CN113221424A - Comprehensive analysis method for fault reasons of turbine moving blade - Google Patents
Comprehensive analysis method for fault reasons of turbine moving blade Download PDFInfo
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Abstract
The invention discloses a comprehensive analysis method for the fault reason of a moving blade of a steam turbine, which carries out site investigation, evidence obtaining and analysis on the fault site of the moving blade of the steam turbine, evaluates the detailed condition of the fault site of the moving blade of the steam turbine, collects technical data and data of the moving blade with the fault of the steam turbine, carries out site static frequency measurement and analysis on the moving blade of the steam turbine, carries out macroscopic appearance of a metallographic structure blade fracture, scanning electron microscope analysis and fracture micro-area energy spectrum on the fracture of the moving blade with the fault, carries out physical and chemical inspection and analysis on the moving blade material with the fault of the steam turbine, establishes a three-dimensional model and a finite element numerical model of the moving blade corresponding to a wheel rim, and carries out centrifugal stress and blade vibration characteristic calculation analysis to obtain the fault reason. The invention can know the detailed failure reason of the turbine moving blade through analysis, and adopts corresponding technical measures and operation means, thereby greatly improving the safety and the availability of the unit, ensuring the operation safety of a power plant and having obvious economic benefit and social benefit.
Description
Technical Field
The invention belongs to the field of power generation and chemical engineering of thermal power turbine units, and particularly relates to a comprehensive analysis method for fault reasons of a moving blade of a steam turbine.
Background
The steam turbine is a rotary machine which takes steam as power and converts the heat energy of the steam into mechanical work, is key equipment of a modern thermal power plant, and is widely applied to metallurgical industry, chemical industry and ship power devices. The steam turbine has the advantages of large single machine power, high efficiency, long service life and the like. The moving blade of the steam turbine works in the environment of high temperature, high rotating speed, high humidity and high-speed steam flow by-pass, bears the important task of converting steam heat energy into mechanical energy, and is one of the core components of the steam turbine. The moving blade of the steam turbine has enough strength and good vibration characteristic, namely, the moving blade avoids a resonance area to ensure the safe operation of the blade and has good aerodynamic characteristic to achieve higher efficiency; reasonable structure and good manufacturability, and is convenient for manufacturing and installation.
Under the operation condition, the moving blade of the steam turbine bears huge centrifugal force, steam acting force, corrosion of corrosive media, erosion of solid particles or high-speed water drops and the like, the working condition and the environment of the moving blade of the steam turbine are very complex and severe, and the moving blade of the steam turbine often has blade fracture or crack failure of various reasons. The faults of the moving blades of the steam turbine are related to a plurality of factors, and particularly mainly comprise blade materials, an assembly process, operating conditions and the like.
With the large capacity of the power station steam turbine in China, the safety and reliability of the steam turbine moving blade and the high efficiency of the steam turbine moving blade are more important. In recent years, in order to solve the problem of increasingly serious wind (light and water) abandonment, the improvement of the consumption capability of new energy and the improvement of the operation flexibility of a thermal power generating unit are urgent tasks, so that the thermal power generating unit has deep peak regulation capability, the load response rate is further increased, and part of the thermal power generating units have the capability of quickly starting and stopping peak regulation. The operation condition of the steam turbine deviates from the design condition seriously, various fault problems such as water erosion, fracture and the like can occur to the moving blade of the steam turbine more easily, and the safety and the economic benefit of power plant equipment are influenced seriously, so that how to research and analyze the fault reasons of the moving blade of the steam turbine and make corresponding measures is very important, and the problem to be solved urgently at present is also prevented from occurring.
The existing fault analysis technology and method for the moving blade of the steam turbine only carry out inspection analysis on fracture and materials of the blade or carry out partial numerical calculation analysis, but do not carry out detailed and comprehensive investigation and analysis on the fault reason of the moving blade of the steam turbine, and also fail to give out concrete and clear reasons of the fault of the moving blade of the steam turbine, so that the fault analysis technology and method have great practical effect on the future safe operation of a unit and the avoidance of the reoccurrence of similar faults, and have great safety risks in the subsequent operation of a unit system.
Disclosure of Invention
The invention aims to overcome the defects and provide a comprehensive analysis method for the fault reasons of the moving blade of the steam turbine, which can provide key reference suggestions and suggestions for reducing the faults of the unit and ensuring the safe long-term operation of the unit and also has very important influence on social production and safety and stability.
In order to achieve the above object, the present invention comprises the steps of:
s1, performing site survey, failure component evidence obtaining and analysis on the turbine moving blade failure site, and evaluating the detailed condition of the turbine moving blade failure site;
s2, collecting related technical data and data of design, manufacture, installation, operation, overhaul, inspection, technical improvement and experimental analysis of the turbine fault moving blade;
s3, carrying out on-site static frequency measurement and analysis on the turbine moving blade;
s4, performing metallographic structure blade fracture morphology macro, scanning electron microscope analysis and fracture micro-region energy spectrum on the steam turbine fault moving blade fracture, and performing physicochemical inspection and analysis on the steam turbine fault moving blade material;
s5, three-dimensional scanning and surveying and mapping the fault moving blade and the fault wheel rim of the steam turbine, and establishing a three-dimensional model of the moving blade and the wheel rim and a finite element numerical model corresponding to the moving blade and the wheel rim according to the surveying and mapping data;
s6, calculating and analyzing the centrifugal stress and the blade vibration characteristics of the moving blade and the wheel rim according to the three-dimensional numerical model of the moving blade and the wheel rim, the moving blade assembling process, the test data and the operation characteristics;
and S7, comprehensively analyzing the technical data and the numerical values obtained in the step S2 to obtain the reason for the fault of the moving blade of the steam turbine.
The specific method of S1 is as follows:
s101, carrying out comprehensive investigation on a fault site of the moving blade of the steam turbine, and recording fault site conditions, fault positions, loss of through-flow components and fault evidence obtaining conditions;
s102, conducting study and judgment analysis on the condition of a fault part of the moving blade of the steam turbine, and confirming the working range of the fault reason analysis of the moving blade and a fracture sample of the fault part;
s103, performing preliminary evaluation and analysis on the fault condition of the turbine moving blade according to the fault condition and the process description of the turbine moving blade.
The specific method of S2 is as follows:
s201, collecting related technical data and reports of design, manufacture, installation, operation, overhaul, inspection, technical improvement and experimental analysis of a turbine fault moving blade;
s202, load, rotating speed and shafting monitoring of the steam turbine set and historical record data of steam parameters of each part are retrieved and analyzed, and a water quality detection file of the steam turbine set is consulted and backed up;
and S203, carrying out survey and inquiry on the running condition of the steam turbine set on the set operator, calling the running record of the set, and backing up and archiving the running record.
The specific method of S3 is as follows:
s301, looking up turbine moving blade inspection records, delivery certification and original static frequency measurement data;
s302, carrying out field static frequency measurement on the turbine moving blade by using a test instrument system;
s303, the static frequency field measurement data of the turbine moving blade are sorted, analyzed and evaluated.
The specific method of S4 is as follows:
s401, carrying out sample processing and sample preparation on the moving blade fault component sampled on site, and sequentially carrying out metallographic structure, macroscopic appearance, scanning electron microscope and fracture microcell energy spectrum analysis on various prepared samples;
s402, carrying out chemical component analysis and mechanical property test on the material of the fault moving blade, wherein the mechanical tensile property, the impact toughness and the hardness are sequentially adopted;
and S403, judging the fault fracture property and the material quality condition of the turbine moving blade according to the fault moving blade fracture and material mechanical property analysis result of the turbine moving blade.
The specific method of S5 is as follows:
s501, three-dimensional scanning and surveying are conducted on the steam turbine fault moving blade and the steam turbine fault wheel rim, and three-dimensional coordinate data of the steam turbine fault moving blade and the steam turbine fault wheel rim are obtained;
s502, after three-dimensional coordinate data of the steam turbine fault moving blade and the wheel rim are sorted and analyzed, a three-dimensional numerical model of the steam turbine moving blade and the wheel rim and a circular symmetry numerical model of an impeller system are established;
s503, establishing a finite element numerical model of the circularly symmetric impeller system corresponding to the moving blade and the rim by using finite element software according to the three-dimensional numerical model of the moving blade and the rim of the steam turbine and the circularly symmetric numerical model of the impeller system.
The specific method of S6 is as follows:
s601, carrying out numerical calculation and analysis evaluation on the centrifugal stress of the moving blade and the rim of the steam turbine according to the three-dimensional numerical model of the moving blade and the rim, the moving blade assembling process, the test data and the technical data and conditions of the operating characteristics;
s602, according to technical data and conditions such as the assembly process, test data and operating characteristics of the turbine moving blade, numerical calculation is carried out on the static and dynamic vibration characteristics of the turbine moving blade and the impeller system;
s603, evaluating the degree and the correlation of the influence on the operation and the fault of the turbine moving blade according to the design data of the turbine moving blade, the fault condition and the condition of the numerical calculation result.
The specific method of S7 is as follows:
s701, sorting and analyzing relevant data and results of site investigation, static frequency measurement results, fault fracture properties, material quality conditions, centrifugal stress and vibration characteristics;
s702, according to the related technical data and numerical results, comprehensively analyzing the reasons of the turbine moving blade faults from the aspects of manufacturing design, installation and operation respectively.
S7, the cause of the failure of the turbine rotor blade is obtained, and then the related improvement proposal is proposed.
Compared with the prior art, the invention evaluates the detailed condition of the fault site of the moving blade of the steam turbine by carrying out site survey, evidence obtaining and analysis of fault parts on the fault site of the moving blade of the steam turbine, collects relevant technical data and data of design, manufacture, installation, operation, overhaul, inspection, technical improvement, experimental analysis and the like of the moving blade with the fault of the steam turbine, carries out site static frequency measurement and analysis on the moving blade of the steam turbine by using a testing instrument system, carries out macroscopic appearance of the fracture of the moving blade with metallographic structure, scanning electron microscope analysis, fracture microcell energy spectrum and the like on the fracture of the moving blade with the fault of the steam turbine, carries out physical and chemical inspection and analysis (testing on chemical components and mechanical properties (tensile property, impact toughness and hardness) of the blade material) on the moving blade with the fault and the rim of the steam turbine, carries out three-dimensional scanning and mapping on the moving blade and the rim, establishes a three-dimensional model of the moving blade and the rim and a finite element numerical model corresponding to the moving blade and the rim according to the mapping data, according to the three-dimensional numerical models of the moving blades and the rims, the moving blade assembling process, the test data and the operating characteristics, the centrifugal stress of the moving blades and the rims and the vibration characteristics of the blades are calculated and analyzed, and various reasons for causing the faults of the moving blades of the steam turbine are comprehensively and comprehensively analyzed. By analyzing the invention and combining with related suggestions, the detailed fault reasons of the turbine moving blade can be clearly known, and corresponding technical measures and operation means are adopted, so that the safety and the availability of the unit are greatly improved, the operation safety of a power plant is ensured, and the economic benefit and the social benefit are obvious.
Detailed Description
The present invention is further explained below.
The invention comprises the following steps:
step 101, carrying out comprehensive investigation on a fault site of a moving blade of a steam turbine, and recording conditions such as fault site conditions, fault positions, flow passage component loss and fault evidence obtaining;
102, carrying out study and judgment analysis on the condition of a fault part of the moving blade of the steam turbine, and confirming the working range of the fault reason analysis of the moving blade and a fracture sample of the fault part;
and 103, performing primary evaluation and analysis on the fault condition of the turbine moving blade according to the fault condition of the turbine moving blade and the process description.
Step 201, collecting related technical data and reports of design, manufacture, installation, operation, overhaul, inspection, technical improvement, test analysis and the like of a turbine fault moving blade;
step 202, acquiring and analyzing historical record data of load, rotating speed, shafting monitoring, steam parameters and the like of the steam turbine set, and looking up and backing up a water quality detection file of the steam turbine set;
step 203, carrying out survey and inquiry on the running condition of the steam turbine set for the set operator, retrieving the running record of the set, and backing up and archiving the record.
Step 301, looking up turbine moving blade inspection records, delivery certification and original static frequency measurement data;
step 302, utilizing a test instrument system to carry out on-site static frequency measurement on the turbine moving blade;
and 303, carrying out sorting, analysis and evaluation on the static frequency field measurement data of the turbine moving blade.
Step 401, carrying out sample processing and sample preparation on the moving blade fault component sampled on site, and carrying out metallographic structure, macroscopic appearance, scanning electron microscope and fracture micro-area energy spectrum analysis on various prepared samples in sequence;
step 402, carrying out chemical component analysis and mechanical property test on the material of the fault moving blade, wherein the mechanical tensile property, the impact toughness, the hardness and the like are sequentially carried out;
and step 403, judging the fault fracture property and the material quality condition of the turbine moving blade according to the fault moving blade fracture and material mechanical property analysis result of the turbine moving blade.
Step 501, three-dimensional scanning and surveying and mapping are carried out on the steam turbine fault moving blade and the steam turbine fault wheel rim, and three-dimensional coordinate data of the steam turbine fault moving blade and the steam turbine fault wheel rim are obtained;
step 502, after three-dimensional coordinate data of the turbine fault moving blade and the rim are sorted and analyzed, a three-dimensional numerical model of the turbine moving blade and the rim and a circular symmetry numerical model of an impeller system are established;
step 503, establishing a finite element numerical model of the circularly symmetric impeller system corresponding to the moving blade and the rim by using finite element software according to the three-dimensional numerical model of the moving blade and the rim of the steam turbine and the circularly symmetric numerical model of the impeller system.
601, carrying out numerical calculation and analysis evaluation on the centrifugal stress of the moving blade and the rim of the steam turbine according to technical data and conditions such as three-dimensional numerical models of the moving blade and the rim, a moving blade assembling process, test data and operating characteristics;
step 602, according to technical data and conditions such as the assembly process of the turbine moving blade, test data, operating characteristics and the like, numerical calculation is carried out on the static and dynamic vibration characteristics of the turbine moving blade and the impeller system;
step 603, evaluating the degree and the correlation of the influence on the operation and the fault of the turbine moving blade according to the conditions of the design data of the turbine moving blade, the fault condition, the numerical calculation result and the like.
Step 701, sorting and analyzing relevant data and results such as site survey, static frequency measurement results, fault fracture properties, material quality conditions, centrifugal stress, vibration characteristics and the like;
step 702, according to the related technical data and numerical results, comprehensively analyzing various reasons causing the turbine moving blade fault from aspects of manufacturing design, installation, operation and the like, and proposing related improvement suggestions.
The invention can comprehensively and comprehensively analyze the detailed reasons of the faults of the moving blades of the steam turbine by carrying out site investigation, technical data and data collection, static frequency measurement and analysis, fracture and material physicochemical inspection and analysis, centrifugal stress and vibration characteristic calculation and analysis of an impeller system on the fault site of the moving blades of the steam turbine, can well solve the problems of the moving blades of the steam turbine, thoroughly eliminate the potential safety hazard of a unit system by combining technical measures and improvement suggestions, greatly improve the safety and the usability of the unit, and powerfully ensure the long-term safe operation of a power plant and a power grid.
Claims (9)
1. A comprehensive analysis method for fault reasons of a moving blade of a steam turbine is characterized by comprising the following steps:
s1, performing site survey, failure component evidence obtaining and analysis on the turbine moving blade failure site, and evaluating the detailed condition of the turbine moving blade failure site;
s2, collecting related technical data and data of design, manufacture, installation, operation, overhaul, inspection, technical improvement and experimental analysis of the turbine fault moving blade;
s3, carrying out on-site static frequency measurement and analysis on the turbine moving blade;
s4, performing metallographic structure blade fracture morphology macro, scanning electron microscope analysis and fracture micro-region energy spectrum on the steam turbine fault moving blade fracture, and performing physicochemical inspection and analysis on the steam turbine fault moving blade material;
s5, three-dimensional scanning and surveying and mapping the fault moving blade and the fault wheel rim of the steam turbine, and establishing a three-dimensional model of the moving blade and the wheel rim and a finite element numerical model corresponding to the moving blade and the wheel rim according to the surveying and mapping data;
s6, calculating and analyzing the centrifugal stress and the blade vibration characteristics of the moving blade and the wheel rim according to the three-dimensional numerical model of the moving blade and the wheel rim, the moving blade assembling process, the test data and the operation characteristics;
and S7, comprehensively analyzing the technical data and the numerical values obtained in the step S2 to obtain the reason for the fault of the moving blade of the steam turbine.
2. The comprehensive analysis method for the fault causes of the moving blades of the steam turbine according to claim 1, wherein the specific method of S1 is as follows:
s101, carrying out comprehensive investigation on a fault site of the moving blade of the steam turbine, and recording fault site conditions, fault positions, loss of through-flow components and fault evidence obtaining conditions;
s102, conducting study and judgment analysis on the condition of a fault part of the moving blade of the steam turbine, and confirming the working range of the fault reason analysis of the moving blade and a fracture sample of the fault part;
s103, performing preliminary evaluation and analysis on the fault condition of the turbine moving blade according to the fault condition and the process description of the turbine moving blade.
3. The comprehensive analysis method for the fault causes of the moving blades of the steam turbine according to claim 1, wherein the specific method of S2 is as follows:
s201, collecting related technical data and reports of design, manufacture, installation, operation, overhaul, inspection, technical improvement and experimental analysis of a turbine fault moving blade;
s202, load, rotating speed and shafting monitoring of the steam turbine set and historical record data of steam parameters of each part are retrieved and analyzed, and a water quality detection file of the steam turbine set is consulted and backed up;
and S203, carrying out survey and inquiry on the running condition of the steam turbine set on the set operator, calling the running record of the set, and backing up and archiving the running record.
4. The comprehensive analysis method for the fault causes of the moving blades of the steam turbine according to claim 1, wherein the specific method of S3 is as follows:
s301, looking up turbine moving blade inspection records, delivery certification and original static frequency measurement data;
s302, carrying out field static frequency measurement on the turbine moving blade by using a test instrument system;
s303, the static frequency field measurement data of the turbine moving blade are sorted, analyzed and evaluated.
5. The comprehensive analysis method for the fault causes of the moving blades of the steam turbine according to claim 1, wherein the specific method of S4 is as follows:
s401, carrying out sample processing and sample preparation on the moving blade fault component sampled on site, and sequentially carrying out metallographic structure, macroscopic appearance, scanning electron microscope and fracture microcell energy spectrum analysis on various prepared samples;
s402, carrying out chemical component analysis and mechanical property test on the material of the fault moving blade, wherein the mechanical tensile property, the impact toughness and the hardness are sequentially adopted;
and S403, judging the fault fracture property and the material quality condition of the turbine moving blade according to the fault moving blade fracture and material mechanical property analysis result of the turbine moving blade.
6. The comprehensive analysis method for the fault causes of the moving blades of the steam turbine according to claim 1, wherein the specific method of S5 is as follows:
s501, three-dimensional scanning and surveying are conducted on the steam turbine fault moving blade and the steam turbine fault wheel rim, and three-dimensional coordinate data of the steam turbine fault moving blade and the steam turbine fault wheel rim are obtained;
s502, after three-dimensional coordinate data of the steam turbine fault moving blade and the wheel rim are sorted and analyzed, a three-dimensional numerical model of the steam turbine moving blade and the wheel rim and a circular symmetry numerical model of an impeller system are established;
s503, establishing a finite element numerical model of the circularly symmetric impeller system corresponding to the moving blade and the rim by using finite element software according to the three-dimensional numerical model of the moving blade and the rim of the steam turbine and the circularly symmetric numerical model of the impeller system.
7. The comprehensive analysis method for the fault causes of the moving blades of the steam turbine according to claim 1, wherein the specific method of S6 is as follows:
s601, carrying out numerical calculation and analysis evaluation on the centrifugal stress of the moving blade and the rim of the steam turbine according to the three-dimensional numerical model of the moving blade and the rim, the moving blade assembling process, the test data and the technical data and conditions of the operating characteristics;
s602, according to technical data and conditions such as the assembly process, test data and operating characteristics of the turbine moving blade, numerical calculation is carried out on the static and dynamic vibration characteristics of the turbine moving blade and the impeller system;
s603, evaluating the degree and the correlation of the influence on the operation and the fault of the turbine moving blade according to the design data of the turbine moving blade, the fault condition and the condition of the numerical calculation result.
8. The comprehensive analysis method for the fault causes of the moving blades of the steam turbine according to claim 1, wherein the specific method of S7 is as follows:
s701, sorting and analyzing relevant data and results of site investigation, static frequency measurement results, fault fracture properties, material quality conditions, centrifugal stress and vibration characteristics;
s702, according to the related technical data and numerical results, comprehensively analyzing the reasons of the turbine moving blade faults from the aspects of manufacturing design, installation and operation respectively.
9. The method for comprehensively analyzing the causes of turbine moving blade failures according to claim 1, wherein the causes of turbine moving blade failures are obtained in S7, and then related improvement suggestions are made.
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| CN113847267A (en) * | 2021-11-16 | 2021-12-28 | 西安热工研究院有限公司 | Fault analysis method applied to gas turbine compressor tie rod bolt |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113503193A (en) * | 2021-08-10 | 2021-10-15 | 西安热工研究院有限公司 | Frequency modulation operation method for preventing blade resonance of supercritical carbon dioxide axial flow compressor |
| CN113503193B (en) * | 2021-08-10 | 2022-09-02 | 西安热工研究院有限公司 | Frequency modulation operation method for preventing blade resonance of supercritical carbon dioxide axial flow compressor |
| CN113847267A (en) * | 2021-11-16 | 2021-12-28 | 西安热工研究院有限公司 | Fault analysis method applied to gas turbine compressor tie rod bolt |
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