Self-enhancement processing and residual stress attenuation testing system of ultrahigh pressure reactor

Abstract

The invention relates to a system for testing self-enhancement and residual stress attenuation of an ultrahigh-pressure reactor. The system comprises a self-enhancement processing unit and a residual stress attenuation testing unit, wherein the self-enhancement processing unit comprises a second pressure regulating valve, a second pressure gauge, a second filter, a 630MPa pressurization system, an ultrahigh-pressure relief valve, an ultrahigh-pressure sensor, various valves and connecting pipelines; the residual stress attenuation testing unit comprises a first pressure regulating valve, a first pressure gauge, a first filter, a 300MPa pressurizing system, an electromagnetic directional valve, a fatigue pressurizer, an ultrahigh pressure one-way valve, an ultrahigh pressure relief valve, an ultrahigh pressure sensor, various valves and connecting pipelines; the data measurement and control unit comprises flow measurement and control and pressure measurement and control. The device is compact in structure, convenient to operate, low in operation cost and reliable in performance, self-enhancement treatment can be conducted on the ultrahigh pressure reactor, residual stress attenuation testing can be conducted on the reactor under the working condition of 300 MPa, the two experimental working conditions can be freely switched, the pressure of an experimental working medium is increased rapidly, and fatigue life prediction of the ultrahigh pressure reactor can be conducted.

Description

Technical Field

[0001] The invention relates to an ultra-high pressure reactor, in particular to a self-enhancement processing and residual stress decay testing system of an ultra-high pressure reactor. Background Art

[0002] Ultra-high pressure reactors are widely used in artificial crystals, chemical industry, petrochemical industry and other fields. Currently, the reactors of newly built high-pressure polyethylene plants use tubular self-enhanced reactors.

[0003] Self-reinforcement technology is an effective measure to improve the elastic bearing capacity of ultra-high pressure reactors, extend their fatigue life, and make their operation safe and reliable. However, during its service life, it is not only subject to the start-up and shutdown cycle loads, but also to the pressure and temperature fluctuations under normal operation, the pulse pressure shock generated by the servo valve action, and the high-temperature thermal shock when the medium in the tube undergoes an over-temperature decomposition reaction. These factors will cause the relaxation of the residual stress of the self-reinforced tube, reducing the safety of the reactor. The remaining service life of the reactor can be predicted by analyzing the residual stress attenuation. Therefore, the test and evaluation method of the residual stress of the self-reinforced tube is an urgent problem to be solved in the current engineering.

[0004] At present, the test equipment can only perform a single 630MPa reactor self-enhancement treatment or a 300MPa residual stress decay test, and cannot combine the high-pressure treatment process with the low-pressure test process. Setting up multiple test benches with different functions at the same time not only takes up a large area and a large investment, but also wastes a lot of resources. In addition, there are certain differences in the performance of experimental equipment on different test benches, which directly affects the accuracy and reliability of the test results. Under the existing conditions, when conducting ultra-high pressure reactor self-enhancement treatment and residual stress decay tests, high-pressure fluids use a multi-stage compression treatment method, but the boosting process takes a long time. In addition, the self-enhancement treatment and residual stress decay tests cannot be performed at the same location, resulting in a long period of time and a large amount of manpower and material resources to obtain a set of reliable test data.

[0005] Patent document CN1414356A discloses an acoustic testing method for residual residual stress in an ultra-high pressure self-enhanced reaction tube. By measuring the change of the acoustic signal of the self-enhanced reaction tube and the cumulative curve, the magnitude of the internal stress when the self-enhanced reaction tube yields is determined to reversely infer the residual stress. However, the test result has a large error and is only applicable to residual stress testing.

[0006] Patent document CN101672748A discloses a 400MPa ultra-high pressure fatigue test device and test method, wherein the test device is composed of a hydraulic unit, an ultra-high pressure unit, an ultra-high pressure relief unit and a control unit. Pressure oil is supplied to the low-pressure end of the supercharger in the ultra-high pressure unit through the hydraulic unit, and the low-pressure water provided by the water supply pipeline is pressurized by the supercharger, and the generated ultra-high pressure water is transported to the ultra-high pressure test section through the ultra-high pressure joint. The ultra-high pressure water is depressurized through a controllable pressure relief valve and a damper, and a tiny pressure relief channel is formed on the ultra-high pressure relief pipeline of the ultra-high pressure fatigue test device, which effectively controls the pressure relief rate. When the internal pressure fatigue test of the specimen is carried out based on the trapezoidal wave pressure cycle, several small trapezoidal waves are superimposed on the upper pressure holding section of the large trapezoidal wave test pressure, which can fully simulate the pressure cycle of ultra-high pressure equipment such as ultra-high pressure polyethylene tubular reactors during actual operation, and check whether its fatigue life and limit can meet the use requirements. However, the patent involves an ultra-high pressure hydraulic fatigue test device, which is mainly used for ultra-high pressure fatigue tests on pressure vessels and pressure pipelines with a maximum test pressure of 400MPa. It is not suitable for ultra-high pressure tests and self-enhancement treatments greater than 400MPa. For example, the operating condition of an ultra-high pressure polyethylene tubular reactor is 360MPa, its test pressure is about 520MPa, and the self-enhancement treatment pressure is about 630MPa. Therefore, the patent can only perform a single test, while this patent can realize functions such as fatigue testing, sealing testing and self-enhancement treatment. Summary of the invention

[0007] The purpose of the present invention is to solve the above-mentioned problems of the prior art and to provide a test system for self-enhancement and residual stress decay of an ultra-high pressure reactor. The system can perform ultra-high pressure (630MPa) reactor self-enhancement treatment and low pressure (300MPa) residual stress decay test. The two experimental conditions can be switched freely. The system has the characteristics of compact structure, convenient operation, fast test fluid pressure boosting speed, low operating cost and reliable performance.

[0008] The technical solution of the present invention is as follows:

[0009] A self-enhancement treatment and residual stress decay test system for an ultra-high pressure reactor, characterized in that: the system comprises a self-enhancement treatment unit, a residual stress decay test unit and a data measurement and control unit, a driving gas source, and a test workpiece located on a working platform;

[0010] The self-enhanced treatment unit includes a water tank, a second pressure regulating valve, a second pressure gauge, a second filter, a 630MPa boosting system, and an ultra-high pressure relief valve;

[0011] The residual stress test unit comprises a fuel tank, a first pressure regulating valve, a first pressure gauge, a first filter, a 300MPa booster pump system, an electromagnetic reversing valve, a fatigue supercharger and an ultra-high pressure check valve;

[0012] The data measurement and control unit includes an ultra-high pressure sensor, a first solenoid valve, a second solenoid valve and a computer, wherein the first solenoid valve is located on the pipeline between the first filter and the 300MPa booster pump system, the second solenoid valve is located on the pipeline between the second filter and the 630MPa booster system, the output end of the ultra-high pressure sensor is connected to the third input end of the computer, the output end of the first solenoid valve is connected to the first input end of the computer, the output end of the second solenoid valve is connected to the second input end of the computer, and the output end of the computer is connected to the control end of the electromagnetic reversing valve;

[0013] The driving gas source is divided into two pipelines through the gas source triplex (regulating valve, pressure gauge, filter):

[0014] The second branch pipeline of the gas source is connected to the inlet of the 630MPa booster pump system through the second pressure regulating valve, the second pressure gauge, the second filter, and the second solenoid valve in sequence, and the outlet of the 630MPa booster pump system is connected to the ultra-high pressure sensor, the test workpiece, and the ultra-high pressure relief valve respectively;

[0015] The first branch pipeline of the gas source is connected to the inlet of the 300MPa booster pump system via the first pressure regulating valve, the first pressure gauge, the first filter, and the first solenoid valve in sequence; the outlet of the 300MPa booster pump system is connected to the inlet of the solenoid reversing valve; the outlet of the solenoid reversing valve is connected to the inlet of the fatigue supercharger; the outlet of the fatigue supercharger is connected to the inlet of the ultra-high pressure one-way valve; the outlet of the ultra-high pressure one-way valve is connected to one end of a test workpiece; and the other end of the test workpiece is connected to the ultra-high pressure sensor and the ultra-high pressure relief valve.

[0016] The working principle of the ultra-high pressure sensor is that the pressure of the measured pressure directly acts on the sensing plate of the ultra-high pressure sensor, causing the sensing plate to produce a micro-displacement proportional to the pressure, and the resistance value of the sensor changes. The electronic circuit is used to detect this change and convert it into an output of a standard measurement signal corresponding to the pressure.

[0017] The function of the 300MPa booster pump system and the 630MPa booster pump system is to utilize the low-pressure gas at the large-area piston end to drive and generate high-pressure liquid at the small-area piston end.

[0018] The function of the electromagnetic reversing valve is to switch the reciprocating operation of the piston of the fatigue supercharger.

[0019] Compared with the prior art, the present invention has the following main advantages:

[0020] 1. The present invention combines the high-pressure treatment process and the low-pressure test process (the difference from patent CN101672748A is that the pressure and test content realized by the test system are different, so the functions realized are different). The residual stress decay test can be quickly performed on the reactor that has completed the ultra-high pressure self-enhancement treatment, and the fatigue life of the ultra-high pressure reactor can be predicted. The system has a compact structure, convenient operation, and low operating cost, which solves the shortcomings of setting up multiple test benches, such as large footprint and waste of resources.

[0021] 2. The present invention has a compact structure, convenient operation, low operating cost and reliable performance. It can not only perform self-reinforcement treatment on the ultra-high pressure reactor, but also perform residual stress decay test on the reactor under 300MPa conditions. The two experimental conditions can be switched freely, and the experimental working fluid is pressurized rapidly, so the fatigue life of the ultra-high pressure reactor can be predicted.

[0022] 3. The accuracy and reliability of the test results of the present invention are greatly improved. The design has been optimized in many places in the test system. The ultra-high pressure working condition adopts a multi-stage compression method, the boosting process is fast, and the high and low pressure working conditions can be switched freely, which greatly reduces the loss of manpower and material resources.

[0023] 3. The present invention is easy to disassemble and assemble. The experimental system consists of three units, each of which is relatively independent and very simple to disassemble and assemble. The self-enhancement treatment and residual stress decay test process of the ultra-high pressure reactor can be realized at any time. The experimental system can not only test the residual stress decay, but also perform a 300MPa fatigue test on the ultra-high pressure reactor. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the self-enhancement treatment and residual stress decay test system of the ultra-high pressure reactor of the present invention;

[0025] Figure 2 It is a schematic diagram of the system operation when the self-enhancement treatment and residual stress decay test system of the ultra-high pressure reactor of the present invention performs self-enhancement treatment;

[0026] Figure 3 It is a schematic diagram of the system operation when the self-enhancement treatment and residual stress decay test system of the ultra-high pressure reactor of the present invention performs a residual stress decay test.

[0027] In the figure, 1-oil tank, 2-water tank, 3-300MPa booster pump system, 4-electromagnetic reversing valve, 5-fatigue booster, 6-ultra-high pressure check valve, 7-test workpiece, 8-ultra-high pressure sensor, 9-computer, 10-630MPa booster pump system, 11-ultra-high pressure relief valve, 12-1-first pressure regulating valve, 12-2-second pressure regulating valve, 13-1-first pressure gauge, 13-2-second pressure gauge, 14-1-first filter, 14-2-second filter, 15-1-first solenoid valve, 15-2-second solenoid valve, 16-driving air source. DETAILED DESCRIPTION

[0028] The test system for self-enhancement and residual stress attenuation of the ultra-high pressure reactor of the present invention is as follows: Figure 1 As shown in the figure, it can be seen that the test system for self-enhancement and residual stress attenuation of ultra-high pressure reaction tubes of the present invention includes a self-enhancement processing unit, a residual stress attenuation test unit and a data measurement and control unit, a driving gas source 16, and a test workpiece 7 is located on a working platform;

[0029] The self-enhanced treatment unit includes a water tank 2, a second pressure regulating valve 12-2, a second pressure gauge 13-2, a second filter 14-2, a 630MPa boosting system 10, and an ultra-high pressure relief valve 11;

[0030] The residual stress test unit comprises an oil tank 1, a first pressure regulating valve 12-1, a first pressure gauge 13-1, a first filter 14-1, a 300MPa booster pump system 3, an electromagnetic reversing valve 4, a fatigue supercharger 5 and an ultra-high pressure check valve 6;

[0031] The data measurement and control unit includes an ultra-high pressure sensor 8, a first solenoid valve 15-1, a second solenoid valve 15-2 and a computer 9, wherein the first solenoid valve 15-1 is located on the pipeline between the first filter 14-1 and the 300MPa boosting pump system 3, and the second solenoid valve 15-2 is located on the pipeline between the second filter 14-2 and the 630MPa boosting system 10, the output end of the ultra-high pressure sensor 8 is connected to the third input end of the computer 9, the output end of the first solenoid valve 15-1 is connected to the first input end of the computer 9, the output end of the second solenoid valve 15-2 is connected to the second input end of the computer 9, and the output end of the computer 9 is connected to the control end of the electromagnetic reversing valve 4;

[0032] The driving gas source 16 is divided into two pipelines through the gas source triplex (regulating valve, pressure gauge, filter):

[0033] The second branch pipeline of the gas source is connected to the inlet of the 630MPa booster pump system 10 through the second pressure regulating valve 12-2, the second pressure gauge 13-2, the second filter 14-2, and the second solenoid valve 15-2 in sequence, and the outlet of the 630MPa booster pump system 10 is connected to the ultra-high pressure sensor 8, the test workpiece 7 and the ultra-high pressure relief valve 11 respectively;

[0034] The first branch pipeline of the gas source is connected to the inlet of the 300MPa boosting pump system 3 via the first pressure regulating valve 12-1, the first pressure gauge 13-1, the first filter 14-1, and the first solenoid valve 15-1 in sequence, the outlet of the 300MPa boosting pump system 10 is connected to the inlet of the solenoid reversing valve 4, the outlet of the solenoid reversing valve 4 is connected to the inlet of the fatigue supercharger 5, the outlet of the fatigue supercharger 5 is connected to the inlet of the ultra-high pressure check valve 6, the outlet of the ultra-high pressure check valve 6 is connected to one end of the test workpiece 7, and the other end of the test workpiece 7 is connected to the ultra-high pressure sensor 8 and the ultra-high pressure relief valve 11.

[0035] The working principle of the ultra-high pressure sensor 8 is that the pressure of the measured pressure directly acts on the sensing plate of the ultra-high pressure sensor 8, causing the sensing plate to produce a micro-displacement proportional to the pressure, and the resistance value of the sensor changes. The electronic circuit is used to detect this change and convert and output a standard measurement signal corresponding to the pressure.

[0036] The function of the 300MPa booster pump system 3 and the 630MPa booster pump system 10 is to utilize the low-pressure gas at the large-area piston end to drive and generate high-pressure liquid at the small-area piston end.

[0037] The function of the electromagnetic reversing valve 4 is to switch the piston reciprocating operation of the fatigue supercharger 5. It is composed of a self-enhancement processing unit, a residual stress decay test unit and a data measurement and control unit.

[0038] The driving air source 16 introduces air into the 630MPa booster pump system 10 through the air source triplet (regulating valve, pressure gauge, filter) via the second pressure regulating valve 12-2 of the second branch, the second pressure gauge 13-2, the second filter 14-2, and the second solenoid valve 15-2. The air-driven liquid pump compresses the water introduced from the water tank 2 to the 630MPa booster pump system 10, and introduces it into the test workpiece 7, so that the reactor can be self-enhanced. The ultra-high pressure sensor 8 can transmit the real-time data of the water pressure in the pipeline to the computer 9. The ultra-high pressure relief valve 11 can release the water in the pipeline after the self-enhancement treatment is completed, and can automatically open to relieve pressure once overpressure occurs, so as to protect the pipeline, the test workpiece 7 and the ultra-high pressure sensor 8.

[0039] The driving air source 16 introduces air into the 300MPa booster pump system 3 through the air source triplet, the first pressure regulating valve 12-1, the first pressure gauge 13-1, and the first filter 14-1. The air-driven liquid pump compresses the oil introduced from the oil tank 1 to the 300MPa booster pump system 3, and introduces it into the electromagnetic reversing valve 4. The electromagnetic reversing valve 4 can control the fatigue supercharger 5 and adjust the pressure of the introduced high-pressure oil. The high-pressure oil is introduced into the test workpiece 7 through the ultra-high pressure one-way valve 6 to perform a residual stress decay test on the reactor. The ultra-high pressure sensor 8 can transmit real-time data of the oil pressure in the pipeline to the computer 9. The ultra-high pressure relief valve 11 can release the oil in the pipeline after the self-enhancement treatment is completed, and can automatically open to relieve pressure once an overpressure situation occurs, thereby protecting the pipeline, the test workpiece 7 and the ultra-high pressure sensor 8.

[0040] The schematic diagram of the system operation during the self-enhancement treatment of the ultra-high pressure reactor self-enhancement and residual stress attenuation test system is shown in Figure 2 , arrows indicate the flow directions of various media.

[0041] The system operation diagram of the test system for self-enhancement and residual stress decay of ultra-high pressure reactors during residual stress decay test is shown in Figure 3 , arrows indicate the flow directions of various media.

[0042] The basic use process of the system of the present invention is:

[0043] 1) First check the system pipeline to ensure that the valves and components are intact before turning on the computer 9;

[0044] 2) If the ultra-high pressure reactor self-enhancement treatment is carried out, follow the instructions Figure 2 As shown by the arrows, the second pressure regulating valve 12-2 and the second solenoid valve 15-2 are opened in sequence to connect the 630MPa booster pump system 3 to the power supply;

[0045] 3) During the experiment, real-time monitoring and recording of data are performed by computer 9;

[0046] 4) If the residual stress decay test of ultra-high pressure reactor is to be carried out, follow the instructions Figure 3 As shown by the arrows, the first pressure regulating valve 12-1 and the first solenoid valve 15-1 are opened in sequence, the 300MPa booster pump system 3 is powered on, and the parameters of the solenoid reversing valve 4 are set through the computer 9;

[0047] 5) During the experiment, the computer 9 is used to monitor and record data in real time;

[0048] 6) After the experiment, first turn off the power of the 300 booster pump system 3, then turn off the first pressure regulating valve 12-1, the first solenoid valve 15-1, and the power of the data measurement and control unit, and finally release the pressure in the pipeline through the ultra-high pressure relief valve 11;

[0049] 7) End the experiment.

[0050] Experiments show that the system of the present invention can be used for both ultra-high pressure (630MPa) reactor self-enhancement treatment and low pressure (300MPa) residual stress decay test. The two experimental conditions can be switched freely. The system has the characteristics of compact structure, convenient operation, fast test fluid pressure boosting speed, low operating cost and reliable performance.

[0051] The preferred specific embodiments of the present invention are described in detail above. It should be understood that a person skilled in the art can make many modifications and changes based on the concept of the present invention without creative work. Therefore, any technical solution that can be obtained by a person skilled in the art through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should be within the scope of protection determined by the claims.

Claims

1. A self-enhancement treatment and residual stress decay test system for an ultra-high pressure reactor, characterized in that: It comprises a self-enhancement processing unit, a residual stress decay test unit, a data measurement and control unit, a driving gas source (16) and a working platform for placing a test workpiece (7); The self-enhanced treatment unit comprises a water tank (2), a second pressure regulating valve (12-2), a second pressure gauge (13-2), a second filter (14-2), a 630MPa pressurizing system (10), and an ultra-high pressure relief valve (11); The residual stress testing unit comprises an oil tank (1), a first pressure regulating valve (12-1), a first pressure gauge (13-1), a first filter (14-1), a 300 MPa booster pump system (3), an electromagnetic reversing valve (4), a fatigue supercharger (5) and an ultra-high pressure check valve (6); The data measurement and control unit comprises a computer (9), a first solenoid valve (15-1), a second solenoid valve (15-2) and an ultra-high pressure sensor (8); The first solenoid valve (15-1) is located on the pipeline between the first filter (14-1) and the 300MPa booster pump system (3), the second solenoid valve (15-2) is located on the pipeline between the second filter (14-2) and the 630MPa booster system (10), the output end of the ultra-high pressure sensor (8) is connected to the third input end of the computer (9), the output end of the first solenoid valve (15-1) is connected to the first input end of the computer (9), the output end of the second solenoid valve (15-2) is connected to the second input end of the computer (9), and the output end of the computer (9) is connected to the control end of the solenoid reversing valve (4); The driving gas source (16) is divided into two pipelines through the gas source triplex (regulating valve, pressure gauge, filter): The second branch pipeline of the gas source is connected to the inlet of the 630MPa booster pump system (10) via the second pressure regulating valve (12-2), the second pressure gauge (13-2), the second filter (14-2), and the second solenoid valve (15-2) in sequence, and the outlet of the 630MPa booster pump system (10) is connected to the ultra-high pressure sensor (8), the test workpiece (7), and the ultra-high pressure relief valve (11) respectively; The first branch pipeline of the gas source is connected to the inlet of the 300MPa booster pump system (3) via the first pressure regulating valve (12-1), the first pressure gauge (13-1), the first filter (14-1), and the first solenoid valve (15-1) in sequence; the outlet of the 300MPa booster pump system (3) is connected to the inlet of the solenoid reversing valve (4); the outlet of the solenoid reversing valve (4) is connected to the inlet of the fatigue supercharger (5); the outlet of the fatigue supercharger (5) is connected to the inlet of the ultra-high pressure check valve (6); the outlet of the ultra-high pressure check valve (6) is connected to one end of the test workpiece (7); the other end of the test workpiece (7) is connected to the ultra-high pressure sensor (8) and the ultra-high pressure relief valve (11).

2. The self-enhancement treatment and residual stress decay test system of the ultra-high pressure reactor according to claim 1, characterized in that: The ultra-high pressure sensor (8) is a sensor chip of the ultra-high pressure sensor (8) in which the pressure of the pressure to be measured directly acts on the sensor chip, causing the sensor chip to produce a micro-displacement proportional to the pressure, and the resistance value of the sensor changes. This change is detected by an electronic circuit and converted and outputted into a standard measurement signal corresponding to the pressure.

3. The self-enhancement treatment and residual stress decay test system of the ultra-high pressure reactor according to claim 1, characterized in that: The 300MPa booster pump system (3) and the 630MPa booster pump system (10) are driven by low-pressure gas at a large-area piston end to generate high-pressure liquid at a small-area piston end.

4. The self-enhancement treatment and residual stress decay test system of the ultra-high pressure reactor according to claim 1, characterized in that: The electromagnetic reversing valve (4) is used to switch the reciprocating operation of the piston of the fatigue supercharger (5).

5. The self-enhancement treatment and residual stress decay test system of the ultra-high pressure reactor according to claim 1, characterized in that: The ultra-high pressure relief valve (11) is used to release ultra-high pressure static pressure and protect the ultra-high pressure sensor.

6. The self-enhancement treatment and residual stress decay test system of the ultra-high pressure reactor according to claim 1, characterized in that: If the ultrahigh pressure reactor is subjected to self-enhancement treatment, the second pressure regulating valve and the second solenoid valve are opened in sequence, the 630 MPa booster pump system is connected to the power supply, and the data is monitored and recorded in real time by a computer.

7. The self-enhancement treatment and residual stress decay test system of the ultra-high pressure reactor according to claim 1, characterized in that: If the residual stress decay test of the ultra-high pressure reactor is carried out, the first pressure regulating valve and the first solenoid valve are opened in sequence, the 300MPa booster pump system is connected to the power supply, and the parameters of the solenoid reversing valve are set through the computer, and the data is monitored and recorded in real time through the computer.

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