CN117131798A - Flue type waste heat boiler water-cooled wall service life assessment method - Google Patents

Flue type waste heat boiler water-cooled wall service life assessment method Download PDF

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CN117131798A
CN117131798A CN202311036760.3A CN202311036760A CN117131798A CN 117131798 A CN117131798 A CN 117131798A CN 202311036760 A CN202311036760 A CN 202311036760A CN 117131798 A CN117131798 A CN 117131798A
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wall
water
waste heat
life
water wall
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马江
陈帅甫
王峰
马喜振
郑伟
李培娟
高元端
王家帮
朱琳
李腾蛟
王海红
张娇娇
朱睿颖
陈静
张梦珂
张刘钢
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Henan Boiler And Pressure Vessel Inspection Technology Scientific Research Institute
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Henan Boiler And Pressure Vessel Inspection Technology Scientific Research Institute
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    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06FELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00Computer-aided design [CAD]
    • G06F30/20Design optimisation, verification or simulation
    • G06F30/28Design optimisation, verification or simulation using fluid dynamics, e.g. using Navier-Stokes equations or computational fluid dynamics [CFD]
    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06FELECTRIC DIGITAL DATA PROCESSING
    • G06F2119/00Details relating to the type or aim of the analysis or the optimisation
    • G06F2119/02Reliability analysis or reliability optimisation; Failure analysis, e.g. worst case scenario performance, failure mode and effects analysis [FMEA]
    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06FELECTRIC DIGITAL DATA PROCESSING
    • G06F2119/00Details relating to the type or aim of the analysis or the optimisation
    • G06F2119/14Force analysis or force optimisation, e.g. static or dynamic forces

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Abstract

The invention discloses a life assessment method of a water wall of a flue type waste heat boiler, which is characterized in that under the combined action of wall thickness reduction and fatigue, the comprehensive assessment life trf of a water wall pipe is calculated according to the residual life tr of the water wall after the wall thickness reduction and the fatigue damage degree Df under the fatigue load action, so that the life assessment of the water wall of the flue type waste heat boiler is realized, equipment management and operators can more comprehensively recognize the safety condition of the water wall of the waste heat boiler, parts which have reached the service life and cannot meet the operation requirement can be repaired or replaced in time, and accidents are avoided and reduced to the greatest extent. Meanwhile, necessary technical transformation can be carried out on the equipment according to the service life evaluation result, equipment replacement is reduced to the greatest extent on the premise of ensuring safety, and equipment maintenance cost is reduced.

Description

Flue type waste heat boiler water-cooled wall service life assessment method
Technical Field
The invention belongs to the technical field of boilers, and particularly relates to a method for evaluating the service life of a water-cooled wall of a flue type waste heat boiler.
Background
The waste heat boiler is an important device for improving the energy utilization rate, and is a boiler for heating water to a certain temperature by utilizing waste heat in waste gas, waste materials or waste liquid in various industrial processes and heat generated after combustible substances in the waste heat are combusted. High-temperature steam can be generated through waste heat recovery, and can be used in industrial production processes, and the high-temperature steam can also be used for pushing a steam turbine to generate electricity or supply heat. Therefore, the waste heat boiler has become an indispensable link in production, and is widely applied in a plurality of industries. According to the structural characteristics, the waste heat boiler can be divided into a shell-and-tube waste heat boiler and a flue type waste heat boiler. According to the definition in GB/T28056-2011 "general technical conditions for flue-type waste heat boilers", flue-type waste heat boilers refer to boilers which utilize sensible heat contained in a waste heat medium (waste gas, waste material or waste liquid in various industrial processes) or heat generated after combustion of (and) combustible substances (additional combustion can be added if necessary), exchange heat with a heating surface of a flue (arranged in the flue), and generate steam or hot water, and have a structure similar to that of a water-tube-type or shell-type boiler. Typical flue type waste heat boilers such as cement kiln and glass kiln waste heat boilers in building material industry, sulfuric acid waste heat boilers in chemical acid production industry, steel-making open-hearth waste heat boilers in metallurgical industry, cupola waste heat boilers, copper-, nickel-, tin-and other waste heat boilers, heating furnace waste heat boilers in mechanical industry, gas turbine waste heat boilers and the like.
The main pressure-bearing members of the flue type waste heat boiler can be divided into an inner pressure-bearing member, an outer pressure-bearing member and a steam-water pipeline. The pressure-containing members within the furnace include water walls, superheaters, reheaters and economizers, commonly referred to simply as "four tubes". The pressure-bearing member outside the furnace comprises a boiler barrel, a steam-water separator and a header. The steam-water pipeline refers to a main steam pipeline, a reheat steam pipeline, a water supply pipeline, a steam guide pipe and the like.
The working condition of the pressure-bearing member in the waste heat boiler is very severe, and the medium in the waste heat boiler often has the characteristics of high temperature, high pressure and the like, and also contains corrosive components and a large amount of solid particles, so that the pressure-bearing member in the waste heat boiler becomes the most severe part of the working condition in the waste heat boiler. As one of the pressure-bearing members in the furnace, the water-cooled wall is subjected to high temperature and high pressure, corrosion, abrasion, fatigue damage and the like from a working medium side or a smoke side, the change of material structure and performance can occur in the long-term service process, and even the failure problems such as leakage, pipe explosion and the like can occur in serious cases. In the accident of the waste heat boiler, the bursting problem of the water cooling wall occupies a considerable proportion, and directly influences the service life of equipment and the economic and safe operation of the device.
At present, the life of the domestic part of waste heat boilers is approaching or even exceeding the life calculated by design, and the most concern of enterprises is when the devices can be used at all, i.e. how long their life is. The service life of the water cooling wall of the waste heat boiler is prolonged, the depreciation cost of equipment can be reduced, and the operation cost is reduced, thereby improving the economic benefit. Although the service life of the water-cooled wall of the waste heat boiler has sufficient margin in design, the water-cooled wall cannot be used without any technical measures. The key to extending the lifetime of the device is lifetime assessment techniques. Since the life evaluation result is directly related to the long-term maintenance schedule, the economic benefit is greatly affected. For example, if the estimated remaining life is longer than the actual life, unexpected accidents may be caused to disturb the original plan. Conversely, if the estimated remaining life is too short, unnecessary advanced repairs may be caused. Therefore, the service life assessment technology plays an important role in ensuring the safe operation of equipment and improving economic benefit.
Therefore, by evaluating the service life of the water-cooling wall of the waste heat boiler, reasonably evaluating the safety condition of the water-cooling wall of the waste heat boiler and grasping the health level of equipment, equipment management and operators can more comprehensively recognize the safety condition of the water-cooling wall of the waste heat boiler, and parts which have reached the service life and cannot meet the operation requirement can be repaired or replaced in time, so that accidents are avoided and reduced to the greatest extent. Meanwhile, the equipment can be subjected to necessary technical transformation according to the service life evaluation result, so that old equipment is updated, and the waste heat recycling efficiency and economical efficiency of new equipment are improved, thereby having great economic significance and social benefit.
Aiming at the safe operation requirement of the water-cooled wall of the power station boiler, the prior technical scheme establishes a mathematical model of the change of the corrosion physical quantity along with time by combining with a mathematical statistical theory, evaluates the service life of the water-cooled wall pipeline, comprehensively considers the influence weight of temperature and medium on the corrosion service life, and determines the residual service life time of the high-temperature corrosion of the water-cooled wall pipeline. At present, a service life assessment method for a flue type waste heat boiler water wall is not seen.
The prior art schemes are based on the service life assessment technology of the water-cooling wall of the utility boiler, and compared with the utility boiler, the water-cooling wall of the flue type waste heat boiler has more complex influencing factors, such as various mediums in the boiler, and also contains corrosive components and a large amount of solid particles, so that the failure mode of the water-cooling wall is more complex than that of the water-cooling wall of the utility boiler. If the service life evaluation method of the water-cooled wall of the power station boiler is simply carried into the service life evaluation of the water-cooled wall of the flue type waste heat boiler, larger errors are inevitably generated, and the judgment of the safety condition of equipment is affected.
Disclosure of Invention
The invention aims to: in order to overcome the defects in the prior art, the invention provides a method for evaluating the service life of a water-cooling wall of a flue type waste heat boiler, which comprehensively analyzes various influencing factors causing the failure of the water-cooling wall and comprehensively evaluates the service state and the residual service life of the water-cooling wall according to the working characteristics of the flue type waste heat boiler.
The technical scheme is as follows: in order to achieve the above purpose, the invention adopts the following technical scheme:
the invention provides a flue type waste heat boiler water wall service life assessment method, which comprises the following steps:
s1, calculating the wall thinning rate C of the water wall pipe during two measurement periods according to the water wall running environment and the material characteristics;
s2, calculating the residual life t of the thinned water-cooled wall according to the strength checking theory and the pipe wall thinning rate C r
S3, calculating the fatigue damage degree D of the water-cooled wall f
S4, considering the wall thickness reduction and fatigue combined action, and according to the residual life t of the water-cooled wall after the reduction r Degree of fatigue damage D f Comprehensive evaluation life t of evaluating water wall pipe rf
In one embodiment of the present invention, in step S1, the wall thinning rate C of the water wall pipe during the two measurements is calculated according to the water wall operating environment and the material characteristics, and the calculation formula is shown in formula (1):
wherein: c is the thinning speed of the pipe wall, and the unit is mm/h per hour;
W 1 the unit mm is the wall thickness of the water wall tube measured in the previous period;
W 2 the unit mm is the wall thickness of the water wall tube measured currently;
t is the time interval of two measurements in h.
In one embodiment of the present invention, in step S2, the remaining life t of the water wall after thinning is calculated according to the strength checking theory at the pipe wall thinning rate C r The calculation formula is shown as formula (2):
wherein: w is the original wall thickness of the water wall tube, and the unit is mm;
W 2 the unit mm is the wall thickness of the water wall tube measured currently;
d is the original outer diameter of the water wall pipe, and the unit is mm;
[σ] J the unit MPa is the basic allowable stress of the material used for the water wall pipe;
and p is the pressure of the medium in the water wall pipe and is unit MPa.
In one embodiment of the present invention, in step S3, the fatigue damage degree D of the water wall is calculated f The calculation formula is shown as formula (3):
wherein: n is the cycle number of the load under the variable working condition;
n is the cycle number when fatigue fails, and is obtained according to the low cycle fatigue test result of the material.
In one embodiment of the present invention, in step S4, the estimated water wall tube integrated estimated life t rf The calculation formula is shown as formula (4):
t rf =2t r D f (4)。
the beneficial effects are that: the key invention is that the service life assessment technology is applied to the flue type waste heat boiler water-cooling wall, and a service life assessment calculation model suitable for the flue type waste heat boiler water-cooling wall is established by analyzing the main failure mode of the waste heat boiler water-cooling wall, so that the residual service life of the water-cooling wall is assessed and obtained, and a powerful guarantee is provided for the safe operation of the flue type waste heat boiler water-cooling wall.
The service life evaluation technology is applied to the water-cooled wall of the flue type waste heat boiler, on one hand, the reliability of the device can be improved, the safety and stability of production are improved, sudden accidents are prevented and avoided, the life and property safety of people is guaranteed, and economic losses are avoided. On the other hand, the method is beneficial to scientifically and reasonably arranging overhaul, rationalizes an overhaul mode, reduces the shutdown times, saves a large amount of overhaul cost for enterprises, reduces the operation cost of the enterprises, and improves the equipment utilization rate, thereby having considerable economic and social benefits.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for the description of the embodiments will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a flow chart of a method for evaluating the service life of a water wall of a flue type waste heat boiler according to an embodiment of the invention.
Detailed Description
The invention will be further described with reference to the drawings and examples. The invention will be better understood from the following examples. However, it will be readily understood by those skilled in the art that the specific material ratios, process conditions and results thereof described in the examples are illustrative of the present invention and should not be construed as limiting the invention described in detail in the claims.
The flue type waste heat boiler water cooling wall not only bears the action of high temperature and high pressure, but also is corroded, worn, fatigued and damaged from a working medium side or a flue gas side, the change of material structure and performance can occur in the long-term service process, and even the failure problems of leakage, pipe explosion and the like can occur in severe cases. In the accident of the waste heat boiler, the bursting problem of the water cooling wall occupies a considerable proportion, and directly influences the service life of equipment and the economic and safe operation of the device. At present, the water-cooled walls of a large number of waste heat boilers are approaching or even exceeding the life calculated by design, and the most concern of enterprises is when these devices can be used at all, i.e. how long their life is.
According to the method for evaluating the service life of the water-cooling wall of the flue type waste heat boiler, provided by the invention, through evaluating the service life of the water-cooling wall of the flue type waste heat boiler, equipment management and operators can more comprehensively recognize the safety condition of the water-cooling wall of the waste heat boiler, and parts which have reached the service life and cannot meet the operation requirement can be repaired or replaced in time, so that accidents are avoided and reduced to the greatest extent. Meanwhile, necessary technical transformation can be carried out on the equipment according to the service life evaluation result, equipment replacement is reduced to the greatest extent on the premise of ensuring safety, and equipment maintenance cost is reduced.
As shown in FIG. 1, the method for evaluating the service life of the water-cooled wall of the flue type waste heat boiler comprises the following steps:
and 1, collecting and analyzing relevant data of the water-cooled wall. The method comprises the steps of original design, installation data, operation courses, actual operation parameters, accumulated operation time, replacement history, past check records, accident conditions, future operation plans and the like.
And 2, checking the current situation of the water wall and analyzing the use state. The condition of the water-cooled wall after operation is basically mastered through on-site comprehensive inspection of the water-cooled wall, the mechanical property, microstructure change and material change rule of the pipe after long-term use are analyzed, the original pipe sample and the on-site pipe section are compared, and the use state of the pipe is assessed.
And 3, evaluating the service life of the water wall, wherein the method comprises the following specific steps of:
s1, calculating the wall thinning rate of the water wall pipe according to the water wall running environment and material characteristics, wherein for the wall thinning rate C during two measurement, the calculation formula is (1):
wherein: c is the pipe wall thinning speed, and the unit is millimeter per hour (mm/h);
W 1 the unit mm is the wall thickness of the water wall tube measured in the previous period;
W 2 the unit mm is the wall thickness of the water wall tube measured currently;
t is the time interval of two measurements in h.
S2, according to an intensity checking theory, the residual life t of the thinned water-cooled wall r The calculation formula is (2):
wherein: w is the original wall thickness of the water wall tube, and the unit is mm;
d is the original outer diameter of the water wall pipe, and the unit is mm;
[σ] J the unit MPa is the basic allowable stress of the material used for the water wall pipe;
and p is the pressure of the medium in the water wall pipe and is unit MPa.
S3, calculating a fatigue damage degree according to the formula (3):
wherein: n is the cycle number of the load under the variable working condition;
n is the cycle number when fatigue fails, and is obtained according to the low cycle fatigue test result of the material;
s4, considering the wall thickness reduction and fatigue combined action, comprehensively evaluating the service life t of the water wall pipe rf The evaluation calculation formula is (4):
t rf =2t r D f (4)
example 1
The original outer diameter d of the water wall tube of a certain flue type waste heat boiler is 63.5mm, the original wall thickness W is 4.50mm, and the basic allowable stress [ sigma ] of the material is achieved] J 84MPa; the medium pressure p in the water wall tube is 12.5MPa.
Wall thickness W of water wall tube measured in previous period 1 At 4.48mm, the wall thickness W of the water wall tube is currently measured 2 The time interval T of the two measurements was 26280h, 4.46mm, during which the cycle of fatigue loading was experienced n 5000 times.
According to the experimental result of low cycle fatigue of the material, when the material is subjected to fatigue damage under constant strain, when the load cycle reaches 5000 times, the corresponding cycle number N under the specific strain amplitude is 13549 times under the laboratory condition.
According to the formula shown in the formula (1), the pipe wall thinning rate C is calculated to be 7.6x10 -7 mm/h。
According to the formula shown in the formula (2), the residual life t of the thinned water-cooled wall is calculated r 103909.3h.
According to the formula shown in the formula (3), the fatigue damage degree D of the water-cooled wall is calculated f 0.369.
Finally, according to the formula shown in the formula (4), calculating to obtain the comprehensive estimated service life t of the water wall pipe rf 76685h.
The foregoing is only a preferred embodiment of the invention, it being noted that: it will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the principles of the present invention, and such modifications and adaptations are intended to be comprehended within the scope of the invention.

Claims (5)

1. The method for evaluating the service life of the water-cooled wall of the flue type waste heat boiler is characterized by comprising the following steps of:
s1, calculating the wall thinning rate C of the water wall pipe during two measurement periods according to the water wall running environment and the material characteristics;
s2, calculating the residual life t of the thinned water-cooled wall according to the strength checking theory and the pipe wall thinning rate C r
S3, calculating the fatigue damage degree D of the water-cooled wall f
S4, considering the wall thickness reduction and fatigue combined action, and according to the residual life t of the water-cooled wall after the reduction r Degree of fatigue damage D f Comprehensive evaluation life t of evaluating water wall pipe rf
2. The method according to claim 1, wherein in step S1, the wall thinning rate C of the water wall pipe during the two measurements is calculated according to the water wall operation environment and the material characteristics, and the calculation formula is shown in formula (1):
wherein: c is the thinning speed of the pipe wall, and the unit is mm/h per hour;
W 1 the unit mm is the wall thickness of the water wall tube measured in the previous period;
W 2 the unit mm is the wall thickness of the water wall tube measured currently;
t is the time interval of two measurements in h.
3. The method according to claim 1, wherein in step S2, the remaining life t of the water-cooled wall after the wall thinning is calculated according to the strength checking theory at the wall thinning rate C r The calculation formula is shown as formula (2):
wherein: w is the original wall thickness of the water wall tube, and the unit is mm;
W 2 the unit mm is the wall thickness of the water wall tube measured currently;
d is the original outer diameter of the water wall pipe, and the unit is mm;
[σ] J the unit MPa is the basic allowable stress of the material used for the water wall pipe;
and p is the pressure of the medium in the water wall pipe and is unit MPa.
4. The method according to claim 1, wherein in step S3, the fatigue damage degree D of the water wall is calculated f The calculation formula is shown as formula (3):
wherein: n is the cycle number of the load under the variable working condition;
n is the cycle number when fatigue fails.
5. The method of claim 1, wherein in step S4, the estimated water wall tube integrated estimated life t rf The calculation formula is shown as formula (4):
t rf =2t r D f (4)。
CN202311036760.3A 2023-08-17 2023-08-17 Flue type waste heat boiler water-cooled wall service life assessment method Pending CN117131798A (en)

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CN202311036760.3A CN117131798A (en) 2023-08-17 2023-08-17 Flue type waste heat boiler water-cooled wall service life assessment method

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