Quantitative evaluation method for erosion damage risk of pressure-bearing equipment, equipment, medium and product

Abstract

The invention discloses a pressure-bearing equipment erosion damage risk quantitative evaluation method, equipment, a medium and a product, and relates to the field of petrochemical engineering pressure-bearing equipment safety, and the method comprises the steps: determining the damage form of the equipment; calculating a local / uniform thinning factor according to the damage form; according to the local / uniform thinning factor, the general condition factor, the mechanical factor and the process factor, calculating to obtain an equipment correction coefficient; according to the equipment correction coefficient, the management system evaluation coefficient, the average failure probability of the similar equipment and the standard exceeding defect influence coefficient, the erosion corrosion failure possibility is obtained through calculation; calculating a leakage result area; according to the leakage consequence area, the erosion corrosion failure consequence is determined; establishing a two-dimensional risk matrix graph according to the erosion corrosion failure possibility and the erosion corrosion failure consequence; the two-dimensional risk matrix graph is used for real-time quantitative evaluation of the erosion risk. The method can effectively guide erosion corrosion risk prevention and control in the petrochemical industry.

Description

Technical Field

[0001] The present invention relates to the field of safety of petrochemical and chemical pressure-bearing equipment, and in particular to a method, equipment, medium and product for quantitatively assessing the risk of erosion damage of pressure-bearing equipment. Background Art

[0002] There is often a coupling mechanism of multiphase flow erosion and corrosion in petrochemical and chemical pressure-bearing equipment, such as the erosion of acidic water and coal powder in the black ash water system of the coal gasification unit, and the erosion of acidic water and catalysts, metal fragments and other solid particles in the quenching system of the methanol to olefins unit. There is uncertainty in the local damage caused, and it is difficult to quantify the risk of erosion-corrosion coupling damage.

[0003] At present, there are few studies on the risk assessment methods of erosion-corrosion coupling damage at home and abroad, and the existing methods cannot be applied to the petrochemical and chemical fields. Most of the relevant risk assessment methods abroad come from the field of oil and gas extraction and transportation. Most of them study the erosion-corrosion damage in a simple environment of sand and water and establish erosion-corrosion coupling risk assessment methods; a typical example is the semi-quantitative erosion damage assessment method in the DNVGL-RP-O501 "Managing sand production and erosion" standard, which divides the possibility of erosion failure into 6 levels according to the fluid flow rate, and combines the daily management level of the object and different restriction requirements to assess the risk acceptability, thereby dividing it into high risk, medium risk and low risk. The API 581 "Risk Based Inspection" standard has a local damage quantitative assessment method, but lacks a prediction model for the coupling of erosion and corrosion and an assessment algorithm based on damage morphology. There is also an erosion-corrosion damage module in the Lloyd's Register API assessment software, but it is mostly applicable to risk prediction in liquefied natural gas extraction and transportation systems, and it is difficult to examine the laws of corrosion and erosion coupling damage. In China, the risk of erosion and corrosion damage is still at the stage of qualitative prediction, which is mostly based on the summary of field experience. Summary of the invention

[0004] The purpose of the present invention is to provide a method, equipment, medium and product for quantitative assessment of erosion damage risk of pressure equipment, which can effectively guide the prevention and control of erosion corrosion risks in the petrochemical industry.

[0005] To achieve the above object, the present invention provides the following solutions:

[0006] In a first aspect, the present invention provides a method for quantitatively assessing the risk of erosion damage to pressure-bearing equipment, the method comprising:

[0007] Determine the damage form of the equipment; the damage form includes: uniform damage and local damage.

[0008] Based on the damage form, the local / uniform thinning factors are calculated.

[0009] The equipment correction factor is calculated according to the local / uniform thinning factor, the general condition factor, the mechanical factor and the process factor; the general condition factor, the mechanical factor and the process factor are obtained according to API 581-2016 or GB / T 26610.4-2022 standards.

[0010] The possibility of erosion corrosion failure is calculated based on the equipment correction coefficient, management system evaluation coefficient, average failure probability of similar equipment and influence coefficient of excessive defects; the management system evaluation coefficient, average failure probability of similar equipment and influence coefficient of excessive defects are obtained according to API 581-2016 or GB / T26610.4-2022 standards.

[0011] Calculate the leakage consequence area; the leakage consequence area includes: the failure consequence area of ​​static data and the failure consequence area of ​​dynamic data.

[0012] According to the leakage consequence area, the erosion corrosion failure consequence is determined; the erosion corrosion failure consequence includes: a quantitative evaluation of the failure consequence of static data and a quantitative evaluation of the failure consequence of dynamic data.

[0013] A two-dimensional risk matrix diagram is established according to the erosion-corrosion failure possibility and the erosion-corrosion failure consequence; the two-dimensional risk matrix diagram is used for real-time quantitative assessment of erosion risk.

[0014] Optionally, determining the damage form of the device specifically includes:

[0015] Determine the action area of ​​the equipment; the action area includes: a corrosion-dominant area, an erosion-dominant area, and an erosion-corrosion synergistic action area.

[0016] Based on the action zone, the damage mode of the equipment is determined.

[0017] Optionally, when the damage form is uniform damage, calculating the local / uniform thinning factor according to the damage form specifically includes:

[0018] It is determined whether the damaged structure is a special structure, and a first determination result is obtained.

[0019] If the first judgment result is no, the uniform thinning factor is determined according to API 581-2016 or GB / T 26610.4-2022 standard.

[0020] If the first judgment result is yes, a structural correction factor is calculated according to the elbow curvature radius.

[0021] According to the structure correction factor, a uniform thinning factor is calculated.

[0022] Optionally, when the damage form is local damage, calculating the local / uniform thinning factor according to the damage form specifically includes:

[0023] It is determined whether the damaged structure is a special structure to obtain a second determination result.

[0024] If the second judgment result is no, the critical wall thickness value for failure is calculated based on the pit assessment method and the suitability for use assessment method, and the maximum value of the critical wall thickness value for failure is recorded.

[0025] The strength correction factor is determined based on the erosion corrosion local damage expansion rate prediction model, the erosion corrosion thinning severity index and the maximum value of the critical wall thickness for failure; the erosion corrosion local damage expansion rate prediction model is used to predict the expansion rate of local damage morphology over time; the erosion corrosion thinning severity index is calculated based on time, erosion corrosion rate and thickness data.

[0026] According to the strength correction factor, a local thinning factor is determined.

[0027] If the second judgment result is yes, the structure correction factor is calculated according to the elbow curvature radius.

[0028] Based on the pit assessment method and the fitness for use evaluation method, the critical wall thickness value for failure is calculated respectively, and the maximum value of the critical wall thickness for failure is recorded.

[0029] The strength correction factor is determined based on the erosion-corrosion local damage growth rate prediction model, the erosion-corrosion thinning severity index and the maximum value of the critical wall thickness for failure.

[0030] A local thinning factor is determined according to the strength correction factor and the structure correction factor.

[0031] Optionally, when the leakage consequence area is a failure consequence area of ​​static data, determining the erosion-corrosion failure consequence according to the leakage consequence area specifically includes:

[0032] According to API 581-2016 or GB / T 26610.5-2022 standards, the quantitative evaluation of failure consequences of static data is calculated.

[0033] Optionally, when the leakage consequence area is a failure consequence area of ​​dynamic data, determining the erosion-corrosion failure consequence according to the leakage consequence area specifically includes:

[0034] The evolution law of leakage hole size over time is deduced based on the prediction model of local damage expansion rate of erosion and corrosion.

[0035] According to the evolution law, the real-time predicted leakage area size is determined.

[0036] According to the real-time predicted leakage area size, a quantitative evaluation of failure consequences of dynamic data is calculated.

[0037] Optionally, the expression of the erosion-corrosion local damage extension rate prediction model is:

[0038]

[0039] Among them, Δx is the local damage expansion rate along the main flow direction, mm / a; Δy is the local damage expansion rate in the circumferential direction along the main flow direction, mm / a; Δz is the local damage expansion rate perpendicular to the main flow direction, mm / a; v is the particle impact velocity, m / s; ε s is the solid volume fraction; ε cor is the volume fraction of corrosive medium; f(·) is the thinning damage expansion function.

[0040] In a second aspect, the present invention provides a computer device comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement any of the above-described methods for quantitatively assessing the risk of erosion damage to pressure-bearing equipment.

[0041] In a third aspect, the present invention provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements any of the above-described methods for quantitatively assessing the risk of erosion damage to pressure-bearing equipment.

[0042] In a fourth aspect, the present invention provides a computer program product, including a computer program, which, when executed by a processor, implements any of the above-mentioned methods for quantitatively assessing the risk of erosion damage to pressure-bearing equipment.

[0043] According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0044] The present invention provides a method, equipment, medium and product for quantitative assessment of erosion damage risk of pressure equipment. By determining the damage form of the equipment, the local thinning factor or the uniform thinning factor can be calculated respectively. According to the local thinning factor or the uniform thinning factor, the general condition factor, the mechanical factor and the process factor, the equipment correction factor can be calculated. Then, according to the equipment correction factor, the management system evaluation factor, the average failure probability of similar equipment and the influence coefficient of the defect exceeding the standard, the possibility of erosion corrosion failure can be calculated; in addition, according to the calculated leakage consequence area, the consequence of erosion corrosion failure can be determined; finally, according to the erosion corrosion failure possibility and the erosion corrosion failure consequence, a two-dimensional risk matrix diagram is established, and the real-time quantitative assessment of erosion risk can be realized. The present invention quantitatively evaluates the possibility of equipment failure and the consequence of failure caused by erosion corrosion, and proposes a method for quantitative assessment of local damage rate, state expansion and failure risk considering the competition and synergistic acceleration of particle erosion and corrosion, which solves the problem that the risk of erosion corrosion coupling damage is difficult to quantitatively assess and deduce in a complex environment, and provides support for the setting of safety boundaries and risk prevention and control of erosion corrosion coupling damage of pressure equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0046] Figure 1 This is a diagram of the application environment of a method for quantitatively assessing erosion damage risk of pressure-bearing equipment in one embodiment of the present invention.

[0047] Figure 2 A schematic flow chart of a method for quantitatively assessing erosion damage risk of pressure-bearing equipment provided in accordance with an embodiment of the present invention.

[0048] Figure 3 A schematic flow chart of a method for quantitatively assessing the risk of erosion-corrosion damage and failure of pressure-bearing equipment in a petrochemical and chemical industry according to an embodiment of the present invention.

[0049] Figure 4 An unbalanced matrix diagram provided by an embodiment of the present invention.

[0050] Figure 5 A balance matrix diagram provided by an embodiment of the present invention.

[0051] Figure 6 A schematic diagram of the structure of a computer device provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0052] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0053] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0054] This invention is aimed at the petrochemical industry for the first time. It aims at the multiphase corrosion and scouring coupling effects in complex pressure vessels and industrial pipelines, and proposes a method for quantitatively evaluating local damage rate, state expansion and failure risk that takes into account the competition and synergistic acceleration of particle scouring and corrosion. It solves the problem that the risk of scouring-corrosion coupling damage in complex environments is difficult to quantify, evaluate and deduce, and provides support for the setting of safety boundaries and risk prevention and control of scouring-corrosion coupling damage in pressure equipment.

[0055] The method for quantitatively assessing the risk of erosion damage to pressure equipment provided by the embodiment of the present invention can be applied to Figure 1In the application environment shown. Among them, the terminal 102 communicates with the server 104 through the network. The data storage system can store the data that the server 104 needs to process. The data storage system can be set up separately, integrated on the server 104, or placed on the cloud or other servers. The terminal 102 can send the damage form of the equipment to the server 104. After the server 104 receives the damage form of the equipment, for the damage form of the equipment, the server 104 calculates the local / uniform thinning factor according to the damage form; according to the local / uniform thinning factor, the general condition factor, the mechanical factor and the process factor, the equipment correction factor is calculated; the general condition factor, the mechanical factor and the process factor are obtained according to API 581-2016 or GB / T26610.4-2022 standards; according to the equipment correction factor, the management system evaluation factor, the average failure probability of similar equipment and the influence coefficient of excessive defects, the possibility of erosion and corrosion failure is calculated; the management system evaluation coefficient, the average failure probability of similar equipment and the influence coefficient of excessive defects are calculated according to API 581-2016 or GB / T 26610.4-2022 standard; calculate the leakage consequence area; the leakage consequence area includes: the failure consequence area of ​​static data and the failure consequence area of ​​dynamic data; according to the leakage consequence area, determine the erosion corrosion failure consequence; the erosion corrosion failure consequence includes: the quantitative evaluation of the failure consequence of static data and the quantitative evaluation of the failure consequence of dynamic data; according to the erosion corrosion failure possibility and the erosion corrosion failure consequence, establish a two-dimensional risk matrix diagram; the two-dimensional risk matrix diagram is used for real-time quantitative evaluation of erosion risk. The server 104 can feed back the obtained two-dimensional risk matrix diagram to the terminal 102. In addition, in some embodiments, the method for quantitative evaluation of erosion damage risk of pressure-bearing equipment can also be implemented by the server 104 or the terminal 102 alone, such as the terminal 102 can directly perform risk quantitative evaluation on the damage form of the equipment, or the server 104 can obtain the damage form of the equipment from the data storage system and perform risk quantitative evaluation on the damage form of the equipment.

[0056] The terminal 102 may be, but is not limited to, various desktop computers, laptop computers, smart phones and tablet computers, IoT devices and portable wearable devices. IoT devices may be smart speakers, smart TVs, smart air conditioners, smart car-mounted devices, etc. Portable wearable devices may be smart watches, smart bracelets, head-mounted devices, etc. The server 104 may be implemented as an independent server or a server cluster consisting of multiple servers, or may be a cloud server.

[0057] In an exemplary embodiment, Figure 2As shown, a method for quantitatively assessing the risk of erosion damage of pressure-bearing equipment is provided. The method is executed by a computer device, and can be executed by a computer device such as a terminal or a server alone, or by a terminal and a server together. In an embodiment of the present invention, the method is applied to Figure 1 The server 104 in the example is used as an example to illustrate the method, which includes the following steps S1 to S7. Among them:

[0058] S1: Determine the damage form of the equipment; the damage form includes: uniform damage and local damage.

[0059] S2: Calculate the local / uniform thinning factor according to the damage form.

[0060] S3: The equipment correction factor is calculated based on the local / uniform thinning factor, the general condition factor, the mechanical factor and the process factor; the general condition factor, the mechanical factor and the process factor are obtained according to API 581-2016 or GB / T26610.4-2022 standards.

[0061] S4: The possibility of erosion corrosion failure is calculated based on the equipment correction factor, the management system evaluation factor, the average failure probability of similar equipment and the influence coefficient of excessive defects; the management system evaluation factor, the average failure probability of similar equipment and the influence coefficient of excessive defects are obtained according to API 581-2016 or GB / T26610.4-2022 standards.

[0062] S5: Calculate the leakage consequence area; the leakage consequence area includes: the failure consequence area of ​​static data and the failure consequence area of ​​dynamic data.

[0063] S6: Determine the erosion corrosion failure consequence according to the leakage consequence area; the erosion corrosion failure consequence includes: a quantitative evaluation of the failure consequence of static data and a quantitative evaluation of the failure consequence of dynamic data.

[0064] S7: Establish a two-dimensional risk matrix diagram according to the erosion corrosion failure possibility and the erosion corrosion failure consequence; the two-dimensional risk matrix diagram is used for real-time quantitative assessment of erosion risk.

[0065] By implementing the above-mentioned steps S1 to S7, the present invention conducts quantitative assessment from two aspects: the possibility of equipment failure caused by erosion and corrosion and the consequences of failure. It takes into account the competition between particle erosion and corrosion, the local damage rate of synergistic acceleration, state expansion, and the method of quantitative assessment of failure risk. It solves the difficult problem of difficult quantitative assessment and deduction of erosion-corrosion coupled damage risk in complex environments, and provides support for the setting of safety boundaries and risk prevention and control of erosion-corrosion coupled damage of pressure equipment.

[0066] In another exemplary embodiment of the present invention, in step S1, it specifically includes:

[0067] S101: Determine the action area of ​​the equipment; the action area includes: a corrosion-dominant area, an erosion-dominant area, and an erosion-corrosion synergistic action area.

[0068] S102: Determine the damage form of the equipment according to the action area.

[0069] like Figure 3 As shown, the present invention quantitatively evaluates the possibility of equipment failure caused by erosion corrosion and the consequences of failure. A two-dimensional risk matrix is ​​established based on the possibility of failure and the consequences of failure, and the risk levels are divided into high risk, medium-high risk, medium risk, and low risk. Among them, in terms of the possibility of erosion corrosion failure, it is necessary to identify the dominant mechanism, identify the boundary and divide the boundary area. It is newly proposed to use the erosion corrosion rate engineering prediction model and the erosion corrosion local damage expansion rate prediction model to predict the maximum erosion position and the damage morphology expansion rate respectively, and deduce the possibility of erosion corrosion failure in the future operation cycle; in terms of the consequences of erosion corrosion failure, different leakage models are selected according to the type of medium. The calculation of the leakage consequence area based on static data needs to be combined with the failure frequency and leakage model for theoretical calculation. The calculation of the leakage consequence area based on dynamic data needs to be combined with the erosion corrosion local damage expansion rate prediction model for calculation. The size of the erosion corrosion failure consequence is quantitatively evaluated by calculating the medium area consequences after failure (leakage toxicity consequences, combustion and explosion consequences) and economic consequences.

[0070] Among them, the expression of the engineering prediction model of erosion corrosion rate is:

[0071]

[0072] In the formula, R erosion is the erosion weight loss rate of the specimen, kg·m -2 ·s -1 ; K is the material constant, unit is (m·s -1 ) n1 ; f(α) is a function of the impact angle. For plastic materials, see formula (2). It can also be calibrated by experiment. ε pack is the volume fraction of dense packing, and the spherical particles are generally 0.63; ε s is the solid volume fraction; d p is the particle size; ε cor is the volume fraction of the corrosive medium; v is the particle impact velocity, m / s; n1 is the velocity factor under erosion corrosion, which is generally between 2 and 4 for simple erosion, and needs experimental calibration for coupled erosion and corrosion; n2 is the corrosion factor, which describes the synergistic acceleration effect of coupled erosion and corrosion, generally n2≤0, and needs to be calibrated experimentally according to the corrosion mechanism; R cis the radius of curvature of the elbow, m; D is the equivalent diameter of the erosion area, m; ρs is the particle density, kg / m 3 ρ face is the metal wall density, kg / m 3 ; α is the structure correction factor.

[0073] The expression of the prediction model for the local damage growth rate of erosion corrosion is:

[0074]

[0075] Among them, Δx is the local damage expansion rate along the main flow direction, mm / a; Δy is the local damage expansion rate in the circumferential direction along the main flow direction, mm / a; Δz is the local damage expansion rate perpendicular to the main flow direction, mm / a; v is the particle impact velocity, m / s; ε s is the solid volume fraction; ε cor is the volume fraction of the corrosive medium; f(·) is the thinning damage expansion function; Δx, Δy, and Δz need to be calibrated through experiments based on the material.

[0076] In another exemplary embodiment of the present invention, when the damage form is uniform damage, step S2 specifically includes:

[0077] A1: Determine whether the damaged structure is a special structure and obtain a first determination result.

[0078] A2: If the first judgment result is no, determine the uniform thinning factor according to API 581-2016 or GB / T 26610.4-2022 standard.

[0079] A3: If the first judgment result is yes, calculate the structure correction factor according to the elbow curvature radius.

[0080] A4: Based on the structural correction factor, the uniform thinning factor is calculated.

[0081] In another exemplary embodiment of the present invention, when the damage form is local damage, in step S2, the steps specifically include:

[0082] B1: Determine whether the damaged structure is a special structure and obtain a second determination result.

[0083] B2: If the second judgment result is no, based on the pit assessment method GB 19624-2004 and the compliance assessment method GB 35013-2018 or API RP 579-1-2021, the critical wall thickness value for failure is calculated respectively, and the maximum value of the critical wall thickness value for failure is recorded.

[0084] B3: Determine the strength correction factor based on the erosion corrosion local damage growth rate prediction model, the erosion corrosion thinning severity index and the maximum value of the critical wall thickness for failure; the erosion corrosion local damage growth rate prediction model is used to predict the growth rate of local damage morphology over time; the erosion corrosion thinning severity index is calculated based on time, erosion corrosion rate and thickness data.

[0085] B4: Determine the local thinning factor based on the strength correction factor.

[0086] B5: If the second judgment result is yes, calculate the structure correction factor according to the elbow curvature radius.

[0087] B6: Based on the pit assessment method GB 19624-2004 and the compliance assessment method GB 35013-2018 or APIRP 579-1-2021, calculate the critical wall thickness value for failure respectively, and record the maximum value of the critical wall thickness for failure.

[0088] B7: Determine the strength correction factor based on the erosion-corrosion local damage expansion rate prediction model, the erosion-corrosion thinning severity index and the maximum value of the critical wall thickness for failure.

[0089] B8: Determine a local thinning factor based on the strength correction factor and the structure correction factor.

[0090] In another exemplary embodiment of the present invention, when the leakage consequence area is a failure consequence area of ​​static data, step S6 specifically includes:

[0091] According to API 581-2016 or GB / T 26610.5-2022 standards, the quantitative evaluation of failure consequences of static data is calculated.

[0092] In another exemplary embodiment of the present invention, when the leakage consequence area is a failure consequence area of ​​dynamic data, step S6 specifically includes:

[0093] C1: The evolution of leakage hole size over time is deduced based on the prediction model of local damage expansion rate of erosion corrosion.

[0094] C2: Determine the real-time predicted leakage area size according to the evolution law.

[0095] C3: Based on the real-time predicted leakage area, a quantitative evaluation of failure consequences of dynamic data is calculated.

[0096] The quantitative assessment method of erosion damage risk of pressure-bearing equipment of the present invention is divided into two categories, one is static assessment based on historical detection data, and the other is dynamic assessment based on real-time data. For static risk quantitative assessment, the input data is valid data under stable conditions without adjustment of process and equipment during a maintenance period, and the input parameters include at least the original wall thickness, the wall thickness detection data of the last shutdown, the type and concentration of corrosive medium, temperature, pressure, flow rate, continuous fluid density and swirl, particle / droplet discrete phase volume fraction and hardness, inner wall material hardness, etc. For dynamic risk quantitative assessment, the input data is valid data monitored in real time within 1 to 24 hours and unchanged structural data within a single maintenance period, and the input parameters include at least the original wall thickness, real-time wall thickness detection data, corrosive medium type and concentration, temperature, pressure, flow rate, continuous fluid density and swirl, particle / droplet discrete phase volume fraction and hardness, inner wall material hardness, local structure type (such as elbow, tee, reducer) and size parameters, etc.

[0097] In another exemplary embodiment of the present invention, the possibility of erosion corrosion failure is obtained by multiplying the management system evaluation coefficient, the average failure probability of similar equipment, the equipment correction coefficient, and the influence coefficient of excessive defects, and its size is divided into five levels: 1, 2, 3, 4, and 5; wherein, the equipment correction coefficient includes 4 factors, namely, local / uniform thinning factor, general condition factor, mechanical factor, and process factor, and the size of the equipment correction coefficient is obtained by multiplying these 4 factors. The calculation method of the management system evaluation coefficient, the average failure probability of similar equipment, the influence coefficient of excessive defects, the general condition factor, the mechanical factor, and the process factor can directly refer to the API 581-2016 or GB / T 26610.4-2022 standard, and the local / uniform thinning factor needs to select the calculation model according to the damage form, and the structural correction factor needs to be added for special structures (such as elbows, tees, and reducers) to correct the erosion corrosion rate. Among them, the erosion corrosion thinning severity index ar / t (calculated by the time a, the erosion corrosion rate r, and the thickness data t) is introduced to describe the wall thickness loss rate caused by thinning. The erosion-corrosion thinning severity index needs to take into account the effects of the coupling effects of corrosion and erosion. Static risk assessment can be roughly calculated using historical wall thickness inspection data, or it can be predicted based on historical data and an engineering prediction model for erosion-corrosion rate. The model can be derived from theoretical / empirical / semi-empirical models in literature / corrosion databases and corrected by actual device inspection and monitoring data. Dynamic risk assessment needs to be calculated based on real-time monitoring data combined with an engineering prediction model for erosion-corrosion rate.

[0098] For the petrochemical acidic water erosion corrosion system, an erosion corrosion rate engineering prediction model based on a large number of field experiments is used to improve the prediction accuracy. The input parameters of the model are all parameters directly collected in engineering, including at least the original wall thickness, real-time wall thickness detection data, corrosive medium type and concentration, temperature, pressure, flow rate, continuous fluid density and rotation, particle / droplet discrete phase volume fraction and hardness, as well as the hardness of the inner wall material, local structure type (such as elbows, tees, reducers) and size parameters.

[0099] When calculating the local thinning factor according to the engineering prediction model of erosion corrosion thinning rate, it is necessary to introduce a strength correction factor to consider the failure boundary. This embodiment adopts a combination of the pit assessment GB 19624-2004 and the use-based evaluation method GB35013-2018 or API RP 579-1-2021 standard method, and takes the maximum value of the critical failure wall thickness calculated by the two. For the evolution of the local thinning factor over time, the erosion corrosion local damage expansion rate prediction model is introduced to deduce the change law of the severity index of erosion corrosion thinning in real time, thereby combining the strength theory calculation method to deduce the nonlinear change law of the local thinning factor, so as to more effectively predict the damage change law. Based on the pit assessment GB 19624-2004 and the use-based evaluation method GB 35013-2018 or API RP 579-1-2021 calculation theoretical value or a large amount of industrial detection data to determine the strength correction factor, and the local thinning factor value is corrected by the strength correction factor.

[0100] In another exemplary embodiment of the present invention, the size of the erosion-corrosion failure consequence is calculated by calculating the leakage consequence area, predicting the toxic hazard, explosion hazard, environmental cleanup cost, and economic loss after failure, and its size is divided into five levels: A, B, C, D, and E; wherein, the quantitative evaluation of the failure consequence based on static data can be directly calculated with reference to API 581-2016 or GB / T26610.5-2022 standards. For the calculation of the dynamic failure consequence area, it is necessary to deduce the evolution law of the leakage hole size over time through the erosion-corrosion local damage expansion rate prediction model, select different leakage models according to the type of medium to calculate the leakage rate in real time, use the real-time leakage rate as the input condition of the diffusion model, and predict the leakage area size in real time; the real-time leakage area size is used as the input condition for the dynamic evaluation of the area consequences (toxic consequences, combustion and explosion consequences) and economic consequences after failure, thereby realizing the dynamic quantitative evaluation of the erosion-corrosion failure consequences. Among them, the economic consequences can refer to the economic consequence algorithm in API 581-2016 or GB / T26610.5-2022 standards to calculate the series of economic losses caused by equipment failure, and classify the economic consequences into levels based on the local socio-economic level at the time and the average annual profit of the factory in recent years.

[0101] The risk of erosion corrosion failure can be expressed by a two-dimensional risk matrix diagram, with the ordinate representing the possibility level of erosion corrosion failure and the abscissa representing the consequence level of erosion corrosion failure. The risk matrix diagram can refer to the GB / T26610.1-2022 or API 581-2016 standard to select the non-equilibrium matrix diagram and the equilibrium matrix diagram for risk grading, and divide the erosion corrosion risk into four levels, namely high risk, medium-high risk, medium risk, and low risk.

[0102] The present invention solves the problem of the difficulty in quantitatively assessing and deducing the risk of erosion-corrosion coupled damage in complex environments through a quantitative assessment method for the local damage failure risk of erosion-corrosion coupled damage in petrochemical and chemical pressure-bearing equipment, and provides support for the setting of safety boundaries and risk prevention and control of erosion-corrosion coupled damage in pressure-bearing equipment.

[0103] The present invention also provides an application scenario, which applies the above-mentioned method for quantitative assessment of erosion damage risk of pressure equipment. Specifically: The method for quantitative assessment of erosion damage risk of pressure equipment provided in this embodiment can be applied in the quantitative assessment of risk of petrochemical and chemical pressure equipment. The risk quantitative assessment scenario of petrochemical and chemical pressure equipment includes a damage form determination link, a erosion corrosion failure possibility calculation link, a erosion corrosion failure consequence calculation link and a quantitative assessment link; after determining the damage form of the equipment, the thinning factor is calculated according to the damage form, and then the equipment correction factor can be calculated according to the thinning factor, and the erosion corrosion failure possibility can be calculated according to the equipment correction factor, the management system evaluation coefficient, the average failure probability of similar equipment and the excess defect influence coefficient; in addition, the erosion corrosion failure consequence can be determined by calculating the leakage consequence area; finally, a quantitative assessment can be achieved based on the erosion corrosion failure possibility and the erosion corrosion failure consequence.

[0104] In an exemplary embodiment, this implementation case is for a black water pipeline of a water-coal slurry gasification device, and a quantitative assessment of the erosion corrosion failure risk is performed based on real-time monitoring data. The material is 20 steel (SA106 Gr.B), and the phase state is liquid-solid two-phase, wherein the particle phase is coal slag, and the liquid phase is alkaline acidic water (the main medium is NH4HS, Cl-, OH-, HCO3-, etc.), wherein the NH4HS concentration is 0.1%, and the pH is 10; the flow rate is between 10 and 20 m / s, and the solid content is between 0.5 and 5%.

[0105] Based on previous experimental research and literature data, the erosion rate exceeds the critical speed of 6m / s. The service environment is a synergistic effect of erosion and corrosion, and the damage form is local thinning. The erosion and corrosion rate engineering prediction model is selected (see formula 5); among them, the erosion and corrosion rate prediction model is corrected for elbows, tees, and reducers (see formula 3).

[0106]

[0107] Based on the engineering prediction model of erosion corrosion rate, the damage rate is predicted in real time in combination with actual monitoring data, and the severity index of erosion corrosion thinning is calculated. The local erosion corrosion thinning factor is determined by considering the detection effectiveness and the number of detections with the highest category effectiveness. The proposed service time T is determined by calculating the theoretical value based on the pit assessment GB 19624-2004 and the fitness for use evaluation method GB 35013-2018 or a large amount of industrial test data. n and the remaining life T SL The ratio of the intended service time to the remaining life is used to determine the strength correction factor value (1 to 500), and this value is used to correct the local thinning factor. Among them, the remaining life needs to be predicted by the erosion local damage extension rate model (see Formula 6 below) to predict the future morphological evolution and erosion thinning severity index changes, and is estimated based on the evaluation method GB 35013-2018 or mature engineering experience.

[0108]

[0109] In the formula, since the concentration of alkaline acidic water is low, it has little effect on the damage extension rate, so ε is ignored here. cor impact.

[0110] According to the local erosion corrosion thinning factor, combined with the calculation method of general condition factor, mechanical factor and process factor in GB / T 26610.1-2022 standard, the equipment correction factor is calculated. Then, the GB / T26610.1-2022 standard method is further used to consider the management system evaluation coefficient, the average failure probability of similar equipment, the equipment correction factor, and the influence coefficient of excessive defects, so as to predict the possibility of erosion failure, and the evaluation level is 3.

[0111] According to the type and stock of hazardous media and combined with monitoring data, the erosion local damage extension rate model is used to predict the equivalent hole diameter at failure in real time, and the small hole Gaussian leakage rate model or the modified Gaussian leakage rate model is selected to calculate the current leakage area size; the GB / T 26610.1-2022 standard method is used to evaluate the area consequences and economic consequences after damage and leakage, so as to predict the current erosion failure consequences, and the evaluation level is C.

[0112] Based on the real-time erosion damage failure possibility and consequence level, a two-dimensional non-equilibrium matrix diagram is drawn, such as Figure 4 As shown, the vertical axis is the possibility of erosion corrosion failure, and the horizontal axis is the consequence of erosion corrosion failure; according to the standard type, the non-equilibrium matrix diagram and the equilibrium matrix diagram are selected as shown in Figure 5 As shown, a real-time quantitative assessment of erosion risk is conducted, and the risk level is medium risk.

[0113] In an exemplary embodiment, a computer device is provided. The computer device may be a server or a terminal. The internal structure diagram thereof may be as follows: Figure 6 As shown. The computer device includes a processor, a memory, an input / output interface (Input / Output, referred to as I / O) and a communication interface. The processor, the memory and the input / output interface are connected through a system bus, and the communication interface is connected to the system bus through the input / output interface. The processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system, a computer program and a database. The internal memory provides an environment for the operation of the operating system and the computer program in the non-volatile storage medium. The database of the computer device is used to store the damage form of the device. The input / output interface of the computer device is used to exchange information between the processor and an external device. The communication interface of the computer device is used to communicate with an external terminal through a network connection. When the computer program is executed by the processor, a method for quantitatively assessing the risk of erosion damage of pressure-bearing equipment is implemented.

[0114] Those skilled in the art will understand that Figure 6 The structure shown in the figure is only a block diagram of a part of the structure related to the solution of the present invention, and does not constitute a limitation on the computer device to which the solution of the present invention is applied. The specific computer device may include more or fewer components than those shown in the figure, or combine certain components, or have a different arrangement of components.

[0115] In an exemplary embodiment, a computer device is further provided, including a memory and a processor, wherein a computer program is stored in the memory, and the above-mentioned method embodiments are implemented when the processor executes the computer program.

[0116] In an exemplary embodiment, a computer-readable storage medium is provided, storing a computer program, and when the computer program is executed by a processor, the above-mentioned method embodiments are implemented.

[0117] In an exemplary embodiment, a computer program product is provided, including a computer program, and when the computer program is executed by a processor, the above-mentioned method embodiments are implemented.

[0118] It should be noted that the user information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for analysis, stored data, displayed data, etc.) involved in the present invention are all information and data authorized by the user or fully authorized by all parties, and the collection, use and processing of relevant data must comply with relevant regulations.

[0119] Those skilled in the art can understand that all or part of the processes in the above-mentioned embodiments can be completed by instructing the relevant hardware through a computer program, and the computer program can be stored in a non-volatile computer-readable storage medium. When the computer program is executed, it can include the processes of the embodiments of the above-mentioned methods. Among them, any reference to the memory, database or other medium used in the embodiments provided by the present invention can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, optical memory, high-density embedded non-volatile memory, resistive random access memory (ReRAM), magnetoresistive random access memory (MRAM), ferroelectric random access memory (FRAM), phase change memory (PCM), graphene memory, etc. Volatile memory can include random access memory (RAM) or external cache memory, etc. By way of illustration and not limitation, RAM may be in various forms, such as static random access memory (SRAM) or dynamic random access memory (DRAM).

[0120] The database involved in each embodiment provided by the present invention may include at least one of a relational database and a non-relational database. The non-relational database may include a distributed database based on blockchain, etc., but is not limited thereto. The processor involved in each embodiment provided by the present invention may be a general-purpose processor, a central processing unit, a graphics processor, a digital signal processor, a programmable logic device, a data processing logic device based on quantum computing, etc., but is not limited thereto.

[0121] The technical features of the above embodiments may be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0122] The principles and implementation methods of the present invention are described in this article using specific examples. The description of the above embodiments is only used to help understand the method and core idea of ​​the present invention. At the same time, for those skilled in the art, according to the idea of ​​the present invention, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. A method for quantitatively assessing the risk of erosion damage to pressure equipment, characterized in that: The method for quantitatively assessing the risk of erosion damage to pressure-bearing equipment includes: Determine the damage form of the equipment; the damage form includes: uniform damage and local damage; According to the damage form, calculate the local / uniform thinning factor; The equipment correction factor is calculated according to the local / uniform thinning factor, the general condition factor, the mechanical factor and the process factor; the general condition factor, the mechanical factor and the process factor are obtained according to API 581-2016 or GB / T 26610.4-2022 standards; The possibility of erosion corrosion failure is calculated according to the equipment correction factor, management system evaluation factor, average failure probability of similar equipment and influence coefficient of excessive defects; the management system evaluation factor, average failure probability of similar equipment and influence coefficient of excessive defects are obtained according to API 581-2016 or GB / T26610.4-2022 standards; Calculating the leakage consequence area; the leakage consequence area includes: the failure consequence area of ​​static data and the failure consequence area of ​​dynamic data; Determine the erosion corrosion failure consequence according to the leakage consequence area; the erosion corrosion failure consequence includes: a quantitative evaluation of the failure consequence of static data and a quantitative evaluation of the failure consequence of dynamic data; A two-dimensional risk matrix diagram is established according to the erosion-corrosion failure possibility and the erosion-corrosion failure consequence; the two-dimensional risk matrix diagram is used for real-time quantitative assessment of erosion risk.

2. The method for quantitatively assessing the risk of erosion damage to pressure equipment according to claim 1 is characterized in that: The determination of the damage form of the equipment specifically includes: Determine the action area of ​​the equipment; the action area includes: a corrosion-dominant area, an erosion-dominant area, and an erosion-corrosion synergistic action area; Based on the action zone, the damage mode of the equipment is determined.

3. The method for quantitatively assessing the risk of erosion damage to pressure equipment according to claim 1, characterized in that: When the damage form is uniform damage, the local / uniform thinning factor is calculated according to the damage form, specifically including: Determine whether the damaged structure is a special structure and obtain a first determination result; If the first judgment result is no, determining the uniform thinning factor according to API 581-2016 or GB / T 26610.4-2022 standard; If the first judgment result is yes, then calculating the structure correction factor according to the elbow curvature radius; According to the structure correction factor, a uniform thinning factor is calculated.

4. The method for quantitatively assessing the risk of erosion damage to pressure equipment according to claim 3 is characterized in that: When the damage form is local damage, the local / uniform thinning factor is calculated according to the damage form, specifically including: determining whether the damaged structure is a special structure, and obtaining a second determination result; If the second judgment result is no, then based on the pit assessment method and the suitability for use assessment method, the critical wall thickness value of failure is calculated respectively, and the maximum value of the critical wall thickness value of failure is recorded; The strength correction factor is determined according to the erosion corrosion local damage expansion rate prediction model, the erosion corrosion thinning severity index and the maximum value of the critical wall thickness for failure; the erosion corrosion local damage expansion rate prediction model is used to predict the expansion rate of the local damage morphology over time; the erosion corrosion thinning severity index is calculated based on time, erosion corrosion rate and thickness data; Determining a local thinning factor according to the strength correction factor; If the second judgment result is yes, calculating the structure correction factor according to the elbow curvature radius; Based on the pit assessment method and the fitness for use assessment method, the critical wall thickness value for failure is calculated respectively, and the maximum value of the critical wall thickness for failure is recorded; Determine the strength correction factor according to the erosion-corrosion local damage growth rate prediction model, the erosion-corrosion thinning severity index and the maximum value of the critical wall thickness for failure; A local thinning factor is determined according to the strength correction factor and the structure correction factor.

5. The method for quantitatively assessing the risk of erosion damage to pressure equipment according to claim 1, characterized in that: When the leakage consequence area is the failure consequence area of ​​static data, the erosion corrosion failure consequence is determined according to the leakage consequence area, specifically including: According to API 581-2016 or GB / T 26610.5-2022 standards, the quantitative evaluation of failure consequences of static data is calculated.

6. The method for quantitatively assessing the risk of erosion damage to pressure equipment according to claim 5, characterized in that: When the leakage consequence area is the failure consequence area of ​​dynamic data, the erosion-corrosion failure consequence is determined according to the leakage consequence area, specifically including: The evolution of leakage hole size over time is deduced based on the prediction model of local damage expansion rate of erosion corrosion; According to the evolution law, determining the real-time predicted leakage area size; According to the real-time predicted leakage area size, a quantitative evaluation of failure consequences of dynamic data is calculated.

7. The method for quantitatively assessing the risk of erosion damage to pressure equipment according to claim 4 or 6, characterized in that: The expression of the erosion-corrosion local damage extension rate prediction model is: Among them, Δx is the local damage expansion rate along the main flow direction, mm / a; Δy is the local damage expansion rate in the circumferential direction along the main flow direction, mm / a; Δz is the local damage expansion rate perpendicular to the main flow direction, mm / a; v is the particle impact velocity, m / s; ε s is the solid volume fraction; ε cor is the volume fraction of corrosive medium; f(·) is the thinning damage expansion function.

8. A computer device comprising: A memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the method for quantitatively assessing the risk of erosion damage to pressure equipment as described in any one of claims 1 to 7.

9. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the method for quantitatively assessing the risk of erosion damage to pressure equipment described in any one of claims 1 to 7 is implemented.

10. A computer program product, comprising a computer program, characterized in that When the computer program is executed by a processor, the method for quantitatively assessing the risk of erosion damage to pressure equipment described in any one of claims 1 to 7 is implemented.

Images