催化裝置油氣分離器環(huán)焊縫斷口分析
發(fā)布時間：2018-11-03 16:56
【摘要】：某石化公司催化裝置氣壓機出口油氣分離器R1341為二類臥式壓力容器,1974年12月設計,1984年10月隨裝置開工投入運行。2008年12月,油氣分離器R1341在運行中發(fā)現筒體環(huán)焊縫下部位置出現2條橫向裂紋,采用鐵膠泥鉚固方案進行了處理。之后一個月內該容器環(huán)縫又出現6處橫向裂紋,均用前述方案進行處理。2009年2月中旬,催化裝置停工消缺,油氣分離器R1341停運更新。在開裂環(huán)焊縫上切取含有二條裂紋(間距450mm)的部分,切700mm×400mm壁板一塊作為油氣分離器試驗分析樣品,分別在樣品壁板的焊縫、母材部位取相應試件進行宏觀檢查、化學成份、金相觀察、硬度測試、拉伸、沖擊試驗、斷口形貌觀察、微區(qū)EDS分析等理化分析�；瘜W成份分析結果表明,筒體鋼板和焊縫金屬中均具有較高的S、P含量,能譜分析結果也證實了裂紋縫隙中確實有MnS夾雜物的存在。由此可見,在濕硫化氫環(huán)境中該設備筒體鋼板和焊縫發(fā)生HIC是不可避免的。近年來該石化公司加工的高含硫原油數量不斷增加,導致油氣分離器R1341工藝介質中H2S濃度不斷上升,隨著介質中硫化氫含量的提升,反應產生的H離子數目顯著增多,氫離子附著到容器表面轉換為氫原子并擴散到鋼材質中。接下來,這些氫原子首先聚集在金屬的焊縫及容器原材料的工藝缺陷(特別是硫化錳雜質)處合成氫分子,氫原子化合成為氫分子后,最終引起了該處氫致開裂(HIC)現象的發(fā)生。該石化公司生產裝置原設計為低硫原油,材質等級較低。從84年開工至2005年,一直加工低硫原油,設備運行基本正常。2006年以來,隨著加工原油硫含量不斷升高,設備腐蝕明顯加劇,設備現狀與實際工況出現明顯的不適應。油氣分離器R1341原設計材質為16MnR,未進行熱處理,無法滿足長期在濕硫化氫環(huán)境下運行的要求。根據以上分析結果,結合該企業(yè)生產實踐具體情況,提出以下技術改造建議。1濕硫化氫環(huán)境用設備應該更加注意設備母材的選擇,如耐硫化氫腐蝕的材料;2在設備設計制造時,選擇更優(yōu)化的工藝,有效降低材料焊縫中金屬硫和磷元素的含量。生產設備整體熱處理,降低焊縫硬度。3設備的內部全面防腐蝕處理,進一步提升設備的抗腐蝕能力;4在根源上控制腐蝕的產生,從工藝設計,設備制造,生產流程全面重視防腐蝕問題,重視工藝注水、注劑的管理。
[Abstract]:The outlet oil and gas separator R1341 of a catalytic unit of a petrochemical company is a kind of horizontal pressure vessel. It was designed in December 1974 and put into operation with the unit in October 1984. In December 2008, the oil and gas separator R1341 is a kind of horizontal pressure vessel. In operation of oil and gas separator R1341, two transverse cracks were found in the lower part of the tube girth weld, which was treated by iron cement riveting scheme. In the following month, six more transverse cracks appeared in the circumferential crack of the vessel, all of which were treated with the aforementioned scheme. In mid February 2009, the catalytic unit was shut down and the oil and gas separator R1341 was replaced. The part containing two cracks (spacing 450mm) was cut on the crack girth weld, and a piece of 700mm 脳 400mm wall plate was cut as the sample for the oil and gas separator test and analysis. The samples were taken from the weld seam and the base metal part of the sample wall respectively for macroscopic inspection and chemical composition. Metallographic observation, hardness test, tensile test, impact test, fracture morphology observation, microzone EDS analysis and other physicochemical analysis. The results of chemical composition analysis show that there is a high content of MnS in steel plate and weld metal, and the existence of MnS inclusions in cracks is confirmed by energy spectrum analysis. It can be seen that HIC is inevitable in the wet hydrogen sulfide environment. In recent years, the quantity of high-sulfur crude oil processed by the petrochemical company has been increasing, resulting in the increasing concentration of H _ 2S in the medium of R1341 process. With the increase of hydrogen sulfide content in the medium, the number of H ~ (2 +) produced by the reaction increases significantly. Hydrogen ions are attached to the surface of the vessel and converted into hydrogen atoms and diffused into steel. Next, these hydrogen atoms first gather in the weld of the metal and at the defects of the raw materials of the container (especially manganese sulphide impurity) to synthesize hydrogen molecules, and after the hydrogen atoms combine to form hydrogen molecules, Finally, the (HIC) phenomenon of hydrogen induced cracking occurred. The production unit of the petrochemical company was originally designed for low sulfur crude oil, and its material grade is lower. Starting from 1984 to 2005, the equipment has been processing low sulfur crude oil, and the equipment operation is basically normal. Since 2006, with the increasing sulfur content of processed crude oil, the corrosion of the equipment has become more and more serious, and the present situation of the equipment is obviously unsuitable to the actual working conditions. The original design material of oil and gas separator R1341 is 16MnR, without heat treatment, it can not meet the requirements of running under wet hydrogen sulfide environment for a long time. According to the above analysis results, combined with the concrete situation of production practice in this enterprise, the following suggestions are put forward. 1 the selection of equipment base materials, such as materials resistant to corrosion of hydrogen sulfide, should be paid more attention to for wet hydrogen sulfide environment equipment; (2) when the equipment is designed and manufactured, the content of metal sulfur and phosphorus in the weld metal can be effectively reduced by selecting more optimized process. The whole heat treatment of the production equipment reduces the weld hardness. 3 the internal corrosion prevention treatment of the equipment further improves the anticorrosion ability of the equipment; (4) to control the origin of corrosion, from the aspects of process design, equipment manufacture and production process, to pay attention to corrosion prevention, process water injection and the management of injection agent.
【學位授予單位】：西安石油大學
【學位級別】：碩士
【學位授予年份】：2015
【分類號】：TE96
本文編號：2308383
[Abstract]:The outlet oil and gas separator R1341 of a catalytic unit of a petrochemical company is a kind of horizontal pressure vessel. It was designed in December 1974 and put into operation with the unit in October 1984. In December 2008, the oil and gas separator R1341 is a kind of horizontal pressure vessel. In operation of oil and gas separator R1341, two transverse cracks were found in the lower part of the tube girth weld, which was treated by iron cement riveting scheme. In the following month, six more transverse cracks appeared in the circumferential crack of the vessel, all of which were treated with the aforementioned scheme. In mid February 2009, the catalytic unit was shut down and the oil and gas separator R1341 was replaced. The part containing two cracks (spacing 450mm) was cut on the crack girth weld, and a piece of 700mm 脳 400mm wall plate was cut as the sample for the oil and gas separator test and analysis. The samples were taken from the weld seam and the base metal part of the sample wall respectively for macroscopic inspection and chemical composition. Metallographic observation, hardness test, tensile test, impact test, fracture morphology observation, microzone EDS analysis and other physicochemical analysis. The results of chemical composition analysis show that there is a high content of MnS in steel plate and weld metal, and the existence of MnS inclusions in cracks is confirmed by energy spectrum analysis. It can be seen that HIC is inevitable in the wet hydrogen sulfide environment. In recent years, the quantity of high-sulfur crude oil processed by the petrochemical company has been increasing, resulting in the increasing concentration of H _ 2S in the medium of R1341 process. With the increase of hydrogen sulfide content in the medium, the number of H ~ (2 +) produced by the reaction increases significantly. Hydrogen ions are attached to the surface of the vessel and converted into hydrogen atoms and diffused into steel. Next, these hydrogen atoms first gather in the weld of the metal and at the defects of the raw materials of the container (especially manganese sulphide impurity) to synthesize hydrogen molecules, and after the hydrogen atoms combine to form hydrogen molecules, Finally, the (HIC) phenomenon of hydrogen induced cracking occurred. The production unit of the petrochemical company was originally designed for low sulfur crude oil, and its material grade is lower. Starting from 1984 to 2005, the equipment has been processing low sulfur crude oil, and the equipment operation is basically normal. Since 2006, with the increasing sulfur content of processed crude oil, the corrosion of the equipment has become more and more serious, and the present situation of the equipment is obviously unsuitable to the actual working conditions. The original design material of oil and gas separator R1341 is 16MnR, without heat treatment, it can not meet the requirements of running under wet hydrogen sulfide environment for a long time. According to the above analysis results, combined with the concrete situation of production practice in this enterprise, the following suggestions are put forward. 1 the selection of equipment base materials, such as materials resistant to corrosion of hydrogen sulfide, should be paid more attention to for wet hydrogen sulfide environment equipment; (2) when the equipment is designed and manufactured, the content of metal sulfur and phosphorus in the weld metal can be effectively reduced by selecting more optimized process. The whole heat treatment of the production equipment reduces the weld hardness. 3 the internal corrosion prevention treatment of the equipment further improves the anticorrosion ability of the equipment; (4) to control the origin of corrosion, from the aspects of process design, equipment manufacture and production process, to pay attention to corrosion prevention, process water injection and the management of injection agent.
【學位授予單位】：西安石油大學
【學位級別】：碩士
【學位授予年份】：2015
【分類號】：TE96
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