder body and all impurities such as sulfur, lead and the like need to be thoroughly removed.
Before welding, the shear hardening layer is removed, and a manual polishing mode can be adopted. And cleaning with acetone cleaning agent. And the bevel can not be wiped by cotton yarn, towels and the like, so that the cotton wool is prevented from being stuck in the bevel and generating carbonization pollution to the welding line during welding.
And adopting an ERNiCrMo-4 argon arc welding wire with the diameter of phi 2.4 for welding. The protective gas is Ar, and the purity is 99.99 percent. The hole is firstly welded, and the flitch is welded and connected with the pipe wall. And polishing the plug welding part after welding. Welding the connection part of the flitch plate, and finally welding the connection two ends of the flitch plate and the cylinder wall.
Note that: the front end of the welding wire is in gas protection, intermittent wire feeding is stopped to ensure the protective atmosphere, the welding wire is prevented from stirring a molten pool, and gas is stopped after dozens of seconds of arc pit filling to prevent hot cracks. The welding speed must not be too slow to prevent over-firing. The factors influencing corrosion such as undercut, unevenness, color change of welding seams, overhigh joints and the like cannot occur. Meanwhile, the sealing welding around the flitch is ensured to be tight without any gap.
Polishing and smoothly transiting the welding seam after welding to meet the PT flaw detection requirement; carrying out 100% PT detection on the repair welding part according to the requirement of NB/T47013.5-2015, wherein the grade I is qualified, no crack is allowed to exist, and the technical grade is grade C; the PT residue was cleaned.
In example 2, the use of build-up welding,
before surfacing, the corroded pit is repaired, and after the repair is qualified, surfacing is carried out on the 347 corrosion-resistant layer. 2 layers of C-276 alloy are deposited with a thickness of about 5 mm. The method has the advantages that the corrosion resistance is good, and the service life can be ensured to be long on the premise of ensuring the welding quality;
the method comprises the following specific steps:
cleaning the area to be subjected to repair welding;
and (3) carrying out surfacing welding by adopting shielded metal arc welding at room temperature, wherein 2 layers of the shielded metal ENiCrMo-4 and phi 4 are required to be surfaced, and the thickness of the surfacing welding layer is more than or equal to 4.5 mm. The welding is carried out by adopting ERNiCrMo-4, phi 2.4 argon arc welding locally. The temperature between layers is controlled not to be more than 100 ℃ in the surfacing process. Note that: the welding rod is baked according to the specification, and the welding rod is used by a welding rod heat-insulating barrel, so that the heat-insulating barrel can be used for heat insulation even if electricity is inserted. In the welding process, the current is adjusted and cannot be too large, the welding heat input is controlled, and the grains are prevented from being thick. The slag between the roads must be cleaned, brushed once by a stainless steel wire brush, then blown clean by compressed air, cleaned by acetone, dried and welded to the next road.
And after welding, the surfacing layer is polished to meet PT detection requirements.
And (3) carrying out 100% PT detection on the repair welding part according to the requirement of NB/T47013.5-2015, wherein the grade I is qualified, no crack is allowed to exist, and the PT residue is cleaned up according to the technical grade C.
The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.
Claims (10)
1. A method for repairing defects of a build-up welding layer on the inner wall of a PTA reactor is characterized by comprising the following steps:
repairing pits in the corrosion area;
welding a layer of flitch on the corroded area;
drilling two rows of plug welding holes on each pasting board at intervals;
assembling the flitch on the inner wall of the pipe wall and welding;
and polishing the welding part, welding the connection part of the flitch, and finally welding the connection part of the flitch and the cylinder wall to connect two ends.
2. The method of repairing defects in a weld overlay on the inner wall of a PTA reactor as claimed in claim 1 wherein the thickness of the patch is 4mm to 6 mm.
3. The method for repairing the defects of the weld overlay on the inner wall of the PTA reactor as claimed in claim 1, wherein the flitch is made of Hastelloy C-276 steel plate.
4. The method for repairing the defects of the weld overlay on the inner wall of the PTA reactor as claimed in claim 1, wherein the periphery of the flitch is provided with a single-sided 30-degree V-shaped groove.
5. The method of repairing weld overlay defect in PTA reactor as recited in claim 1, wherein said two rows of plug weld holes alternate in a zigzag pattern.
6. The method for repairing the defects of the weld overlay on the inner wall of the PTA reactor as claimed in claim 1, wherein the welding is performed by using an ERNiCrMo-4 argon arc welding wire with the diameter of phi 2.4.
7. The method for repairing the defect of the weld overlay on the inner wall of the PTA reactor as claimed in claim 1, wherein the method further comprises the steps of inspecting/inspecting the weld overlay, wherein the inspecting steps are as follows:
measuring and recording the thickness of the overlaying layer with the surface defect area by adopting a UT thickness measuring mode;
carrying out 100% UT detection on a defective area according to NB/T47013.3-2015 from the side of the overlaying layer, and marking and recording a defective part;
the PT/UT residue was cleaned.
8. The method of repairing the defect in the weld overlay of the PTA reactor as recited in claim 7, wherein the PT/UT residue cleaning method comprises:
removing defects by adopting a polishing method;
the bottom of the area where the defects are removed by polishing is smooth and transited with the edge of the original surfacing layer smoothly;
the depth of the defect removal site was measured and recorded.
9. The method for repairing the defect of the weld overlay on the inner wall of the PTA reactor as claimed in claim 8, wherein when the depth of the defect removal portion is greater than or equal to 6.0mm, a copper sulfate solution is applied to the corresponding area to confirm whether the polishing of the area has been performed to the base parent metal, and the defect portion of the base parent metal is specially marked and recorded.
10. The method for repairing the defect of the weld overlay on the inner wall of the PTA reactor as claimed in claim 8, wherein when the depth of the defect removal part is less than or equal to 6.0mm, an external electric heating crawler belt is switched on to preheat the part to be repaired and the part nearby to be repaired to be more than or equal to 150 ℃;
and after the temperature is reached, the external electric heating crawler is powered off, the transition layer is subjected to surfacing by adopting ER309L welding wire argon arc welding, the temperature is observed at any time in the repair welding process, the welding is stopped when the temperature is lower than 100 ℃, and the external electric heating crawler is electrified and preheated again to be more than or equal to 150 ℃.
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Application publication date: 20210806 |