WO2020037879A1 - 生物质燃料锅炉热交换管寿命的评估装置及方法 - Google Patents

生物质燃料锅炉热交换管寿命的评估装置及方法 Download PDF

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WO2020037879A1
WO2020037879A1 PCT/CN2018/119139 CN2018119139W WO2020037879A1 WO 2020037879 A1 WO2020037879 A1 WO 2020037879A1 CN 2018119139 W CN2018119139 W CN 2018119139W WO 2020037879 A1 WO2020037879 A1 WO 2020037879A1
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tube
heat exchange
thickness
wall
life
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PCT/CN2018/119139
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English (en)
French (fr)
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李廉明
胡一鸣
龚俊
何德峰
孟志浩
李岱俊
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李廉明
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
    • G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
    • G01B21/08—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
    • G01K13/00—Thermometers specially adapted for specific purposes
    • G01K13/02—Thermometers specially adapted for specific purposes for measuring temperature of moving fluids or granular materials capable of flow
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
    • G01K13/00—Thermometers specially adapted for specific purposes
    • G01K13/02—Thermometers specially adapted for specific purposes for measuring temperature of moving fluids or granular materials capable of flow
    • G01K13/024—Thermometers specially adapted for specific purposes for measuring temperature of moving fluids or granular materials capable of flow of moving gases

Definitions

  • the invention relates to a device and method for evaluating the life of a heat exchange tube of a biomass fuel boiler.
  • General boiler heat exchange tubes mainly include four types of water-cooled wall tubes, economizer tubes, superheater tubes, and reheater tubes; biomass fuel generators are characterized by a small boiler furnace type, no reheat tubes in the furnace, and heat in the furnace The surface is severely corroded by alkali metal during operation. Unlike traditional coal-fired boiler heat exchange tubes, which fail due to overheating, creep, corrosion, and fatigue, the failure of biomass fuel boiler heat exchange tubes is mainly the result of the combined effect of overheating and corrosion.
  • the technical problem to be solved by the present invention is to provide a device and method for evaluating the life of a heat exchanger tube of a biomass fuel boiler.
  • the device and method overcome the shortcomings of the traditional life evaluation of a heat exchanger tube, and realize a quantitative evaluation and regular monitoring of the life of a heat exchanger tube. When the heat exchange tube reaches the end of its life, it will give early warning to ensure the safe and reliable operation of the boiler.
  • the apparatus for evaluating the life of a heat exchanger tube of a biomass fuel boiler includes a pipe thickness gauge, a temperature sensor, a cloud service platform, and a visual interaction platform.
  • the pipe thickness gauge and the temperature sensor respectively detect heat exchange.
  • the pipe wall thickness and the measured flue gas temperature at the wall thickness, and the detection data is transmitted to the cloud service platform via a wired network or a wireless network.
  • the cloud service platform has built-in flue gas temperature distribution data during the operation of the boiler.
  • the cloud service platform is communicatively connected with a visual interaction platform, which provides curve, three-dimensional molding, printing, and life-cycle early warning services according to demand.
  • a method for evaluating the life of a heat exchanger tube of a biomass fuel boiler based on the above evaluation device includes the following steps:
  • Step 1 During the boiler shutdown and maintenance, a pipe thickness gauge is used to detect the wall thickness of the boiler heat exchange tube and transmit it to the cloud service platform;
  • Step 2 The temperature of the flue gas at the wall thickness of the measured heat exchange tube is detected by the temperature sensor and transmitted to the cloud service platform.
  • the cloud service platform calls the temperature distribution data of the flue gas in the furnace during the operation of the boiler and is based on the measured heat exchange tube.
  • the flue gas temperature at the wall thickness determines whether the measured heat exchange tube is a superheater tube, an economizer tube or a water-cooled wall tube;
  • Step 3 If it is judged as a superheater tube, considering the combined effect of wall thickness reduction and high temperature creep, calculate the remaining life of the superheater tube according to formula (1).
  • t is the wall thickness over the remaining lifetime and high-temperature creep under the action
  • K is a wall thickness reduction rates
  • the stress n-sensitivity is R & lt creep rupture life
  • the thickness reduction ratio K of the pipe wall is calculated according to formula (2),
  • ⁇ is the initial thickness of the pipe wall
  • ⁇ f is the final thickness of the pipe wall
  • ⁇ op is the running time of the pipe
  • Step 4 If it is judged as an economizer tube, calculate the remaining life of the economizer tube according to formula (3).
  • t is the province of Economizer remaining lifetime
  • D is the outer diameter of the original pipe
  • ⁇ y is the lowest temperature creep strength in the steel
  • p is the operating pressure tube
  • ⁇ 2 is the current measured wall Thickness
  • K is the thinning rate of the wall thickness
  • ⁇ 1 is the thickness of the tube wall measured last time
  • H is the time between the previous time and the current thickness of the tube wall
  • Step 5 If it is judged as a water-cooled wall pipe, when evaluating the remaining life of the water-walled pipe, if the metal temperature of the pipe wall does not exceed the creep temperature of the material, calculate the remaining life according to the theory of normal temperature strength check. The specific calculation method It is consistent with the remaining life of the economizer tube, and is evaluated and predicted according to the wall thickness reduction rate. If the metal temperature of the tube wall exceeds the creep temperature of the material, the impact of high temperature creep on the life needs to be considered. The calculation method and the remaining life of the superheater tube Calculations are consistent;
  • Step 6 The visual interactive platform outputs the calculation result of the remaining life of the heat exchange tube in a curve and / or three-dimensional shape, and sends out a remaining life early warning signal to provide the remaining life control measures and the maintenance operation plan of the biomass fuel boiler heat exchange tube.
  • the remaining life of the heat exchange tubes of the biomass fuel boiler calculated by the evaluation, if the remaining life is less than 3 years, plan overhaul within one year, and repair or replace it based on the thickness measurement results; if 6 years ⁇ the remaining life ⁇ 9 years , Then overhaul is planned one year later but within three years, and repair or replacement is performed according to the thickness measurement results; if the remaining life is ⁇ 9 years, detailed thickness inspection will be carried out in the next planned maintenance.
  • step 2 when the temperature of the flue gas at the wall thickness of the heat exchange tube to be measured is 540 to 750 ° C, it is determined to be 540 to 750 ° C, 295 to 540 ° C is determined to be an economizer tube, and 750 to 850 ° C is determined to be Water-cooled wall tube.
  • the device is composed of a pipe thickness gauge, a temperature sensor, a cloud service platform, and a visual interaction platform.
  • the pipe thickness gauge and temperature sensor are connected to the cloud service platform in a wireless or wired form;
  • the cloud service platform has the functions of data calculation, comparison and storage, and transmits the calculation results to the visual interaction platform;
  • the visual interaction platform provides the curve , 3D molding, printing, and life-cycle warning services.
  • the type of the heat exchange tube is determined by the device.
  • the cloud service platform calculates the remaining life of the superheater tube, economizer tube, or water-cooled wall tube respectively.
  • the visual interaction platform outputs the calculation result of the remaining life of the heat exchange tube and sends it out.
  • Remaining life warning signal providing remaining life control measures and maintenance work plan for heat exchange tube of biomass fuel boiler.
  • the device and method overcome the shortcomings of the traditional heat exchange tube life evaluation, realize the quantitative evaluation and regular monitoring of the life of the heat exchange tube, and timely warn when the heat exchange tube reaches the life limit to ensure the safe and reliable operation of the boiler.
  • FIG. 1 is a principle block diagram of an apparatus for evaluating the life of a heat exchange tube of a biomass fuel boiler according to the present invention
  • FIG. 2 is a flow block diagram of the method.
  • the apparatus for evaluating the life of a heat exchanger tube of a biomass fuel boiler includes a pipe thickness gauge 1, a temperature sensor 2, a cloud service platform 3, and a visual interaction platform 4.
  • the pipe thickness gauge 1 and The temperature sensor 2 detects the wall thickness of the heat exchange tube and the temperature of the flue gas at the measured wall thickness, and the detection data is transmitted to the cloud service platform 3 via a wired network or a wireless network.
  • the cloud service platform 3 has a built-in furnace during operation of the boiler.
  • the internal smoke temperature distribution data, the cloud service platform 3 and the visual interaction platform 4 are communicatively connected, and the visual interaction platform 4 provides curve, three-dimensional molding, printing, and life-cycle early warning services according to demand.
  • a method for evaluating the life of a heat exchanger tube of a biomass fuel boiler based on the above evaluation device includes the following steps:
  • Step 1 During the boiler shutdown and maintenance, a pipe thickness gauge is used to detect the wall thickness of the boiler heat exchange tube and transmit it to the cloud service platform;
  • Step 2 The temperature of the flue gas at the wall thickness of the measured heat exchange tube is detected by the temperature sensor and transmitted to the cloud service platform.
  • the cloud service platform calls the temperature distribution data of the flue gas in the furnace during the operation of the boiler and is based on the measured heat exchange tube.
  • the flue gas temperature at the wall thickness determines whether the measured heat exchange tube is a superheater tube, an economizer tube or a water-cooled wall tube;
  • Step 3 If it is judged as a superheater tube, considering the combined effect of wall thickness reduction and high temperature creep, calculate the remaining life of the superheater tube according to formula (1).
  • t is the wall thickness over the remaining lifetime and high-temperature creep under the action
  • K is a wall thickness reduction rates
  • the stress n-sensitivity is R & lt creep rupture life
  • the thickness reduction ratio K of the pipe wall is calculated according to formula (2),
  • ⁇ is the initial thickness of the pipe wall
  • ⁇ f is the final thickness of the pipe wall
  • ⁇ op is the running time of the pipe.
  • the above formula is a mathematical analytical formula for estimating the high-temperature durable strength of the material.
  • LMP is the material strength
  • C is the material aging factor
  • T is the metal equivalent temperature
  • ⁇ is the circumferential stress of the inner wall of the pipe.
  • p is the working pressure in the pipe
  • D is the inner diameter of the pipe
  • a and b are the material constants
  • x is the thickness of the scale on the inner wall of the pipe
  • t is the operating time of the superheater
  • Step 4 If it is judged as an economizer tube, calculate the remaining life of the economizer tube according to formula (3).
  • t is the province of Economizer remaining lifetime
  • D is the outer diameter of the original pipe
  • ⁇ y is the lowest temperature creep strength in the steel
  • p is the operating pressure tube
  • ⁇ 2 is the current measured wall Thickness
  • K is the thinning rate of the wall thickness
  • ⁇ 1 is the thickness of the tube wall measured last time
  • H is the time between the previous time and the current thickness of the tube wall
  • Step 5 If it is judged as a water-cooled wall pipe, when evaluating the remaining life of the water-walled pipe, if the metal temperature of the pipe wall does not exceed the creep temperature of the material, calculate the remaining life according to the theory of normal temperature strength check. The specific calculation method It is consistent with the remaining life of the economizer tube, and is evaluated and predicted according to the wall thickness reduction rate. If the metal temperature of the tube wall exceeds the creep temperature of the material, the impact of high temperature creep on the life needs to be considered. The calculation method and the remaining life of the superheater tube Calculations are consistent;
  • Step 6 The visual interactive platform outputs the calculation result of the remaining life of the heat exchange tube in a curve and / or three-dimensional shape, and sends out a remaining life early warning signal to provide the remaining life control measures and the maintenance operation plan of the biomass fuel boiler heat exchange tube.
  • the remaining life of the heat exchange tubes of the biomass fuel boiler calculated according to the assessment, if the remaining life is less than 3 years, plan overhaul within one year, and repair or replace it according to the thickness measurement results; if 6 years ⁇ the remaining life ⁇ 9 Year, then overhaul is planned one year later but within three years, and repair or replacement based on thickness measurement results; if the remaining life is ⁇ 9 years, detailed thickness inspection will be carried out in the next planned maintenance.
  • the overhaul of heat exchange tubes for biomass fuel boilers is carried out in accordance with the overhaul cycle and overhaul items of the "Guidelines for the Overhaul of Equipment for Power Generation Enterprises", which mainly include inspection of tube wear, corrosion, bending, deformation, cracks, fatigue, bulging, overheating, bulging, Creep, etc., and measure thickness, replace defective heat exchange tubes.
  • the temperature of the flue gas at the wall thickness of the heat exchange tube to be measured in step 2 is 540 to 750 ° C, it is determined to be 540 to 750 ° C, 295 to 540 ° C is determined to be an economizer tube, and 750 to 850 ° C.
  • 540 to 750 ° C a temperature of the flue gas at the wall thickness of the heat exchange tube to be measured in step 2
  • 295 to 540 ° C is determined to be an economizer tube
  • 750 to 850 ° C For water-cooled wall tubes.
  • the device and method realize the regular assessment and monitoring of the remaining life of the heat exchange tubes of the biomass fuel boiler, the online calculation and archiving, and the life limit early warning. If the remaining life of the boiler heat exchange tube is short-term, if the remaining life of the boiler heat exchange tube is short, the remaining life of the boiler heat exchange tube can be reasonably used by timely scheduling the planned maintenance, and the technical effect of regularly monitoring the remaining life of the boiler heat exchange tube is achieved, thereby reducing The unplanned shutdown time of the biomass fuel boiler ensures the safe and reliable operation of the boiler.
  • the device and method are used to evaluate and calculate the life of the boiler heat exchange tube.
  • the wall thickness of the heat exchange tube of the boiler was measured with a pipe thickness gauge, and the wall thickness was 5.5mm;
  • the cloud service platform calls the distribution of the flue gas temperature during the boiler operation. If the heat exchange pipe is an economizer pipe, the remaining life of the economizer pipe is calculated;
  • the thickness of the wall of the economizer tube measured at the last shutdown was 5.7mm, and the time from the shutdown was 7300h.
  • the thickness of the tube wall of the economizer tube measured at this shutdown was 5.5mm. for:
  • the original thickness of the economizer pipe wall is 6mm, the original outer diameter is 60mm, the pipe working pressure is 9.8MPa, the pipe wall material is 20G, and the minimum strength at the creep temperature of the steel is 240MPa, then the remaining of the economizer pipe Life can be carried out as follows:
  • the remaining life of the economizer tube is about 18.7 years> 9 years, then in the next planned maintenance, detailed thickness inspection should be carried out, and the planned overhaul period and planned overhaul of the boiler should be arranged in accordance with the "Guidelines for Maintenance of Equipment for Power Generation Enterprises" project.
  • the visual interactive platform outputs the calculation result of the remaining life of the economizer tube by curve, three-dimensional modeling or other visualization means, issues a warning signal of the remaining life, provides the remaining life control measures, and guides the maintenance operation of the heat exchange tube of the biomass fuel boiler. .

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Regulation And Control Of Combustion (AREA)
  • Investigating And Analyzing Materials By Characteristic Methods (AREA)
  • Control Of Steam Boilers And Waste-Gas Boilers (AREA)

Abstract

一种生物质燃料锅炉热交换管寿命的评估装置及方法，所述装置由管道测厚仪（1）、温度传感器（2）、云服务平台（3）、可视交互平台（4）组成，管道测厚仪（1）和温度传感器（2）与云服务平台（3）连接；云服务平台（3）具有数据计算、比对和存储的功能，并将计算结果传送到可视交互平台（4）；可视交互平台（4）提供曲线、三维成型、打印、寿命期限预警服务。所述方法通过所述装置确定热交换管种类，云服务平台（3）分别对过热器管、省煤器管或水冷壁管的剩余寿命进行计算，可视交互平台（4）输出热交换管剩余寿命的计算结果，并发出剩余寿命预警信号，提供剩余寿命控制措施及生物质燃料锅炉热交换管检修作业计划。所述装置及方法实现热交换管寿命的定量评估和定期监控，确保锅炉安全可靠运行。

Description

生物质燃料锅炉热交换管寿命的评估装置及方法 技术领域
本发明涉及一种生物质燃料锅炉热交换管寿命的评估装置及方法。
背景技术
一般锅炉热交换管主要包括水冷壁管、省煤器管、过热器管、再热器管四种类型；生物质燃料发电机组的特点是锅炉炉型小、炉内无再热管、炉内受热面在运行过程中受碱金属腐蚀情况严重。与传统燃煤锅炉热交换管过热、蠕变、腐蚀和疲劳导致的失效形式不同，生物质燃料锅炉热交换管的失效主要是过热与腐蚀共同作用的结果。
在生物质燃料锅炉中，通过入炉燃料的元素分析不能确定燃料在燃烧过程中碱金属元素的释放量，进而无法评估其对生物质燃料锅炉热交换管寿命的影响以及热交换管受腐蚀的情况，并且生物质燃料锅炉运行中更是无法监测热交换管的腐蚀情况。随着运行时长的增加，当锅炉热交换管的管壁厚度达到临界尺寸时，就有可能发生爆管，导致锅炉运行发生事故。现有生物质燃料锅炉热交换管寿命评估大多仅仅依靠运行经验进行估计，并没有合适的装置和方法供生物质燃料锅炉热交换管进行寿命评估。
发明内容
本发明所要解决的技术问题是提供一种生物质燃料锅炉热交换管寿命的评估装置及方法，本装置及方法克服传统热交换管寿命评估的缺陷，实现热交换管寿命的定量评估和定期监控，当热交换管达到寿命极限时及时预警，确保锅炉安全可靠运行。
为解决上述技术问题，本发明生物质燃料锅炉热交换管寿命的评估装置包括管道测厚仪、温度传感器、云服务平台和可视交互平台，所述管道测厚仪和温度传感器分别检测热交换管壁厚和被测壁厚处的烟气温度，并且检测数据经有线网络或无线网络传输至所述云服务平台，所述云服务平台内置锅炉运行期间炉内烟气温度分布数据，所述云服务平台与可视交互平台通讯连接，所述可视交互平台根据需求提供曲线、三维成型、打印、寿命期限预警服务。
一种基于上述评估装置的生物质燃料锅炉热交换管寿命的评估方法包括如下步骤：
步骤一、在锅炉停炉检修期间，采用管道测厚仪检测锅炉热交换管壁厚尺寸并传输至云服务平台；
步骤二、由温度传感器检测锅炉运行时被测热交换管壁厚处的烟气温度并传输至云服务平台，云服务平台调用锅炉运行期间炉内烟气温度分布数据并依据被测热交换管壁厚处的烟气温度判断该被测热交换管是过热器管、省煤器管或水冷壁管；
步骤三、如判断为过热器管，考虑壁厚减薄和高温蠕变共同作用的情况下，按式(1)计算过热器管的剩余寿命，
Figure PCTCN2018119139-appb-000001
式(1)中，t 过为壁厚减薄和高温蠕变共同作用下的剩余寿命，K为管壁厚度减薄率，n为应力敏感性，t r为蠕变断裂寿命，
其中：管壁厚度减薄率K按式(2)计算，
Figure PCTCN2018119139-appb-000002
式(2)中，δ为管壁初始厚度，δ f为管壁最终厚度，τ op为管子运行时间；
步骤四、如判断为省煤器管，按式(3)计算省煤器管的剩余寿命，
Figure PCTCN2018119139-appb-000003
式(3)中，t 省为省煤器管剩余寿命，D为管子原始外径，σ y为钢材蠕变温度下的最低强度，p为管内工作压力，δ 2为当前测得的管壁厚度，K为管壁厚度减薄率，
其中：K＝(δ 1-δ 2)/H  (4)
式(4)中，δ 1为前次测得的管壁厚度，H为前次与当前管壁测厚之间的时间；
步骤五、如判断为水冷壁管，在评估水冷壁管的剩余寿命时，如果其管壁金属温度未超过材料的蠕变温度，则按常温强度校核理论进行剩余寿命的计算，具体计算方法同省煤器管剩余寿命一致，按壁厚减薄率进行评估预测；如 果其管壁金属温度超过材料的蠕变温度，则需考虑高温蠕变对寿命的影响，计算方法与过热器管剩余寿命计算一致；
步骤六、可视交互平台以曲线和/或三维造型输出热交换管剩余寿命的计算结果，并发出剩余寿命预警信号，提供剩余寿命控制措施及生物质燃料锅炉热交换管检修作业计划。
进一步，按评估计算的生物质燃料锅炉热交换管的剩余寿命，若剩余寿命＜3年，则在一年内计划大修，并根据测厚结果进行修补或更换；若6年≤剩余寿命＜9年，则在一年后但在三年内计划大修，并根据测厚结果进行修补或更换；若剩余寿命≥9年，则在下一次计划检修中予以详细的测厚检查。
进一步，上述步骤二中被测热交换管壁厚处的烟气温度为540～750℃时判断为540～750℃、295～540℃时判断为省煤器管、750-850℃时判断为水冷壁管。
由于本发明生物质燃料锅炉热交换管寿命的评估装置及方法采用了上述技术方案，即本装置由管道测厚仪、温度传感器、云服务平台、可视交互平台组成。管道测厚仪和温度传感器以无线或有线的形式与云服务平台连接；云服务平台具有数据计算、比对和存储的功能，并将计算结果传送到可视交互平台；可视交互平台提供曲线、三维成型、打印、寿命期限预警服务。本方法通过本装置确定热交换管种类，云服务平台分别对过热器管、省煤器管或水冷壁管的剩余寿命进行计算，可视交互平台输出热交换管剩余寿命的计算结果，并发出剩余寿命预警信号，提供剩余寿命控制措施及生物质燃料锅炉热交换管检修作业计划。本装置及方法克服传统热交换管寿命评估的缺陷，实现热交换管寿命的定量评估和定期监控，当热交换管达到寿命极限时及时预警，确保锅炉安全可靠运行。
附图说明
下面结合附图和实施方式对本发明作进一步的详细说明：
图1为本发明生物质燃料锅炉热交换管寿命的评估装置的原理框图；
图2为本方法的流程框图。
具体实施方式
实施例如图1所示，本发明生物质燃料锅炉热交换管寿命的评估装置包括 管道测厚仪1、温度传感器2、云服务平台3和可视交互平台4，所述管道测厚仪1和温度传感器2分别检测热交换管壁厚和被测壁厚处的烟气温度，并且检测数据经有线网络或无线网络传输至所述云服务平台3，所述云服务平台3内置锅炉运行期间炉内烟气温度分布数据，所述云服务平台3与可视交互平台4通讯连接，所述可视交互平台4根据需求提供曲线、三维成型、打印、寿命期限预警服务。
一种基于上述评估装置的生物质燃料锅炉热交换管寿命的评估方法包括如下步骤：
步骤一、在锅炉停炉检修期间，采用管道测厚仪检测锅炉热交换管壁厚尺寸并传输至云服务平台；
步骤二、由温度传感器检测锅炉运行时被测热交换管壁厚处的烟气温度并传输至云服务平台，云服务平台调用锅炉运行期间炉内烟气温度分布数据并依据被测热交换管壁厚处的烟气温度判断该被测热交换管是过热器管、省煤器管或水冷壁管；
步骤三、如判断为过热器管，考虑壁厚减薄和高温蠕变共同作用的情况下，按式(1)计算过热器管的剩余寿命，
Figure PCTCN2018119139-appb-000004
式(1)中，t 过为壁厚减薄和高温蠕变共同作用下的剩余寿命，K为管壁厚度减薄率，n为应力敏感性，t r为蠕变断裂寿命，
其中：管壁厚度减薄率K按式(2)计算，
Figure PCTCN2018119139-appb-000005
式(2)中，δ为管壁初始厚度，δ f为管壁最终厚度，τ op为管子运行时间，
上述计算基于应力解析法中的Larson-Miller参数法，其具体数学模型为：
LMP＝T(C+lgt r)＝C 0+C 1logσ+C 2log 2σ+C 3log 3σ
上式为推导估算材料高温持久强度的数学解析式，上式中，LMP为材料强度，C为材料老化因子，T为金属当量温度，σ为管子内壁周向应力，
其中：
Figure PCTCN2018119139-appb-000006
Figure PCTCN2018119139-appb-000007
式两式中，p为管内工作压力，D 内为管子内径，a和b分别为材料常数，x为管子内壁氧化皮厚度，t为过热器已运行时间；
步骤四、如判断为省煤器管，按式(3)计算省煤器管的剩余寿命，
Figure PCTCN2018119139-appb-000008
式(3)中，t 省为省煤器管剩余寿命，D为管子原始外径，σ y为钢材蠕变温度下的最低强度，p为管内工作压力，δ 2为当前测得的管壁厚度，K为管壁厚度减薄率，
其中：K＝(δ 1-δ 2)/H  (4)
式(4)中，δ 1为前次测得的管壁厚度，H为前次与当前管壁测厚之间的时间；
步骤五、如判断为水冷壁管，在评估水冷壁管的剩余寿命时，如果其管壁金属温度未超过材料的蠕变温度，则按常温强度校核理论进行剩余寿命的计算，具体计算方法同省煤器管剩余寿命一致，按壁厚减薄率进行评估预测；如果其管壁金属温度超过材料的蠕变温度，则需考虑高温蠕变对寿命的影响，计算方法与过热器管剩余寿命计算一致；
步骤六、可视交互平台以曲线和/或三维造型输出热交换管剩余寿命的计算结果，并发出剩余寿命预警信号，提供剩余寿命控制措施及生物质燃料锅炉热交换管检修作业计划。
优选的，按评估计算的生物质燃料锅炉热交换管的剩余寿命，若剩余寿命＜3年，则在一年内计划大修，并根据测厚结果进行修补或更换；若6年≤剩余寿命＜9年，则在一年后但在三年内计划大修，并根据测厚结果进行修补或更换；若剩余寿命≥9年，则在下一次计划检修中予以详细的测厚检查。生物质燃料锅炉热交换管的大修按《发电企业设备检修导则》的大修周期和大修项目进行，其主要包括检查管子磨损、腐蚀、弯曲、变形、裂纹、疲劳、胀粗、过热、鼓包、蠕变等情况，并测厚、更换缺陷热交换管。
优选的，上述步骤二中被测热交换管壁厚处的烟气温度为540～750℃时判断为540～750℃、295～540℃时判断为省煤器管、750-850℃时判断为水冷壁 管。
本装置和方法实现了生物质燃料锅炉热交换管剩余寿命的定期评估监控、在线计算存档、寿命期限预警。如果接到评估装置预警，锅炉热交换管的剩余寿命偏短时，通过及时安排计划检修来合理使用锅炉热交换管的剩余寿命，达到了定期监控锅炉热交换管剩余寿命的技术效果，从而减少生物质燃料锅炉的非计划停炉时间，确保锅炉安全可靠运行。
例如对于某型号130t/h的生物质燃料锅炉，在该锅炉停炉检修期间，采用本装置和方法对锅炉热交换管的寿命进行评估计算。
首先在锅炉停炉检修期间，采用管道测厚仪测量锅炉热交换管壁厚，得到壁厚＝5.5mm；
输入测厚位置的烟气温度420℃，云服务平台调用锅炉运行期间炉内烟气温度的分布，判断该热交换管是省煤器管，则对该省煤器管剩余寿命进行计算；
该省煤器管上次停炉测得管壁厚度为5.7mm，距离本次停炉时间为7300h，本次停炉测得省煤器管管壁厚度为5.5mm，那么管壁减薄率为：
K＝(δ 1-δ 2)/H＝(5.7-5.5)/7300＝36500
省煤器管管壁的原始厚度为6mm，原始外径为60mm，管道工作压力为9.8MPa，管壁材质为20G，钢材蠕变温度下的最低强度取240MPa，那么该省煤器管的剩余寿命可按下式进行：
Figure PCTCN2018119139-appb-000009
该省煤器管的剩余寿命约为18.7年＞9年，那么在下一次计划检修中，应予以详细的测厚检查，并按照《发电企业设备检修导则》安排锅炉的计划大修周期和计划大修项目。同时由可视交互平台以曲线、三维造型或其他可视化手段输出该省煤器管剩余寿命的计算结果，发出剩余寿命预警信号，提供剩余寿命控制措施，指导生物质燃料锅炉热交换管的检修作业。

Claims (4)

  1. 一种生物质燃料锅炉热交换管寿命的评估装置，其特征在于：包括管道测厚仪、温度传感器、云服务平台和可视交互平台，所述管道测厚仪和温度传感器分别检测热交换管壁厚和被测壁厚处的烟气温度，并且检测数据经有线网络或无线网络传输至所述云服务平台，所述云服务平台内置锅炉运行期间炉内烟气温度分布数据，所述云服务平台与可视交互平台通讯连接，所述可视交互平台根据需求提供曲线、三维成型、打印、寿命期限预警服务。
  2. 一种基于权利要求1所述评估装置的生物质燃料锅炉热交换管寿命的评估方法，其特征在于本方法包括如下步骤：
    步骤一、在锅炉停炉检修期间，采用管道测厚仪检测锅炉热交换管壁厚尺寸并传输至云服务平台；
    步骤二、由温度传感器检测锅炉运行时被测热交换管壁厚处的烟气温度并传输至云服务平台，云服务平台调用锅炉运行期间炉内烟气温度分布数据并依据被测热交换管壁厚处的烟气温度判断该被测热交换管是过热器管、省煤器管或水冷壁管；
    步骤三、如判断为过热器管，考虑壁厚减薄和高温蠕变共同作用的情况下，按式(1)计算过热器管的剩余寿命，
    Figure PCTCN2018119139-appb-100001
    式(1)中，t 过为壁厚减薄和高温蠕变共同作用下的剩余寿命，K为管壁厚度减薄率，n为应力敏感性，t r为蠕变断裂寿命，
    其中：管壁厚度减薄率K按式(2)计算，
    Figure PCTCN2018119139-appb-100002
    式(2)中，δ为管壁初始厚度，δ f为管壁最终厚度，τ op为管子运行时间；
    步骤四、如判断为省煤器管，按式(3)计算省煤器管的剩余寿命，
    Figure PCTCN2018119139-appb-100003
    式(3)中，t 省为省煤器管剩余寿命，D为管子原始外径，σ y为钢材蠕变温 度下的最低强度，p为管内工作压力，δ 2为当前测得的管壁厚度，K为管壁厚度减薄率，
    其中：K＝(δ 1-δ 2)/H (4)
    式(4)中，δ 1为前次测得的管壁厚度，H为前次与当前管壁测厚之间的时间；
    步骤五、如判断为水冷壁管，在评估水冷壁管的剩余寿命时，如果其管壁金属温度未超过材料的蠕变温度，则按常温强度校核理论进行剩余寿命的计算，具体计算方法同省煤器管剩余寿命一致，按壁厚减薄率进行评估预测；如果其管壁金属温度超过材料的蠕变温度，则需考虑高温蠕变对寿命的影响，计算方法与过热器管剩余寿命计算一致；
    步骤六、可视交互平台以曲线和/或三维造型输出热交换管剩余寿命的计算结果，并发出剩余寿命预警信号，提供剩余寿命控制措施及生物质燃料锅炉热交换管检修作业计划。
  3. 根据权利要求2所述的生物质燃料锅炉热交换管寿命的评估方法，其特征在于：按评估计算的生物质燃料锅炉热交换管的剩余寿命，若剩余寿命＜3年，则在一年内计划大修，并根据测厚结果进行修补或更换；若6年≤剩余寿命＜9年，则在一年后但在三年内计划大修，并根据测厚结果进行修补或更换；若剩余寿命≥9年，则在下一次计划检修中予以详细的测厚检查。
  4. 根据权利要求2或3所述的生物质燃料锅炉热交换管寿命的评估方法，其特征在于：步骤二中被测热交换管壁厚处的烟气温度为540～750℃时判断为540～750℃、295～540℃时判断为省煤器管、750-850℃时判断为水冷壁管。
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