A furnace tube integrity management system and method

Abstract

This invention relates to an integrity management system and method for heating furnace tubes. It stores basic furnace tube data through a basic data storage and management module, generates a visual furnace tube arrangement diagram, and allows for data querying, editing, and modification. A furnace tube detection and monitoring result recording and management module stores and manages historical detection and monitoring data. A furnace tube safety life assessment module evaluates the damage status, safety status, and remaining life of the furnace tubes based on the basic data, historical detection data, and historical monitoring data, providing early warnings for tubes with excessive damage, abnormal safety status, or insufficient remaining life. A furnace tube process integrity operation module sets safety boundaries for process operating temperature parameters and provides early warnings for tubes whose metal wall temperature monitoring values ​​exceed these safety boundaries. This system enables visualized management of the entire lifecycle data of furnace tubes within the heating furnace, dynamically monitoring various status information of the furnace tubes, and improving the management level of the entire furnace tube lifecycle.

Description

Technical Field

[0001] This invention relates to the field of furnace tube integrity management technology, and in particular to a furnace tube integrity management system and method. Background Technology

[0002] Large-scale heating furnaces are essential and widely used equipment in petrochemical enterprises. The furnace tube system is a crucial component of the furnace. Exposed to harsh operating environments of flame, flue gas, high temperatures, and the pressure and corrosion of the internal media, furnace tubes are highly susceptible to failures such as carburizing cracking, bending, creep cracking, thermal fatigue cracking, bulging, oxidation, and high-temperature sulfur corrosion. These failures not only lead to unplanned shutdowns and significant economic losses, but also cause gas leaks and potential safety hazards during operation. Furthermore, the investment cost of the furnace tube system accounts for approximately 50% of the total investment cost of a heating furnace. High-level management of the furnace tubes can extend their service life and allow for more efficient replacement cycles, thereby saving the company substantial costs.

[0003] Mechanical integrity, also known as equipment integrity (MI), refers to maintaining process equipment in a state that meets its specific service functions from its initial installation until the end of its service life. It is a management system used to ensure the continued durability and functionality of equipment throughout its lifecycle. For pressure vessels and industrial pipelines in petrochemical plants, the common equipment integrity management method is risk-based inspection (RBI); while for rotating equipment such as pumps and compressors, the method is reliability-centered maintenance (RCM). Both types of equipment have relatively complete risk assessment and management methods, and mature software systems for implementing integrity management and evaluation techniques for each piece of equipment. However, for heating furnaces, there is currently a lack of systematic integrity management and evaluation techniques and systems. Due to the large number of furnace tubes, equipment managers generally only understand the overall operation of the furnace, but lack detailed assessments and management measures for the quality, historical operation, safety status, and lifespan of each individual furnace tube, leading to problems such as furnace tube lifespan significantly shorter than expected. Summary of the Invention

[0004] The purpose of this invention is to provide an integrity management system and method for heating furnace tubes, which can visualize and manage the full life cycle data of each furnace tube in the heating furnace, dynamically grasp the status information of various furnace tubes, and thus improve the management level of the full life cycle of furnace tubes.

[0005] To achieve the above objectives, the present invention provides the following solution:

[0006] This invention provides an integrity management system for heating furnace tubes, the system comprising:

[0007] The furnace tube basic data storage and management module is used to store the basic data of the heating furnace and each furnace tube in the heating furnace, generate a visual furnace tube arrangement diagram, and query, edit and modify the data of the furnace tubes according to the furnace tube arrangement diagram; the basic data includes design data, manufacturing data and usage data;

[0008] The furnace tube inspection, monitoring result recording and management module is used to store and manage historical inspection data and historical monitoring data for each furnace tube of the heating furnace; the historical inspection data includes inspection items and inspection results; the historical monitoring data includes monitoring items and monitoring results.

[0009] The furnace tube safety life assessment module is used to assess the damage status, safety status and remaining life of each furnace tube based on the basic data, historical test data and historical monitoring data of the furnace tube, and to issue early warnings for furnace tubes with excessive damage status, abnormal safety status or insufficient remaining life.

[0010] The furnace tube process integrity operation module is used to set safety boundaries for process operation temperature parameters for each furnace tube and to issue early warnings for furnace tubes whose metal wall temperature monitoring values ​​exceed the safety boundary values.

[0011] Optionally, the furnace tube basic data storage and management module specifically includes:

[0012] The data storage unit is used to store basic data of the heating furnace and furnace tubes; the basic data is divided into enterprise information, equipment information, heating furnace information and furnace tube information according to hierarchy.

[0013] The furnace tube arrangement and quantity determination unit is used to determine the furnace tube arrangement, the number of furnace tube columns, and the number of furnace tube rows; the furnace tube arrangement includes vertical or horizontal arrangements.

[0014] The furnace tube arrangement diagram generation unit is used to generate a top-view or side-view furnace tube arrangement diagram based on the arrangement method, the number of furnace tube columns, and the number of furnace tube rows; the furnace tube arrangement diagram is a two-dimensional matrix diagram of furnace tube arrangement;

[0015] The furnace tube information management unit is used to query, edit, and modify data on the furnace tubes on the furnace tube arrangement diagram.

[0016] Optionally, the furnace tube detection, monitoring result recording and management module specifically includes:

[0017] The test result recording unit is used to manually or in batches enter the test items and corresponding test results of each furnace tube on the furnace tube arrangement diagram according to the test time; the test items include macroscopic inspection, wall thickness measurement, surface defect detection, buried defect detection, metallographic inspection, creep detection and carburization detection;

[0018] The monitoring result recording unit is used to record the wall temperature monitoring results and pressure monitoring results of each furnace tube according to the monitoring time, either by manual reading or by automatic input from pressure and temperature sensors.

[0019] Optionally, the furnace tube safety life assessment module specifically includes:

[0020] The test result evaluation unit is used to evaluate and verify the damage status of the furnace tube based on the test results.

[0021] The strength verification and evaluation unit is used to verify and evaluate the remaining strength of the furnace tube based on the test results, monitoring results, and elastic stress theory; the remaining strength and the test results are used to characterize the safety status of the furnace tube.

[0022] The remaining life assessment unit is used to verify and assess the creep remaining life of the furnace tube based on the test results, monitoring results, and creep cumulative damage theory.

[0023] Optionally, the furnace tube process integrity operation module specifically includes:

[0024] The safety boundary setting unit is used to calculate the critical operating temperature of the furnace tube under the set creep remaining life condition based on the furnace tube material, operating pressure and the furnace tube wall thickness and diameter data of the last test. The critical operating temperature under different set creep remaining life conditions is set as the information boundary, acceleration boundary and failure boundary of the temperature process parameter respectively.

[0025] The judgment unit is used to determine in real time whether the metal wall temperature monitoring value is higher than each safety boundary value based on the information boundary, acceleration boundary, failure boundary and metal wall temperature monitoring value;

[0026] The early warning unit is used to output different colored warning messages on the furnace tube arrangement diagram when the monitored temperature is higher than the safety boundary value.

[0027] To achieve the above objectives, the present invention also provides a method for managing the integrity of furnace tubes in a heating furnace, the method comprising:

[0028] The system stores basic data of the heating furnace and each furnace tube within it, generates a visual furnace tube arrangement diagram, and allows for data querying, editing, and modification of the furnace tubes based on this diagram. The basic data includes design data, manufacturing data, and usage data.

[0029] Store and manage historical inspection data and historical monitoring data for the heating furnace and each furnace tube; the historical inspection data includes inspection items and inspection results; the historical monitoring data includes monitoring items and monitoring results;

[0030] Based on the basic data, historical test data, and historical monitoring data of the furnace tubes, assess the damage status, safety status, and remaining life of each furnace tube, and issue early warnings for furnace tubes with excessive damage, abnormal safety status, or insufficient remaining life.

[0031] A safety boundary for the process operating temperature parameters is set for each furnace tube, and the metal wall temperature of the furnace tube is monitored in real time. An early warning is issued for furnace tubes whose metal wall temperature exceeds the safety boundary value.

[0032] Optionally, the storage of basic data for the heating furnace and each furnace tube within it, generating a visual furnace tube arrangement diagram, and querying, editing, and modifying the furnace tube data based on the furnace tube arrangement diagram specifically includes:

[0033] Store basic data of the heating furnace and furnace tubes; the basic data is divided into enterprise information, equipment information, heating furnace information and furnace tube information according to hierarchy;

[0034] The arrangement of furnace tubes, the number of columns of furnace tubes, and the number of rows of furnace tubes are determined; the arrangement of furnace tubes may be vertical or horizontal.

[0035] Based on the arrangement method, the number of furnace tube columns, and the number of furnace tube rows, a top-view or side-view furnace tube arrangement diagram is generated; the furnace tube arrangement diagram is a two-dimensional matrix diagram of furnace tube arrangement;

[0036] The furnace tubes can be queried, edited, and modified on the furnace tube arrangement diagram.

[0037] Optionally, the storage and management of historical detection data and historical monitoring data of the heating furnace and each furnace tube specifically includes:

[0038] According to the testing time, the testing items and corresponding test results for each furnace tube are manually or in batches entered on the furnace tube arrangement diagram; the testing items include macroscopic inspection, wall thickness measurement, surface defect detection, buried defect detection, metallographic inspection, creep detection and carburization detection;

[0039] According to the monitoring time, the wall temperature monitoring results and pressure monitoring results of each furnace tube are recorded by manual reading or automatic input by pressure and temperature sensors.

[0040] Optionally, the assessment of the test results, safety status, and remaining lifespan of each furnace tube based on its basic data, historical test data, and historical monitoring data specifically includes:

[0041] Based on the test results of the furnace tubes, the damage status of the furnace tubes is assessed and verified;

[0042] Based on the test results and monitoring results of the furnace tube, as well as the elastic stress theory, the remaining strength of the furnace tube is checked and evaluated; the remaining strength and the test results are used to characterize the safety status of the furnace tube.

[0043] Based on the test results and monitoring results of the furnace tubes, as well as the theory of creep cumulative damage, the remaining creep life of the furnace tubes is checked and evaluated.

[0044] Optionally, the step of setting a safety boundary for the process operating temperature parameters for each furnace tube, monitoring the metal wall temperature of the furnace tube in real time, and issuing an early warning for furnace tubes whose metal wall temperature exceeds the safety boundary value specifically includes:

[0045] Based on the furnace tube material, operating pressure, and the furnace tube wall thickness and diameter data from the previous test, the critical operating temperature of the furnace tube under the set creep remaining life condition is calculated, and the critical operating temperature under different set creep remaining life conditions is set as the information boundary, acceleration boundary, and failure boundary of the temperature process parameter, respectively.

[0046] Based on the aforementioned information boundaries, acceleration boundaries, failure boundaries, and metal wall temperature monitoring values, it is determined in real time whether the metal wall temperature monitoring values ​​are higher than each safety boundary value;

[0047] When the monitored temperature exceeds the safety boundary value, different colored warning messages are output on the furnace tube arrangement diagram.

[0048] According to specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0049] This invention provides an integrity management system and method for heating furnace tubes. The system includes: a furnace tube basic data storage and management module for storing basic data of the heating furnace and each furnace tube within it, generating a visualized furnace tube arrangement diagram, and querying, editing, and modifying data for the furnace tubes based on the diagram; a furnace tube detection, monitoring result recording, and management module for storing and managing historical detection and monitoring data for the heating furnace and each furnace tube; a furnace tube safe life assessment module for assessing the damage status, safety status, and remaining life of each furnace tube based on its basic data, historical detection data, and historical monitoring data, and issuing warnings for furnace tubes with excessive damage, abnormal safety status, or insufficient remaining life; and a furnace tube process integrity operation module for setting safety boundaries for process operation temperature parameters for each furnace tube and issuing warnings for furnace tubes whose metal wall temperature monitoring values ​​exceed the safety boundary values. This invention enables visualized management of the entire lifecycle data of each furnace tube within the heating furnace, dynamically monitoring various status information of the furnace tubes, thereby improving the management level of the entire lifecycle of the furnace tubes. Attached Figure Description

[0050] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0051] Figure 1 This is a schematic diagram of the module structure of a furnace tube integrity management system according to the present invention;

[0052] Figure 2 This is a two-dimensional visualization of the furnace tube arrangement matrix of the present invention;

[0053] Figure 3 This is a flowchart of a method for managing the integrity of furnace tubes in a heating furnace according to the present invention.

[0054] Symbol explanation:

[0055] Furnace tube basic data storage and management module-1, data storage unit-11, furnace tube arrangement and quantity determination unit-12, furnace tube arrangement diagram generation unit-13, furnace tube information management unit-14, furnace tube detection and monitoring result recording and management module-2, detection result recording unit-21, monitoring result recording unit-22, furnace tube safe life assessment module-3, detection result assessment unit-31, strength verification assessment unit-32, remaining life assessment unit-33, furnace tube process integrity operation module-4, safety boundary setting unit-41, judgment unit-42, early warning unit-43. Detailed Implementation

[0056] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0057] The purpose of this invention is to provide an integrity management system and method for heating furnace tubes, which can visualize and manage the full life cycle data of each furnace tube in the heating furnace, dynamically grasp the status information of various furnace tubes, and thus improve the management level of the full life cycle of furnace tubes.

[0058] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0059] like Figure 1As shown, the present invention provides an integrity management system for heating furnace tubes, the system comprising: a furnace tube basic data storage and management module 1, a furnace tube detection, monitoring result recording and management module 2, a furnace tube safe life assessment module 3, and a furnace tube process integrity operation module 4.

[0060] The furnace tube basic data storage and management module 1 is used to store the basic data of the heating furnace and each furnace tube in the heating furnace, generate a visual furnace tube arrangement diagram, and query, edit and modify the data of the furnace tubes according to the furnace tube arrangement diagram, as well as realize the subsequent evaluation of individual furnace tubes; the basic data includes design data, manufacturing data and usage data.

[0061] The furnace tube detection, monitoring result recording and management module 2 is used to store and manage historical detection data and historical monitoring data of the heating furnace and each furnace tube of the heating furnace; the historical detection data includes detection items and detection results; the historical monitoring data includes monitoring items and monitoring results.

[0062] The furnace tube safety life assessment module 3 is used to assess the damage status, safety status and remaining life of each furnace tube based on the basic data, historical test data and historical monitoring data of the furnace tube. It provides early warning for furnace tubes with excessive damage, abnormal safety status or insufficient remaining life, and gives a recommendation on whether to replace them.

[0063] The furnace tube process integrity operation module 4 is used to set safety boundaries for process operation temperature parameters for each furnace tube, and to issue early warnings for furnace tubes whose metal wall temperature monitoring values ​​exceed the safety boundary values, and to provide handling measures and suggestions.

[0064] Furthermore, the furnace tube basic data storage and management module 1 specifically includes:

[0065] Data storage unit 11 is used to store basic data of the heating furnace and furnace tubes. The basic data is divided into enterprise information, equipment information, heating furnace information and furnace tube information according to hierarchy. Among them, enterprise information includes enterprise name and location; equipment information includes equipment name, process description and commissioning time; heating furnace information includes heating furnace name, number, design and manufacturing unit, process temperature and pressure parameters; furnace tube information includes furnace tube arrangement, furnace tube type, number of columns, number of rows, number of each furnace tube, material, wall thickness, diameter, length, medium, design temperature, design pressure, operating temperature, operating pressure and other information.

[0066] The furnace tube arrangement and quantity determination unit 12 is used to determine the furnace tube arrangement, the number of furnace tube columns, and the number of furnace tube rows; the furnace tube arrangement includes vertical or horizontal arrangement.

[0067] The furnace tube arrangement diagram generation unit 13 is used to generate a top-view or side-view furnace tube arrangement diagram based on the arrangement method, the number of furnace tube columns, and the number of furnace tube rows; the furnace tube arrangement diagram is a two-dimensional matrix diagram of furnace tube arrangement;

[0068] The furnace tube information management unit 14 is used to query, edit, and modify data on the furnace tubes on the furnace tube arrangement diagram.

[0069] The furnace tube information interface in module 1, which is part of the furnace tube basic data storage and management module, requires the user to first select the arrangement of the furnace tubes as vertical or horizontal, and then select the furnace tube type, including convection section DL, upper manifold SJ, upper tail tube SW, radiation section FS, lower tail tube XW, lower manifold XJ, cold wall tube LB, etc. After selection, the user enters the number of furnace tube columns and rows, based on which the computer automatically generates a two-dimensional visual furnace tube arrangement matrix diagram, such as... Figure 2 As shown; finally, select each furnace tube on the furnace tube arrangement diagram, enter the furnace tube information interface, and enter the relevant furnace tube information.

[0070] Furthermore, the furnace tube detection, monitoring result recording and management module 2 specifically includes:

[0071] The test result recording unit 21 is used to manually or in batches enter the test items and corresponding test results of each furnace tube on the furnace tube arrangement diagram according to the test time; the test items include macroscopic inspection, wall thickness measurement, surface defect detection, buried defect detection, metallographic inspection, creep detection and carburizing detection.

[0072] The monitoring result recording unit 22 is used to record the wall temperature monitoring results and pressure monitoring results of each furnace tube according to the monitoring time, either by manual reading or by automatic input from pressure and temperature sensors.

[0073] The test results for each test item can be manually entered into the system or selected by option, as detailed below:

[0074] 1) Macroscopic inspection results include bending, severe bending, creep, corrosion, mechanical damage, etc.; 2) Wall thickness measurement results include the actual measured wall thickness value of each measuring point; 3) Surface defect detection: first select the detection type (PT, others), and the corresponding detection result is to select whether there is a defect or crack (yes, no); 4) Buried defect detection results: first select the detection type (climbing wall UT, RT, eddy current, others), and the corresponding climbing wall UT detection result is to select the detection level (A, B+, B-, C level), and the corresponding RT, eddy current and others detection results are to select whether there is a defect or crack (yes, no); 5) Metallographic inspection results: select the detection level (1-5 levels); 6) Creep detection results include the actual measured outer diameter value of each measuring point; 7) Carburizing detection results include the actual measured carburized layer thickness value of each measuring point.

[0075] Furthermore, the furnace tube safety life assessment module 3 specifically includes:

[0076] The test result evaluation unit 31 is used to evaluate and verify the damage status of the furnace tube based on the test results of the furnace tube.

[0077] The strength verification and evaluation unit 32 is used to verify and evaluate the remaining strength of the furnace tube based on the test results, monitoring results, and elastic stress theory; the remaining strength and the test results are used to characterize the safety status of the furnace tube.

[0078] The remaining life assessment unit 33 is used to verify and assess the creep remaining life of the furnace tube based on the test results of the furnace tube, the monitoring results of the furnace tube, and the creep cumulative damage theory.

[0079] The inspection result evaluation unit 31 evaluates and verifies the inspection results of the furnace tubes, as follows: 1) Buried defect inspection results: When the wall climbing UT inspection result is Grade C, the evaluation and verification result is unsuccessful, and replacement is recommended; 2) Macroscopic inspection results: When the macroscopic inspection result is "severe bending", the evaluation and verification result is unsuccessful, and replacement is recommended; 3) Creep inspection results: When the creep rate calculated from the tube outer diameter measurement is 2%-5%, or when the creep rate doubles compared to the previous cycle, the evaluation and verification result is unsuccessful, and replacement is recommended; 4) Surface defect inspection results: When the inspection result shows cracks, the evaluation and verification result is unsuccessful, and replacement is recommended; 5) Carburizing inspection results: When the carburized layer thickness accounts for more than 60% of the furnace tube wall thickness, the evaluation and verification result is unsuccessful, and replacement is recommended; 6) Metallographic inspection results: When the inspection result is Grade 5, the evaluation and verification result is unsuccessful, and replacement is recommended.

[0080] The remaining strength of the furnace tubes is checked and evaluated based on the test results, monitoring results, and elastic stress theory. This includes:

[0081] Take the maximum monitored pressure of each furnace tube as p; take the maximum measured outer diameter of the furnace tube from the previous creep test as D; take the minimum measured wall thickness of the furnace tube from the previous wall thickness measurement as δ, and automatically calculate the furnace tube stress σ according to Formula 1:

[0082]

[0083] When the furnace tube stress σ exceeds the allowable elastic stress of the material at the monitored temperature, the evaluation and verification result is deemed unsatisfactory, and replacement is recommended. The allowable elastic stress of the material at each temperature is built into the software's material database and is automatically selected based on the furnace tube material in the furnace tube's basic information.

[0084] Among them, the remaining life assessment unit 33 verifies and assesses the remaining creep life of the furnace tube based on the detection and monitoring results and the creep cumulative damage theory, specifically including:

[0085] 1) Based on the historical data of the test result recording unit 21, the computer automatically divides the entire operating cycle of the furnace tube into N segments. For example, if there are two test historical data, the operating cycle will be divided into three segments: from the commissioning date to the first test time point, from the first test time point to the second test time point, and from the second test point to the current time point.

[0086] 2) The temperature Ti and pressure pi within the i-th period are selected as the maximum values ​​of the monitoring results within that period;

[0087] 3) The wall thickness value δi within the i-th period is selected as the minimum measured wall thickness among the test results within that period;

[0088] 4) The duration ti within the i-th period is automatically calculated based on the detection time;

[0089] 5) The inner and outer diameter values ​​Di for the i-th period are selected from the maximum measured outer diameter values ​​in the test results within that period;

[0090] 6) The computer calculates the stress value σi within the i-th period according to Formula 2:

[0091]

[0092] 7) The computer automatically calculates the expected creep life tri within the i-th segment of the cycle according to Formula 3:

[0093]

[0094] Where LMP(σi) is a material-related function of σi, and C is a material creep parameter. The function and parameter are built into the software material database and are automatically selected based on the furnace tube material in the furnace tube basic information.

[0095] 8) The computer calculates the remaining creep life fraction Dc of the furnace tubes according to formula 4:

[0096]

[0097] 9) When Dc is greater than or equal to 1, the evaluation and verification result is unsuccessful, and replacement is recommended.

[0098] Finally, based on the combined evaluation and verification results of the three units, furnace tubes that fail the verification are marked with a warning in red on the furnace tube arrangement matrix diagram, and a recommendation to replace them is given.

[0099] Furthermore, the furnace tube process integrity operation module 4 specifically includes:

[0100] The safety boundary setting unit 41 is used to calculate the critical operating temperature of the furnace tube under the set creep remaining life condition based on the furnace tube material, operating pressure and the furnace tube wall thickness and diameter data of the last test, and set the critical operating temperature under different set creep remaining life conditions as the information boundary, acceleration boundary and failure boundary of the temperature process parameter respectively.

[0101] The judgment unit 42 is used to determine in real time whether the metal wall temperature monitoring value is higher than each safety boundary value based on the information boundary, acceleration boundary, failure boundary and metal wall temperature monitoring value.

[0102] The early warning unit 43 is used to output different colored early warning information on the furnace tube arrangement diagram when the monitored temperature is higher than the safety boundary value.

[0103] Specifically, the safety boundary setting unit 41 calculates the future service critical operating temperature of each furnace tube with a creep remaining life of 100,000 hours, 35,000 hours, and 5,000 hours, based on the furnace tube material, monitoring pressure, and the measured wall thickness and diameter of the previous test, according to the calculation logic of formula 2-4 in the remaining life assessment unit 33. The future service critical operating temperature corresponding to the three life times is set as the information boundary, acceleration boundary, and failure boundary of the temperature process parameter, respectively.

[0104] Among them, the information boundary represents the possibility that the long-term reliability of the furnace tube may be affected beyond this boundary, and the material may deteriorate. The critical temperature of 100,000 hours of remaining life is selected because 100,000 hours is generally the design life of the furnace tube, indicating that the design life of the furnace tube will not be affected at this temperature. The acceleration boundary represents the possibility that the furnace tube will suffer creep and other damage beyond this boundary, reducing the normal service life of the equipment. The critical temperature of 35,000 hours of remaining life is selected because 35,000 hours is generally the life of one service cycle of the furnace tube (4 years), indicating that the furnace tube can safely continue to operate for one cycle at this temperature. The failure boundary represents the possibility that the furnace tube will fail due to short-term overheating beyond this boundary, including creep fracture and a significant reduction in tensile strength. The critical temperature of 5,000 hours of remaining life is selected because 5,000 hours does not meet the conditions for one cycle of operation, but there is sufficient time to ensure the operation of the furnace tube and material preparation in the short term.

[0105] The early warning unit 42 acquires the metal wall temperature monitoring data from the safety boundaries and monitoring result recording unit 22, and determines in real time whether the monitored temperature exceeds each safety boundary value. When the furnace tube monitoring temperature exceeds the information boundary, a yellow warning message is output on the matrix diagram, and the system prompts "Pay attention to temperature monitoring, conduct expert analysis, and formulate necessary inspection plans for the over-temperature location"; when the furnace tube monitoring temperature exceeds the acceleration boundary, an orange warning message is output on the matrix diagram, and the system prompts "Warning and expert analysis should be conducted to determine the cause of the over-temperature, and temperature control should be implemented, and an inspection plan should be formulated for the over-temperature location"; when the monitoring temperature exceeds the failure boundary, a red warning message is output on the matrix diagram, and the system prompts "An early warning is required, and temperature control measures or furnace shutdown and maintenance should be taken immediately."

[0106] To achieve the above objectives, such as Figure 3 As shown, the present invention also provides a method for integrity management of furnace tubes in a heating furnace, the method comprising:

[0107] S1: Store the basic data of the heating furnace and each furnace tube in the heating furnace, generate a visual furnace tube arrangement diagram, and query, edit and modify the data of the furnace tubes according to the furnace tube arrangement diagram; the basic data includes design data, manufacturing data and usage data.

[0108] S2: Store and manage historical inspection data and historical monitoring data for the heating furnace and each furnace tube; the historical inspection data includes inspection items and inspection results; the historical monitoring data includes monitoring items and monitoring results.

[0109] S3: Based on the basic data, historical test data, and historical monitoring data of the furnace tubes, assess the damage status, safety status, and remaining life of each furnace tube, and issue early warnings for furnace tubes with excessive damage, abnormal safety status, or insufficient remaining life.

[0110] S4: Set a safety boundary for the process operating temperature parameters for each furnace tube, monitor the metal wall temperature of the furnace tube in real time, and issue an early warning for furnace tubes whose metal wall temperature exceeds the safety boundary value.

[0111] Further, in step S1, the storage of basic data for the heating furnace and each furnace tube within it, the generation of a visualized furnace tube arrangement diagram, and the querying, editing, and modification of furnace tube data based on the furnace tube arrangement diagram specifically include:

[0112] S11: Store basic data of the heating furnace and furnace tubes; the basic data is divided into enterprise information, device information, heating furnace information and furnace tube information according to hierarchy.

[0113] S12: Determine the furnace tube arrangement, the number of furnace tube columns, and the number of furnace tube rows; the furnace tube arrangement includes vertical or horizontal.

[0114] S13: Based on the arrangement method, the number of furnace tube columns and the number of furnace tube rows, generate a top-view or side-view furnace tube arrangement diagram; the furnace tube arrangement diagram is a two-dimensional matrix diagram of furnace tube arrangement.

[0115] S14: Query, edit and modify the data of the furnace tubes on the furnace tube arrangement diagram.

[0116] Further, in step S2, the storage and management of historical detection data and historical monitoring data of the heating furnace and each furnace tube specifically includes:

[0117] S21: According to the testing time, manually or in batches enter the testing items and corresponding test results of each furnace tube on the furnace tube arrangement diagram; the testing items include macroscopic inspection, wall thickness measurement, surface defect detection, buried defect detection, metallographic inspection, creep detection and carburization detection.

[0118] S22: Record the wall temperature monitoring results and pressure monitoring results of each furnace tube according to the monitoring time, either manually or automatically by pressure and temperature sensors.

[0119] Further, in step S3, the evaluation of the test results, safety status, and remaining lifespan of each furnace tube based on its basic data, historical test data, and historical monitoring data specifically includes:

[0120] S31: Based on the test results of the furnace tubes, assess and verify the damage status of the furnace tubes.

[0121] S32: Based on the test results of the furnace tube, the monitoring results of the furnace tube, and the elastic stress theory, the remaining strength of the furnace tube is checked and evaluated; the remaining strength and the test results are used to characterize the safety status of the furnace tube.

[0122] S33: Based on the test results of the furnace tube, the monitoring results of the furnace tube, and the theory of creep cumulative damage, the creep remaining life of the furnace tube is checked and evaluated.

[0123] Further, in step S4, setting a safety boundary for the process operating temperature parameters for each furnace tube, monitoring the metal wall temperature of the furnace tube in real time, and issuing an early warning for furnace tubes whose metal wall temperature exceeds the safety boundary value specifically includes:

[0124] S41: Based on the furnace tube material, operating pressure, and the furnace tube wall thickness and diameter data from the previous test, calculate the critical operating temperature of the furnace tube under the set creep remaining life condition, and set the critical operating temperature under different set creep remaining life conditions as the information boundary, acceleration boundary, and failure boundary of the temperature process parameter, respectively.

[0125] S42: Based on the information boundary, acceleration boundary, failure boundary and metal wall temperature monitoring value, determine in real time whether the metal wall temperature monitoring value is higher than each safety boundary value.

[0126] S43: When the monitored temperature is higher than the safety boundary value, output different colored warning information on the furnace tube arrangement diagram.

[0127] Technical effects of the present invention:

[0128] (1) A new method for managing the full life cycle data of each furnace tube by automatically generating a two-dimensional matrix diagram by computer has been established, which makes the management of furnace tubes more refined, visualized and convenient, and is conducive to the accumulation and effective use of historical data of each furnace tube.

[0129] (2) By storing historical detection and monitoring data and incorporating built-in evaluation and verification calculation logic, the computer can automatically perform evaluation and verification calculations based on the detection and monitoring results, saving a lot of manual evaluation time and greatly improving evaluation efficiency and accuracy.

[0130] (3) It integrates three methods, namely, test result verification and evaluation, strength verification and evaluation, and creep remaining life verification and evaluation, which can comprehensively evaluate various failure modes such as furnace tube strength failure and creep failure, and can more accurately provide early warning of the safety status of furnace tubes, thus avoiding sudden failure and unplanned shutdown of the heating furnace.

[0131] (4) A method for setting the acceleration boundary and failure boundary of furnace tube temperature process parameters and a computer real-time early warning module were established. This can provide timely early warning for typical problems such as furnace tube overheating, thereby avoiding accelerated damage and failure of furnace tubes, extending the service life of furnace tubes, and improving the economic benefits of enterprises.

[0132] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0133] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. An integrity management system for a furnace tube of a heating furnace, characterized by, The system includes: The furnace tube basic data storage and management module is used to store the basic data of the heating furnace and each furnace tube in the heating furnace, generate a visual furnace tube arrangement diagram, and query, edit and modify the data of the furnace tubes according to the furnace tube arrangement diagram; the basic data includes design data, manufacturing data and usage data; The furnace tube inspection, monitoring result recording and management module is used to store and manage historical inspection data and historical monitoring data for each furnace tube of the heating furnace; the historical inspection data includes inspection items and inspection results; the historical monitoring data includes monitoring items and monitoring results. The furnace tube safety life assessment module is used to assess the damage status, safety status and remaining life of each furnace tube based on the basic data, historical test data and historical monitoring data of the furnace tube, and to issue early warnings for furnace tubes with excessive damage status, abnormal safety status or insufficient remaining life. The furnace tube process integrity operation module is used to set safety boundaries for process operation temperature parameters for each furnace tube and to issue early warnings for furnace tubes whose metal wall temperature monitoring values ​​exceed the safety boundary values. The furnace tube basic data storage and management module specifically includes: The data storage unit is used to store basic data of the heating furnace and furnace tubes. The basic data is divided into enterprise information, equipment information, heating furnace information and furnace tube information according to the hierarchy. The furnace tube types include convection section DL, upper manifold SJ, upper tail tube SW, radiation section FS, lower tail tube XW, lower manifold XJ or cold wall tube LB. The furnace tube arrangement and quantity determination unit is used to determine the furnace tube arrangement, the number of furnace tube columns, and the number of furnace tube rows; the furnace tube arrangement includes vertical or horizontal arrangements. The furnace tube arrangement diagram generation unit is used to generate a top-view or side-view furnace tube arrangement diagram based on the arrangement method, the number of furnace tube columns, and the number of furnace tube rows; the furnace tube arrangement diagram is a two-dimensional matrix diagram of furnace tube arrangement; The furnace tube information management unit is used to query, edit, and modify data on the furnace tubes in the furnace tube arrangement diagram; The furnace tube detection, monitoring result recording and management module specifically includes: The test result recording unit is used to manually or in batches enter the test items and corresponding test results for each furnace tube on the furnace tube arrangement diagram according to the test time. The test items include macroscopic inspection, wall thickness measurement, surface defect detection, buried defect detection, metallographic inspection, creep detection, and carburizing detection. The buried defect detection includes wall-climbing UT detection, and the corresponding test results for wall-climbing UT detection are divided into grade A, grade B+, grade B-, and grade C. When the wall-climbing UT test result is grade C, the evaluation and verification result is "fail". The carburizing detection includes entering the measured value of the carburized layer thickness. When the carburized layer thickness accounts for more than 60% of the furnace tube wall thickness, the evaluation and verification result is "fail". The monitoring result recording unit is used to record the wall temperature monitoring results and pressure monitoring results of each furnace tube according to the monitoring time, either by manual reading or by automatic input from pressure and temperature sensors. The furnace tube safety life assessment module specifically includes: The test result evaluation unit is used to evaluate and verify the damage status of the furnace tube based on the test results. The strength verification and evaluation unit is used to verify and evaluate the remaining strength of the furnace tube based on the test results, monitoring results, and elastic stress theory; the remaining strength and the test results are used to characterize the safety status of the furnace tube. The remaining life assessment unit is used to verify and assess the creep remaining life of the furnace tube based on the test results, monitoring results, and creep cumulative damage theory. The furnace tube process integrity operation module specifically includes: The safety boundary setting unit is used to calculate the critical operating temperature of the furnace tube under the set creep remaining life condition based on the furnace tube material, operating pressure, and the furnace tube wall thickness and diameter data from the last test. The critical operating temperature under different set creep remaining life conditions is set as the information boundary, acceleration boundary, and failure boundary of the temperature process parameter, respectively. Specifically, the unit calculates the future service critical operating temperature of each furnace tube with a creep remaining life of 100,000 hours, 35,000 hours, and 5,000 hours, and sets the future service critical operating temperature corresponding to the three life time as the information boundary, acceleration boundary, and failure boundary of the temperature process parameter, respectively. The judgment unit is used to determine in real time whether the metal wall temperature monitoring value is higher than each safety boundary value based on the information boundary, acceleration boundary, failure boundary and metal wall temperature monitoring value; The early warning unit is used to output different colored warning messages on the furnace tube arrangement diagram when the monitored temperature is higher than the safety boundary value.

2. A method of integrity management of a furnace tube of a heating furnace, characterized by, The method includes: The system stores basic data of the heating furnace and each furnace tube within it, generates a visual furnace tube arrangement diagram, and allows for data querying, editing, and modification of the furnace tubes based on this diagram. The basic data includes design data, manufacturing data, and usage data. Store and manage historical inspection data and historical monitoring data for the heating furnace and each furnace tube; the historical inspection data includes inspection items and inspection results; the historical monitoring data includes monitoring items and monitoring results; Based on the basic data, historical test data, and historical monitoring data of the furnace tubes, assess the damage status, safety status, and remaining life of each furnace tube, and issue early warnings for furnace tubes with excessive damage, abnormal safety status, or insufficient remaining life. A safety boundary for the process operating temperature parameters is set for each furnace tube, and the metal wall temperature of the furnace tube is monitored in real time. An early warning is issued for furnace tubes whose metal wall temperature exceeds the safety boundary value. The system stores basic data on the heating furnace and each furnace tube within it, generates a visual furnace tube arrangement diagram, and allows for data querying, editing, and modification of the furnace tubes based on this diagram. Specifically, this includes: Store basic data of the heating furnace and furnace tubes; the basic data is divided into enterprise information, equipment information, heating furnace information and furnace tube information according to hierarchy; The arrangement of furnace tubes, the number of columns of furnace tubes, and the number of rows of furnace tubes are determined; the arrangement of furnace tubes may be vertical or horizontal. Based on the arrangement method, the number of furnace tube columns, and the number of furnace tube rows, a top-view or side-view furnace tube arrangement diagram is generated; the furnace tube arrangement diagram is a two-dimensional matrix diagram of furnace tube arrangement; The furnace tubes can be queried, edited, and modified on the furnace tube arrangement diagram. The storage and management of historical detection data and historical monitoring data for the heating furnace and each furnace tube specifically includes: According to the testing time, the testing items and corresponding test results for each furnace tube are manually or batch-entered on the furnace tube arrangement diagram. The testing items include macroscopic inspection, wall thickness measurement, surface defect detection, embedded defect detection, metallographic inspection, creep detection, and carburizing detection. The embedded defect detection includes wall-climbing UT detection, and the corresponding test results for wall-climbing UT detection are divided into Grade A, Grade B+, Grade B-, and Grade C. When the wall-climbing UT test result is Grade C, the evaluation and verification result is "fail". The carburizing detection includes entering the measured value of the carburized layer thickness. When the carburized layer thickness accounts for more than 60% of the furnace tube wall thickness, the evaluation and verification result is "fail". According to the monitoring time, the wall temperature monitoring results and pressure monitoring results of each furnace tube are recorded by manual reading or automatic input by pressure and temperature sensors. The assessment of the inspection results, safety status, and remaining lifespan of each furnace tube based on its basic data, historical inspection data, and historical monitoring data specifically includes: Based on the test results of the furnace tubes, the damage status of the furnace tubes is assessed and verified; Based on the test results and monitoring results of the furnace tube, as well as the elastic stress theory, the remaining strength of the furnace tube is checked and evaluated; the remaining strength and the test results are used to characterize the safety status of the furnace tube. Based on the test results of the furnace tubes, the monitoring results of the furnace tubes, and the theory of creep cumulative damage, the creep remaining life of the furnace tubes is checked and evaluated. The process of setting safety boundaries for the operating temperature parameters of each furnace tube, monitoring the metal wall temperature of the furnace tube in real time, and issuing an early warning for furnace tubes whose metal wall temperature exceeds the safety boundary value specifically includes: Based on the furnace tube material, operating pressure, and the furnace tube wall thickness and diameter data from the previous test, the critical operating temperature of the furnace tube under the set creep remaining life condition is calculated, and the critical operating temperature under different set creep remaining life conditions is set as the information boundary, acceleration boundary, and failure boundary of the temperature process parameter, respectively. Based on the information boundary, acceleration boundary, failure boundary, and metal wall temperature monitoring value, it is determined in real time whether the metal wall temperature monitoring value is higher than each safety boundary value; wherein, the future service critical operating temperature of each furnace tube with a creep remaining life of 100,000 hours, 35,000 hours, and 5,000 hours is calculated, and the future service critical operating temperature corresponding to the three life times is set as the information boundary, acceleration boundary, and failure boundary of the temperature process parameter, respectively. When the monitored temperature exceeds the safety boundary value, different colored warning messages are output on the furnace tube arrangement diagram.

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