加氢反应器接管法兰密封槽失效原因分析及改进措施  

Failure analysis and improvement measures of hydrogenation reactor flange sealing groove

作　　者：张春义 朱戈 田志勇 宋明[1] 都亮[1,3] 吴远建 ZHANG Chunyi;ZHU Ge;TIAN Zhiyong;SONG Ming;DU Liang;WU Yuanjian(China Special Equipment Inspection and Research Institute,Beijing 100029,China;Oil and Gas Pipeline and Storage Equipment Safety for State Market Regulation,Technology Innovation Center,Beijing 100029,China;Zhenhai Refining&Chemical Company,SINOPEC,Ningbo Zhejiang 315207,China)

机构地区：[1]中国特种设备检测研究院,北京100029 [2]国家市场监管技术创新中心油气管道与储存设备安全,北京100029 [3]中国石油化工股份有限公司镇海炼化分公司,浙江宁波315207

出　　处：《中国安全科学学报》2024年第12期100-107,共8页China Safety Science Journal

基　　金：横向课题(K-20-I01);“十三五”国家科技攻关项目(2018YFC0808600)。

摘　　要：为预防加氢反应器法兰密封槽失效发生事故,采用宏观检查、断口分析、铁素体检测、化学成分分析、硬度检测、金相检测、扫描电镜(SEM)分析以及操作过程分析等失效分析方法,研究损伤模式、开停工操作过程、堆焊层铁素体含量、材料性能及异常元素等影响因素,分析加氢反应器出口接管法兰密封槽失效原因。结果表明:密封槽失效主要是由于密封槽堆焊层与母材之间存在较高应力,在含氟、硫等元素的腐蚀介质作用下产生应力腐蚀开裂;开裂法兰密封槽底面存在无堆焊层,穿晶裂纹起裂于表面堆焊层与无堆焊层的交界处,以在无堆焊层侧表面起裂为主。针对失效原因,从制造、选材、维护等方面提出相应的改进措施。In order to prevent accidents caused by the failure of the flange sealing groove in the hydrogenation reactor,failure analysis methods such as macroscopic inspection,fracture analysis,ferrite detection,chemical composition analysis,hardness detection,metallographic detection,SEM analysis and operation process analysis were adopted.The influencing factors of damage mode,start-stop operation process,ferrite content in the weld overlay layer,material properties,and abnormal elements were studied,and the reasons for the failure of the flange sealing groove at the outlet of the hydrogenation reactor were analyzed.The results indicate that the failure of the sealing groove is mainly due to the high stress between the weld overlay layer and base metal of the sealing groove,which produces stress corrosion cracking under the action of a corrosive medium containing F,S and other elements.There is no weld overlay layer on the bottom surface of the cracked flange sealing groove,and the transgranular cracks started at the junction of the surface weld overlay layer and the non-weld overlay layer,mainly on the surface of the non-weld overlay layer side.According to the failure causes,the corresponding improvement measures are put forward from the aspects of manufacturing,material selection and maintenance.

关 键 词：加氢反应器 法兰密封槽 失效原因 扫描电镜(SEM) 堆焊层 应力腐蚀开裂 

分 类 号：X937[环境科学与工程—安全科学]