CN115238924A - Integrity management system and method for furnace tube of heating furnace - Google Patents
Integrity management system and method for furnace tube of heating furnace Download PDFInfo
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Abstract
The invention relates to an integrity management system and a method for a furnace tube of a heating furnace, wherein furnace tube basic data are stored through a furnace tube basic data storage and management module to generate a visual furnace tube arrangement diagram, and data query, editing and modification are carried out on the furnace tube; historical detection and monitoring data of the furnace tubes are stored and managed through a furnace tube detection and monitoring result recording and management module; evaluating the damage state, the safety state and the residual life of the furnace tube by a furnace tube safety life evaluation module according to furnace tube basic data, historical detection data and historical monitoring data, and performing early warning on the furnace tube with the damage state exceeding the standard, the safety state being abnormal or the residual life being insufficient; and setting a safety boundary of a process operation temperature parameter for the furnace tube through the furnace tube process integrity operation module, and early warning the furnace tube with the metal wall temperature monitoring value exceeding the safety boundary. The data of the whole life cycle of the furnace tube in the heating furnace can be visually managed, various state information of the furnace tube can be dynamically mastered, and the management level of the whole life cycle of the furnace tube is improved.
Description
Technical Field
The invention relates to the technical field of heating furnace tube integrity management, in particular to a heating furnace tube integrity management system and method.
Background
The large-scale heating furnace is an important device which is widely applied and indispensable in petrochemical enterprises. The furnace tube system is an important component of the heating furnace, and the furnace tube is in a harsh operating environment of flame, smoke, high temperature, medium pressure in the tube and corrosion for a long time, so that failure accidents such as carburization cracking, bending, creep cracking, thermal fatigue cracking, bulging, oxidation, high-temperature sulfur corrosion and the like are easily caused, so that the unplanned shutdown of the device is caused, huge economic loss is caused on production, and gas leakage and safety accidents are caused by the failure of the furnace tube in the operation process. In addition, the investment cost of the furnace tube system accounts for 50% of the investment cost of the heating furnace, the service life of the furnace tube can be prolonged through high-level management of the furnace tube, and the replacement period is reasonably determined, so that a large amount of cost is saved for enterprises.
Mechanical Integrity, also known as equipment Integrity-MI, refers to maintaining process equipment in a state that can satisfy its particular service function from the time the equipment is first installed until the end of its useful life. It is a management system used to ensure that the device maintains sustained durability and functionality over its life cycle. For pressure-bearing equipment such as pressure vessels, industrial pipelines and the like in petrochemical plants, a general equipment integrity management method is a risk-based inspection technology (RBI); for rotating equipment such as pumps and compressors, the equipment integrity management method is reliability-centric maintenance technology (RCM). Both types of equipment have relatively perfect risk evaluation and management methods, and mature software systems are used for implementing the integrity management and evaluation technology of each piece of equipment. However, for the heating furnace, a systematic integrity management and evaluation technology and a systematic integrity evaluation system are still absent at present, and due to the fact that the number of furnace tubes is large, an equipment manager can only know the operation condition of the whole furnace generally, but detailed evaluation and management measures are not provided for the quality, the historical operation, the safety condition and the service life condition of each furnace tube, and the service life of the furnace tubes is obviously lower than the expected service life.
Disclosure of Invention
The invention aims to provide a heating furnace tube integrity management system and a heating furnace tube integrity management method, which can visually manage the full life cycle data of each furnace tube in a heating furnace and dynamically master various state information of the furnace tubes, thereby improving the management level of the full life cycle of the furnace tubes.
In order to achieve the purpose, the invention provides the following scheme:
the invention provides an integrity management system of a heating furnace tube, which comprises:
the furnace tube basic data storage and management module is used for storing basic data of the heating furnace and each furnace tube in the heating furnace, generating a visual furnace tube arrangement diagram, and inquiring, editing and modifying data of the furnace tubes according to the furnace tube arrangement diagram; the base data includes design data, manufacturing data, and usage data;
the furnace tube detection and monitoring result recording and management module is used for storing and managing historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace; the historical detection data comprises detection items and detection results; the historical monitoring data comprises monitoring items and monitoring results;
the furnace tube safe life evaluation module is used for evaluating the damage state, the safety state and the residual life of each furnace tube according to the basic data, the historical detection data and the historical monitoring data of the furnace tubes and early warning the furnace tubes with the damage state exceeding the standard, the safety state being abnormal or the residual life being insufficient;
and the furnace tube process integrity operation module is used for setting a safety boundary of process operation temperature parameters for each furnace tube and early warning the furnace tubes of which the metal wall temperature monitoring value exceeds the safety boundary value.
Optionally, the furnace tube basic data storage and management module specifically includes:
the data storage unit is used for storing basic data of the heating furnace and the furnace tube; the basic data is divided into enterprise information, device information, heating furnace information and furnace tube information according to levels;
the furnace tube arrangement mode and number determining unit is used for determining the furnace tube arrangement mode, the number of rows of furnace tubes and the number of rows of furnace tubes; the arrangement mode of the furnace tubes comprises a vertical mode or a horizontal mode;
the furnace tube arrangement diagram generating unit is used for generating a furnace tube arrangement diagram of the furnace tube in a top view or a side view according to the arrangement mode, the number of rows of the furnace tubes and the number of rows of the furnace tubes; the furnace tube arrangement diagram is a furnace tube arrangement two-dimensional matrix diagram;
and the furnace tube information management unit is used for inquiring, editing and modifying data of the furnace tubes on the furnace tube arrangement diagram.
Optionally, the furnace tube detecting, monitoring result recording and managing module specifically includes:
the detection result recording unit is used for manually or batch-recording the detection items and the corresponding detection results of each furnace tube on the furnace tube arrangement diagram according to the detection time; the detection items comprise macroscopic inspection, wall thickness measurement, surface defect detection, buried defect detection, metallographic detection, creep expansion detection and carburization detection;
and the monitoring result recording unit is used for recording the wall temperature monitoring result and the pressure monitoring result of each furnace tube in a manual reading mode or an automatic recording mode of the pressure sensor and the temperature sensor according to the monitoring time.
Optionally, the furnace tube safe life assessment module specifically includes:
the detection result evaluation unit is used for evaluating and checking the damage state of the furnace tube according to the detection result of the furnace tube;
the strength checking and evaluating unit is used for checking and evaluating the residual strength of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the elastic stress theory; the residual strength and the detection result are used for representing the safety state of the furnace tube;
and the residual life evaluation unit is used for checking and evaluating the creep residual life of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the creep accumulated damage theory.
Optionally, the furnace tube process integrity operation module specifically includes:
the safety boundary setting unit is used for calculating the critical operating temperature of the furnace tube under the condition of the set creep residual life according to the furnace tube material, the operating pressure and the last detected wall thickness and diameter data of the furnace tube, and respectively setting the critical operating temperature under different conditions of the set creep residual life as an information boundary, an acceleration boundary and a failure boundary of the temperature process parameter;
the judging unit is used for judging whether the metal wall temperature monitoring value is higher than each safety boundary value in real time according to the information boundary, the acceleration boundary, the failure boundary and the metal wall temperature monitoring value;
and the early warning unit is used for outputting early warning information of different colors on the furnace tube arrangement diagram when the monitored temperature is higher than the safety boundary value.
In order to achieve the above object, the present invention further provides a method for managing the integrity of a furnace tube of a heating furnace, the method comprising:
storing basic data of the heating furnace and each furnace tube in the heating furnace, generating a visual furnace tube arrangement diagram, and inquiring, editing and modifying the data of the furnace tubes according to the furnace tube arrangement diagram; the base data includes design data, manufacturing data, and usage data;
storing and managing historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace; the historical detection data comprises detection items and detection results; the historical monitoring data comprises monitoring items and monitoring results;
evaluating the damage state, the safety state and the residual life of each furnace tube according to the basic data, the historical detection data and the historical monitoring data of the furnace tubes, and early warning the furnace tubes with the damage state exceeding the standard, the safety state being abnormal or the residual life being insufficient;
setting a safety boundary of a process operation temperature parameter for each furnace tube, monitoring the metal wall temperature value of the furnace tube in real time, and early warning the furnace tube of which the metal wall temperature monitoring value exceeds the safety boundary value.
Optionally, the storing basic data of the heating furnace and each furnace tube in the heating furnace, generating a visual furnace tube arrangement diagram, and querying, editing, and modifying data for the furnace tube according to the furnace tube arrangement diagram specifically includes:
storing basic data of the heating furnace and the furnace tube; the basic data is divided into enterprise information, device information, heating furnace information and furnace tube information according to levels;
determining the arrangement mode, the number of rows of furnace tubes and the number of rows of furnace tubes; the arrangement mode of the furnace tubes comprises a vertical mode or a horizontal mode;
generating a furnace tube arrangement diagram of furnace tube overlooking or side view according to the arrangement mode, the number of furnace tube rows and the number of furnace tube rows; the furnace tube arrangement diagram is a furnace tube arrangement two-dimensional matrix diagram;
and inquiring, editing and modifying data of the furnace tubes on the furnace tube arrangement diagram.
Optionally, the storing and managing historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace specifically includes:
manually or batch-inputting the detection items and the corresponding detection results of each furnace tube on the furnace tube arrangement diagram according to the detection time; the detection items comprise macroscopic inspection, wall thickness measurement, surface defect detection, buried defect detection, metallographic detection, creep expansion detection and carburization detection;
and recording the wall temperature monitoring result and the pressure monitoring result of each furnace tube in a manual reading mode or an automatic recording mode of a pressure sensor and a temperature sensor according to the monitoring time.
Optionally, the evaluating the detection result, the safety state, and the remaining life of each furnace tube according to the basic data, the historical detection data, and the historical monitoring data of the furnace tubes specifically includes:
according to the detection result of the furnace tube, evaluating and checking the damage state of the furnace tube;
checking and evaluating the residual strength of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the elastic stress theory; the residual strength and the detection result are used for representing the safety state of the furnace tube;
and checking and evaluating the creep residual life of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the creep accumulated damage theory.
Optionally, a safety boundary of the process operation temperature parameter is set for each furnace tube, the metal wall temperature value of the furnace tube is monitored in real time, and the furnace tube with the metal wall temperature monitoring value exceeding the safety boundary value is subjected to early warning, and the method specifically comprises the following steps:
calculating the critical operating temperature of the furnace tube under the condition of the set creep residual life according to the furnace tube material, the operating pressure and the last detected wall thickness and diameter data of the furnace tube, and respectively setting the critical operating temperatures under different set creep residual life conditions as an information boundary, an acceleration boundary and a failure boundary of a temperature process parameter;
judging whether the metal wall temperature monitoring value is higher than each safety boundary value in real time according to the information boundary, the acceleration boundary, the failure boundary and the metal wall temperature monitoring value;
and when the monitored temperature is higher than the safety boundary value, outputting early warning information of different colors on the furnace tube arrangement diagram.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
the invention provides a heating furnace tube integrity management system and a method thereof, wherein the system comprises: the furnace tube basic data storage and management module is used for storing basic data of the heating furnace and each furnace tube in the heating furnace, generating a visual furnace tube arrangement diagram, and inquiring, editing and modifying data of the furnace tubes according to the furnace tube arrangement diagram; the furnace tube detection and monitoring result recording and management module is used for storing and managing historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace; the furnace tube safe life evaluation module is used for evaluating the damage state, the safety state and the residual life of each furnace tube according to the basic data, the historical detection data and the historical monitoring data of the furnace tubes and early warning the furnace tubes with the damage state exceeding the standard, the safety state being abnormal or the residual life being insufficient; and the furnace tube process integrity operation module is used for setting a safety boundary of process operation temperature parameters for each furnace tube and early warning the furnace tubes of which the metal wall temperature monitoring value exceeds the safety boundary value. The invention can visually manage the life cycle data of each furnace tube in the heating furnace and dynamically master the state information of each furnace tube, thereby improving the management level of the life cycle of the furnace tubes.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic block diagram of an integrity management system for a furnace tube of a heating furnace according to the present invention;
FIG. 2 is a two-dimensional visualized furnace tube arrangement matrix diagram of the furnace tube of the present invention;
FIG. 3 is a flowchart illustrating a method for managing the integrity of a furnace tube of a heating furnace according to the present invention.
Description of the symbols:
the system comprises a furnace tube basic data storage and management module-1, a data storage unit-11, a furnace tube arrangement mode and quantity determination unit-12, a furnace tube arrangement diagram generation unit-13, a furnace tube information management unit-14, a furnace tube detection, monitoring result recording and management module-2, a detection result recording unit-21, a monitoring result recording unit-22, a furnace tube safe life evaluation module-3, a detection result evaluation unit-31, a strength checking evaluation unit-32, a residual life evaluation unit-33, a furnace tube process integrity operation module-4, a safety boundary setting unit-41, a judgment unit-42 and an early warning unit-43.
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.
The invention aims to provide a heating furnace tube integrity management system and a heating furnace tube integrity management method, which can visually manage the full life cycle data of each furnace tube in a heating furnace and dynamically master various state information of the furnace tubes, thereby improving the management level of the full life cycle of the furnace tubes.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
As shown in fig. 1, the present invention provides an integrity management system for a furnace tube of a heating furnace, the system comprising: the device comprises a furnace tube basic data storage and management module 1, a furnace tube detection and monitoring result recording and management module 2, a furnace tube safe life evaluation module 3 and a furnace tube process integrity operation module 4.
The furnace tube basic data storage and management module 1 is used for storing basic data of the heating furnace and each furnace tube in the heating furnace, generating a visual furnace tube arrangement diagram, inquiring, editing and modifying the data of the furnace tubes according to the furnace tube arrangement diagram, and realizing subsequent evaluation of a single furnace tube; the base data includes design data, manufacturing data, and usage data.
The furnace tube detection and monitoring result recording and management module 2 is used for storing and managing historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace; the historical detection data comprises detection items and detection results; the historical monitoring data comprises monitoring items and monitoring results.
And the furnace tube safe life evaluation module 3 is used for evaluating the damage state, the safety state and the residual life of each furnace tube according to the basic data, the historical detection data and the historical monitoring data of the furnace tubes, carrying out early warning on the furnace tubes with the damage state exceeding the standard, the safety state being abnormal or the residual life being insufficient, and giving a suggestion whether to recommend replacement.
And the furnace tube process integrity operation module 4 is used for setting a safety boundary of a process operation temperature parameter for each furnace tube, and giving an early warning to the furnace tube of which the metal wall temperature monitoring value exceeds the safety boundary value, and giving treatment measures and suggestions.
Further, the furnace tube basic data storage and management module 1 specifically includes:
the data storage unit 11 is used for storing basic data of the heating furnace and the furnace tube; the basic data is divided into enterprise information, device information, heating furnace information and furnace tube information according to levels; the enterprise information comprises an enterprise name and a position; the device information comprises device name, process introduction and commissioning time; the heating furnace information comprises the name, the number, the design and manufacturing unit, the process temperature and the pressure parameter of the heating furnace; the furnace tube information includes the arrangement mode of the furnace tubes, the type of the furnace tubes, the number of columns and rows, the number of each furnace tube, the material, the wall thickness, the diameter, the length, the medium, the design temperature, the design pressure, the operation temperature, the operation pressure and other information.
A furnace tube arrangement mode and number determining unit 12 for determining the furnace tube arrangement mode, the number of rows of furnace tubes, and the number of rows of furnace tubes; the arrangement mode of the furnace tubes comprises a vertical mode or a horizontal mode;
a furnace tube arrangement diagram generating unit 13 for generating a furnace tube arrangement diagram of a furnace tube top view or a furnace tube side view according to the arrangement mode, the number of rows of furnace tubes and the number of rows of furnace tubes; the furnace tube arrangement diagram is a furnace tube arrangement two-dimensional matrix diagram;
and the furnace tube information management unit 14 is used for inquiring, editing and modifying data for the furnace tubes on the furnace tube arrangement diagram.
Wherein, the furnace tube information interface in the furnace tube basic data storage and management module 1 needs a user to firstly select the arrangement mode of the furnace tubes to be vertical or horizontal, and then select the types of the furnace tubes, including a convection section DL, an upper collecting tube SJ, an upper tail tube SW, a radiation section FS, a lower tail tube XW, a lower collecting tube XJ, a cold wall tube LB and the like; after the selection is finished, inputting the column number and the row number of the furnace tubes, and accordingly, automatically producing a two-dimensional visual furnace tube arrangement matrix diagram of the furnace tubes by a computer, as shown in fig. 2; and finally, selecting each furnace tube on the furnace tube arrangement diagram, entering a furnace tube information interface, and inputting related furnace tube information.
Further, the furnace tube detecting, monitoring result recording and managing module 2 specifically includes:
the detection result recording unit 21 is configured to manually or batch-type in the detection item and the corresponding detection result of each furnace tube on the furnace tube arrangement diagram according to the detection time; the detection items comprise macroscopic inspection, wall thickness measurement, surface defect detection, buried defect detection, metallographic detection, creep expansion detection and carburization detection.
And the monitoring result recording unit 22 is used for recording the wall temperature monitoring result and the pressure monitoring result of each furnace tube in a manual reading mode or an automatic recording mode of the pressure sensor and the temperature sensor according to the monitoring time.
The detection result of each detection item can be manually input in the system or selected according to options, and the specific steps are as follows:
1) Macroscopic examination results include bending, severe bending, creep, corrosion, mechanical damage, and the like; 2) The wall thickness measurement result comprises a wall thickness measured value recorded in each measurement point; 3) Firstly, selecting detection types (PT and other types) for surface defect detection, and selecting whether defects or cracks (existence or nonexistence) exist according to detection results; 4) Firstly selecting detection types (wall climbing UT, RT, vortex and other) from the detection results of the buried defects, selecting detection levels (A, B +, B and C) from the detection results of the wall climbing UT, and selecting whether defects or cracks (existence or nonexistence) from the detection results of the RT, the vortex and other detection results; 5) Selecting a detection grade (grade 1-5) as a metallographic detection result; 6) The creep expansion detection result comprises an outer diameter measured value recorded into each measuring point; 7) The carburization detection result comprises a carburization layer thickness measured value recorded in each measuring point.
Further, the furnace tube safe life evaluation module 3 specifically includes:
and a detection result evaluation unit 31 for evaluating and checking the damage state of the furnace tube according to the detection result of the furnace tube.
The strength checking and evaluating unit 32 is used for checking and evaluating the residual strength of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the elastic stress theory; and the residual strength and the detection result are used for representing the safety state of the furnace tube.
And the residual life evaluation unit 33 is used for checking and evaluating the creep residual life of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the creep accumulated damage theory.
The detection result evaluation unit 31 evaluates and checks the detection result of the furnace tube, which is specifically as follows: 1) Buried defect detection results: when the UT detection result of wall climbing is level C, the assessment and check result is failed, and replacement is recommended; 2) And (4) macroscopic inspection results: when the macroscopic inspection result is 'severe bending', the evaluation and check result is failed, and replacement is recommended; 3) The creep expansion detection result is as follows: the calculated result of the creep expansion rate obtained by measuring the outer diameter dimension of the pipe is 2% -5%, or when the creep expansion rate is doubled compared with the last period, the evaluation and check result is failed, and replacement is recommended; 4) Surface defect detection results: when the detection result is that cracks exist, the check result is evaluated to be failed, and replacement is recommended; 5) And (3) carburization detection result: when the thickness of the carburized layer accounts for more than 60 percent of the wall thickness of the furnace tube, evaluating that the check result is failed, and recommending to replace; 6) And (3) metallographic detection results: and when the detection result is in grade 5, evaluating that the check result is failed, and recommending to replace.
Wherein, according to the testing result of boiler tube, the monitoring result and the elastic stress theory of boiler tube, check the aassessment to boiler tube residual strength, specifically include:
taking the maximum value of the monitoring pressure of each furnace tube as p; taking the actually measured maximum value of the outer diameter of the furnace tube of the last creep expansion detection as D; taking the minimum value of the actually measured wall thickness of the furnace tube of the last wall thickness measurement as delta, and automatically calculating the stress sigma of the furnace tube according to the formula 1 as follows:
and when the stress sigma of the furnace tube is larger than the allowable elastic stress of the material at the monitoring temperature, evaluating that the checking result is failed, and recommending to replace. Wherein the allowable material elasticity stress at each temperature is built in a software material database and is automatically selected according to furnace tube materials in the furnace tube basic information.
Wherein, the residual life evaluation unit 33 checks and evaluates the creep residual life of the furnace tube according to the detection result, the monitoring result and the creep cumulative damage theory, and specifically comprises:
1) According to the historical data of the detection result recording unit 21, the computer automatically divides the whole operation cycle of the furnace tube into N sections, for example, if the historical data is detected for 2 times, the operation cycle is divided into 3 sections, namely, the operation date is from the first detection time point to the first detection time point, the first detection time point is from the second detection time point to the second detection time point, and the second detection time point is from the current time point;
2) Selecting the maximum value of the monitoring result in the period of the ith period according to the temperature Ti and the pressure pi;
3) Selecting the minimum value of the actually measured wall thickness in the detection result in the period of the ith period according to the wall thickness value delta i in the period of the ith period;
4) The duration ti in the ith period is automatically calculated according to the detection time;
5) Selecting the maximum value of the actually measured outer diameter in the detection result in the period of the ith period according to the inner and outer diameter values Di;
6) The computer calculates the stress value sigma i in the ith period according to formula 2:
7) The computer automatically calculates the expected creep life tri in the i period according to the formula 3:
wherein LMP (sigma i) is a function related to sigma i and materials, C is a parameter related to material creep, the function and the parameter are arranged in a software material database, and automatic selection is carried out according to furnace tube materials in the furnace tube basic information.
8) The computer calculates the creep residual life fraction Dc of the furnace tube according to the formula 4 as follows:
9) And when Dc is greater than or equal to 1, evaluating that the checking result is failed, and recommending replacement.
And finally, integrating the evaluation and check results of 3 units, carrying out early warning on the furnace tubes which do not pass the check on a furnace tube arrangement matrix diagram, displaying red color, and giving a recommendation of replacement recommendation.
Further, the furnace tube process integrity operation module 4 specifically includes:
and a safety boundary setting unit 41, configured to calculate a critical operating temperature of the furnace tube under the condition of the set creep residual life according to the furnace tube material, the operating pressure, and the last detected wall thickness and diameter data of the furnace tube, and set the critical operating temperatures under different conditions of the set creep residual life as an information boundary, an acceleration boundary, and a failure boundary of the temperature process parameter, respectively.
And the judging unit 42 is used for judging whether the metal wall temperature monitoring value is higher than each safety boundary value in real time according to the information boundary, the acceleration boundary, the failure boundary and the metal wall temperature monitoring value.
And the early warning unit 43 is used for outputting early warning information with different colors on the furnace tube arrangement diagram when the monitored temperature is higher than the safety boundary value.
Specifically, the safety boundary setting unit 41 performs back-stepping according to the calculation logics of formulas 2 to 4 in the remaining life evaluation unit 33 according to the furnace tube material, the monitored pressure, and the last detected actual wall thickness and diameter, calculates the future service critical operating temperature of each furnace tube with the creep remaining life of 100000 hours, 35000 hours, and 5000 hours, and sets the future service critical operating temperatures corresponding to the three life times as the information boundary, the acceleration boundary, and the failure boundary of the temperature process parameter, respectively.
Wherein, the information boundary represents that the long-term reliability of the furnace tube beyond the boundary is possibly influenced and the possibility of material degradation occurs, the 100000-hour residual life critical temperature is selected because 100000 hours is generally the design life of the furnace tube, which indicates that the design life of the furnace tube is not influenced at the temperature; the accelerated boundary represents that the furnace tube beyond the boundary can be damaged by creep and the like, the normal service life of the equipment is reduced, and the selected 35000-hour residual life critical temperature is the service life (4 years) of the furnace tube generally in one service cycle of 35000 hours, which indicates that the furnace tube can safely continue to operate for one cycle at the temperature; the failure boundary represents that the furnace tube beyond the boundary can be overheated and failed in a short period, including creep rupture and great reduction of tensile strength, the critical temperature of the residual service life of 5000 hours is selected because 5000 hours does not meet the condition of one period operation, and sufficient time is provided for ensuring that the furnace tube operates and prepares materials in a short period.
The early warning unit 42 obtains the above-mentioned metal wall temperature monitoring data in the safety boundary and monitoring result recording unit 22, and judges whether the monitoring temperature is higher than each safety boundary value in real time. When the monitored temperature of the furnace tube is higher than the information boundary, outputting early warning information on a matrix diagram to be yellow, and prompting 'attention to temperature monitoring, carrying out expert analysis and making a necessary inspection plan aiming at an overtemperature position' by a system; when the monitoring temperature of the furnace tube is higher than the acceleration boundary, outputting early warning information in orange on a matrix diagram, and prompting 'warning and carrying out expert analysis, determining the reason of the overtemperature, carrying out temperature control and making an inspection plan for the overtemperature position' by a system; when the monitored temperature is higher than the failure boundary, the early warning information is output in red on the matrix diagram, and the system prompts that 'the early warning is needed and the temperature control measure or the furnace shutdown maintenance is immediately adopted'.
In order to achieve the above object, as shown in fig. 3, the present invention further provides a method for managing the integrity of a furnace tube of a heating furnace, the method comprising:
s1: storing basic data of the heating furnace and each furnace tube in the heating furnace, generating a visual furnace tube arrangement diagram, and inquiring, editing and modifying the data of the furnace tubes according to the furnace tube arrangement diagram; the base data includes design data, manufacturing data, and usage data.
S2: storing and managing historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace; the historical detection data comprises detection items and detection results; the historical monitoring data comprises monitoring items and monitoring results.
S3: and evaluating the damage state, the safety state and the residual life of each furnace tube according to the basic data, the historical detection data and the historical monitoring data of the furnace tubes, and early warning the furnace tubes with the damage state exceeding the standard, the safety state being abnormal or the residual life being insufficient.
S4: setting a safety boundary of a process operation temperature parameter for each furnace tube, monitoring the metal wall temperature value of the furnace tube in real time, and early warning the furnace tube of which the metal wall temperature monitoring value exceeds the safety boundary value.
Further, in step S1, the storing basic data of the heating furnace and each furnace tube in the heating furnace, generating a visual furnace tube arrangement diagram, and querying, editing, and modifying data for the furnace tube according to the furnace tube arrangement diagram specifically includes:
s11: storing basic data of the heating furnace and the furnace tube; the basic data divides enterprise information, device information, heating furnace information and furnace tube information according to levels.
S12: determining the arrangement mode, the number of rows of furnace tubes and the number of rows of furnace tubes; the arrangement mode of the furnace tubes comprises a vertical mode or a horizontal mode.
S13: generating a furnace tube arrangement diagram of furnace tube overlooking or side view according to the arrangement mode, the number of furnace tube rows and the number of furnace tube rows; the furnace tube arrangement diagram is a furnace tube arrangement two-dimensional matrix diagram.
S14: and inquiring, editing and modifying data of the furnace tubes on the furnace tube arrangement diagram.
Further, in step S2, the storing and managing historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace specifically includes:
s21: manually or batch-inputting the detection items and the corresponding detection results of each furnace tube on the furnace tube arrangement diagram according to the detection time; the detection items comprise macroscopic detection, wall thickness measurement, surface defect detection, buried defect detection, metallographic detection, creep expansion detection and carburization detection.
S22: and recording the wall temperature monitoring result and the pressure monitoring result of each furnace tube in a manual reading mode or an automatic recording mode of the pressure sensor and the temperature sensor according to the monitoring time.
Further, in step S3, the evaluating the detection result, the safety state, and the remaining life of each furnace tube according to the basic data, the historical detection data, and the historical monitoring data of the furnace tubes specifically includes:
s31: and evaluating and checking the damage state of the furnace tube according to the detection result of the furnace tube.
S32: checking and evaluating the residual strength of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the elastic stress theory; and the residual strength and the detection result are used for representing the safety state of the furnace tube.
S33: and checking and evaluating the creep residual life of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the creep accumulated damage theory.
Further, in step S4, a safety boundary of the process operation temperature parameter is set for each furnace tube, the metal wall temperature value of the furnace tube is monitored in real time, and the furnace tube in which the metal wall temperature monitoring value exceeds the safety boundary value is subjected to early warning, which specifically includes:
s41: according to the furnace tube material, the operating pressure and the last detected furnace tube wall thickness and diameter data, calculating the critical operating temperature of the furnace tube under the condition of the set creep residual life, and respectively setting the critical operating temperatures under different set creep residual life as an information boundary, an acceleration boundary and a failure boundary of the temperature process parameter.
S42: and judging whether the metal wall temperature monitoring value is higher than each safety boundary value in real time according to the information boundary, the acceleration boundary, the failure boundary and the metal wall temperature monitoring value.
S43: and when the monitored temperature is higher than the safety boundary value, outputting early warning information of different colors on the furnace tube arrangement diagram.
The invention has the technical effects that:
(1) A new method for managing the full life cycle data of each furnace tube in a mode of automatically generating a two-dimensional matrix diagram by a computer is established, so that the management of the furnace tubes is more refined, visualized and convenient, and the accumulation and the effective utilization of the historical data of each furnace tube are favorably realized.
(2) By storing historical detection and monitoring data and internally arranging evaluation check calculation logic, computer automatic evaluation check calculation based on detection and monitoring results is realized, a large amount of manual evaluation time is saved, and evaluation efficiency and accuracy are greatly improved.
(3) The three methods of checking and evaluating the detection result, checking and evaluating the strength, checking and evaluating the creep residual life and the like are integrated, so that the comprehensive evaluation can be performed on various failure modes such as the strength failure and the creep failure of the furnace tube, the early warning can be performed on the safety state of the furnace tube more accurately, and the sudden failure and the unplanned shutdown of the heating furnace are avoided.
(4) The method for setting the accelerated boundary and the failure boundary of the furnace tube temperature process parameter and the real-time early warning module of the computer are established, and the early warning can be timely carried out on the typical problems of overtemperature and the like of the furnace tube, so that the accelerated damage and the failure of the furnace tube are avoided, the service life of the furnace tube is prolonged, and the economic benefit of an enterprise is improved.
In the present specification, the embodiments are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the foregoing, the description is not to be taken in a limiting sense.
Claims (10)
1. An integrity management system for a furnace tube of a heating furnace, the system comprising:
the furnace tube basic data storage and management module is used for storing basic data of the heating furnace and each furnace tube in the heating furnace, generating a visual furnace tube arrangement diagram, and inquiring, editing and modifying the data of the furnace tubes according to the furnace tube arrangement diagram; the base data includes design data, manufacturing data, and usage data;
the furnace tube detection and monitoring result recording and management module is used for storing and managing historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace; the historical detection data comprises detection items and detection results; the historical monitoring data comprises monitoring items and monitoring results;
the furnace tube safe life evaluation module is used for evaluating the damage state, the safety state and the residual life of each furnace tube according to the basic data, the historical detection data and the historical monitoring data of the furnace tubes and early warning the furnace tubes with the damage state exceeding the standard, the safety state being abnormal or the residual life being insufficient;
and the furnace tube process integrity operation module is used for setting a safety boundary of process operation temperature parameters for each furnace tube and carrying out early warning on the furnace tubes with the metal wall temperature monitoring values exceeding the safety boundary values.
2. The integrity management system for furnace tubes of a heating furnace according to claim 1, wherein the furnace tube basic data storage and management module specifically comprises:
the data storage unit is used for storing basic data of the heating furnace and the furnace tube; the basic data is divided into enterprise information, device information, heating furnace information and furnace tube information according to levels;
the furnace tube arrangement mode and number determining unit is used for determining the furnace tube arrangement mode, the number of rows of furnace tubes and the number of rows of furnace tubes; the arrangement mode of the furnace tubes comprises a vertical mode or a horizontal mode;
the furnace tube arrangement diagram generating unit is used for generating a furnace tube arrangement diagram of the furnace tube in a top view or a side view according to the arrangement mode, the number of rows of the furnace tubes and the number of rows of the furnace tubes; the furnace tube arrangement diagram is a furnace tube arrangement two-dimensional matrix diagram;
and the furnace tube information management unit is used for inquiring, editing and modifying data of the furnace tubes on the furnace tube arrangement diagram.
3. The integrity management system for a furnace tube of a heating furnace according to claim 1, wherein the furnace tube detection, monitoring result recording and management module specifically comprises:
the detection result recording unit is used for manually or batch-recording the detection items and the corresponding detection results of each furnace tube on the furnace tube arrangement diagram according to the detection time; the detection items comprise macroscopic detection, wall thickness measurement, surface defect detection, buried defect detection, metallographic detection, creep expansion detection and carburization detection;
and the monitoring result recording unit is used for recording the wall temperature monitoring result and the pressure monitoring result of each furnace tube in a manual reading mode or a pressure sensor and temperature sensor automatic recording mode according to the monitoring time.
4. The integrity management system for a furnace tube of a heating furnace of claim 1, wherein the furnace tube safe life evaluation module specifically comprises:
the detection result evaluation unit is used for evaluating and checking the damage state of the furnace tube according to the detection result of the furnace tube;
the strength checking and evaluating unit is used for checking and evaluating the residual strength of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the elastic stress theory; the residual strength and the detection result are used for representing the safety state of the furnace tube;
and the residual life evaluation unit is used for checking and evaluating the creep residual life of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the creep accumulated damage theory.
5. The integrity management system for a furnace tube of a heating furnace of claim 1, wherein the furnace tube process integrity operation module specifically comprises:
the safety boundary setting unit is used for calculating the critical operating temperature of the furnace tube under the condition of the set creep residual life according to the furnace tube material, the operating pressure and the last detected wall thickness and diameter data of the furnace tube, and respectively setting the critical operating temperature under different set creep residual life conditions as an information boundary, an acceleration boundary and a failure boundary of the temperature process parameter;
the judging unit is used for judging whether the metal wall temperature monitoring value is higher than each safety boundary value in real time according to the information boundary, the acceleration boundary, the failure boundary and the metal wall temperature monitoring value;
and the early warning unit is used for outputting early warning information of different colors on the furnace tube arrangement diagram when the monitored temperature is higher than the safety boundary value.
6. A method for managing the integrity of a furnace tube of a heating furnace is characterized by comprising the following steps:
storing basic data of the heating furnace and each furnace tube in the heating furnace, generating a visual furnace tube arrangement diagram, and inquiring, editing and modifying data of the furnace tubes according to the furnace tube arrangement diagram; the base data includes design data, manufacturing data, and usage data;
storing and managing historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace; the historical detection data comprises detection items and detection results; the historical monitoring data comprises monitoring items and monitoring results;
evaluating the damage state, the safety state and the residual life of each furnace tube according to the basic data, the historical detection data and the historical monitoring data of the furnace tubes, and early warning the furnace tubes with the damage state exceeding the standard, the safety state being abnormal or the residual life being insufficient;
setting a safety boundary of a process operation temperature parameter for each furnace tube, monitoring the metal wall temperature value of the furnace tube in real time, and early warning the furnace tube of which the metal wall temperature monitoring value exceeds the safety boundary value.
7. The method according to claim 6, wherein the storing of the basic data of the heating furnace and each furnace tube in the heating furnace, the generating of the visualized furnace tube arrangement diagram, and the querying, editing and modifying of the data of the furnace tube according to the furnace tube arrangement diagram specifically comprise:
storing basic data of the heating furnace and the furnace tube; the basic data is divided into enterprise information, device information, heating furnace information and furnace tube information according to levels;
determining the arrangement mode, the number of rows of furnace tubes and the number of rows of furnace tubes; the arrangement mode of the furnace tubes comprises a vertical mode or a horizontal mode;
generating a furnace tube arrangement diagram of furnace tube overlooking or side view according to the arrangement mode, the number of furnace tube rows and the number of furnace tube rows; the furnace tube arrangement diagram is a furnace tube arrangement two-dimensional matrix diagram;
and inquiring, editing and modifying data of the furnace tubes on the furnace tube arrangement diagram.
8. The integrity management method for the furnace tube of the heating furnace according to claim 6, wherein the storing and managing of the historical detection data and the historical monitoring data of each of the heating furnace and the furnace tube specifically comprises:
manually or batch-inputting the detection items and the corresponding detection results of each furnace tube on the furnace tube arrangement diagram according to the detection time; the detection items comprise macroscopic inspection, wall thickness measurement, surface defect detection, buried defect detection, metallographic detection, creep expansion detection and carburization detection;
and recording the wall temperature monitoring result and the pressure monitoring result of each furnace tube in a manual reading mode or an automatic recording mode of a pressure sensor and a temperature sensor according to the monitoring time.
9. The method for managing the integrity of the furnace tube of the heating furnace of claim 6, wherein the evaluating the detection result, the safety status and the remaining life of each furnace tube according to the basic data, the historical detection data and the historical monitoring data of the furnace tube specifically comprises:
according to the detection result of the furnace tube, evaluating and checking the damage state of the furnace tube;
checking and evaluating the residual strength of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the elastic stress theory; the residual strength and the detection result are used for representing the safety state of the furnace tube;
and checking and evaluating the creep residual life of the furnace tube according to the detection result of the furnace tube, the monitoring result of the furnace tube and the creep accumulated damage theory.
10. The integrity management method for the furnace tube of the heating furnace according to claim 6, wherein the setting of the safety boundary of the process operation temperature parameter for each furnace tube, the real-time monitoring of the metal wall temperature value of the furnace tube, and the early warning of the furnace tube with the metal wall temperature monitoring value exceeding the safety boundary value specifically comprise:
calculating the critical operating temperature of the furnace tube under the condition of the set creep residual life according to the material and the operating pressure of the furnace tube and the wall thickness and the diameter data of the furnace tube detected last time, and respectively setting the critical operating temperatures under different set creep residual life conditions as an information boundary, an acceleration boundary and a failure boundary of a temperature process parameter;
judging whether the metal wall temperature monitoring value is higher than each safety boundary value in real time according to the information boundary, the acceleration boundary, the failure boundary and the metal wall temperature monitoring value;
and when the monitored temperature is higher than the safety boundary value, outputting early warning information of different colors on the furnace tube arrangement diagram.
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| CN202210875480.0A CN115238924A (en) | 2022-07-25 | 2022-07-25 | Integrity management system and method for furnace tube of heating furnace |
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| CN202210875480.0A CN115238924A (en) | 2022-07-25 | 2022-07-25 | Integrity management system and method for furnace tube of heating furnace |
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