Method and device for detecting structural integrity of a hot high-pressure knock-out drum

Abstract

A kind of hot high-pressure knock-out drum structural integrity detection method and device based on short-time over-temperature scene.The method comprises the following steps: obtaining stress field distribution data of hot high-pressure knock-out drum under over-temperature working condition, generating classified stress intensity value through stress linearization processing according to the stress field distribution data; generating stress checking result according to the comparison between classified stress intensity value and material allowable stress intensity; generating cumulative creep damage amount through creep damage tolerance evaluation model according to stress field distribution data and process parameters of over-temperature working condition; determining structural integrity detection result according to stress checking result and cumulative creep damage amount, when stress checking result meets analysis design strength criterion and cumulative creep damage amount is less than allowable threshold, determining that the ability of equipment to maintain structural integrity after short-time over-temperature is not affected. In this way, the fusion of over-temperature working condition stress analysis and quantitative creep damage evaluation is realized, and scientific judgment basis is provided for whether equipment can continue to serve safely after short-time over-temperature.

Description

Technical Field

[0001] This application relates to the field of pressure equipment safety assessment technology, and in particular to a method and device for detecting the structural integrity of a thermal high-pressure separator based on a short-term overheating scenario. Background Technology

[0002] In modern chemical refining units, the hot high-pressure separator, as the core pressure-bearing equipment of the hydrogenation reaction system, operates under harsh conditions of high temperature, high pressure, and hydrogen immersion. Its main body is typically made of Cr-Mo series heat-resistant steel such as 12Cr2Mo1R, with an inner wall clad in stainless steel to meet corrosion resistance requirements. The design temperature of this type of equipment usually does not exceed 300℃, and the normal operating temperature is generally controlled below 246℃. However, under abnormal circumstances such as emergency shutdowns, upstream unit interlocking, or process disturbances, the equipment may experience unplanned short-term overheating events. For example, a certain refining company experienced multiple emergency shutdowns between June and September 2024, leading to overheating of its hot high-pressure separator, with the highest temperature reaching 386℃ and the longest single duration approximately 186 minutes, accompanied by localized peeling of the fire-retardant coating.

[0003] The potential hazards of short-term overheating to equipment cannot be ignored. Theoretically, overheating will exacerbate the thermal gradient effect in thick-walled structures, inducing increased thermal stress and stress redistribution, while simultaneously reducing the material's yield strength and elastic modulus. For Cr-Mo heat-resistant steels like 12Cr2Mo1R, during long-term service in the 350℃ to 575℃ range, impurity elements will agglomerate at grain boundaries, leading to an increased tendency for temper embrittlement. Under the combined effects of high temperature and structural stress, it may also induce microstructural degradation such as pearlite spheroidization, carbide aggregation along grain boundaries, and grain coarsening, as well as the nucleation and aggregation of creep pores, ultimately resulting in irreversible creep damage.

[0004] Currently, the serviceability assessment of in-service pressure vessels after overheating mainly involves the following methods. The first is the conventional periodic inspection method, which, according to the Safety Technical Supervision Regulations for Fixed Pressure Vessels, conducts macroscopic inspections, wall thickness measurements, magnetic particle testing, and ultrasonic testing. The test results are compared with standard limits; if the limits are met, the vessel is deemed ready for service. This method can only detect macroscopic or near-surface defects and cannot assess the microstructural degradation and creep damage that may be caused by overheating, resulting in an incomplete assessment. The second method is the finite element stress analysis method based on design conditions. A model is established according to pressure vessel analysis and design standards, and conventional design loads are applied for stress classification and strength verification. However, this method uses linear elastic assumptions and does not consider nonlinear creep behavior at high temperatures, making it unable to quantify cumulative creep damage and remaining service life, and therefore unsuitable for assessing short-term overheating abnormal conditions.

[0005] In summary, existing technologies lack a comprehensive method that can systematically integrate non-destructive testing, stress analysis under over-temperature conditions, and quantitative creep damage assessment. This makes it impossible to scientifically answer the key question of whether short-term over-temperature has caused irreversible structural damage. Therefore, a targeted structural integrity testing solution is urgently needed. Summary of the Invention

[0006] The purpose of this application is to solve the technical problem that the existing technology cannot systematically and quantitatively assess the microscopic degradation and creep damage of materials caused by short-term overheating to hot high-pressure separators. It provides a method and device for detecting the structural integrity of hot high-pressure separators, so as to accurately determine whether a short-term overheating event has induced irreversible structural damage, and provide a scientific basis for determining whether the equipment can continue to serve safely.

[0007] To achieve the above objectives, the structural integrity testing method for a high-pressure thermal separator provided in this application specifically includes: acquiring stress field distribution data of the high-pressure thermal separator under over-temperature conditions; generating classified stress intensity values ​​based on the stress field distribution data through stress linearization processing; generating stress verification results based on the comparison between the classified stress intensity values ​​and the allowable stress intensity of the material; generating cumulative creep damage amount based on the stress field distribution data and the process parameters of the over-temperature conditions through a creep damage tolerance assessment model; and determining the structural integrity testing result of the high-pressure thermal separator based on the stress verification result and the cumulative creep damage amount.

[0008] In the above-mentioned method for detecting the structural integrity of a hot-pressure separator, optionally, determining the structural integrity detection result of the hot-pressure separator includes: when the stress verification result meets the strength criteria specified in the pressure vessel analysis and design standard, and the cumulative creep damage is less than the allowable creep damage threshold, it is determined that the ability of the hot-pressure separator to maintain structural integrity after a short-term overheating is not affected.

[0009] In the above-mentioned method for detecting the structural integrity of a hot-pressure separator, optionally, before obtaining the stress field distribution data of the hot-pressure separator under over-temperature conditions, the method further includes: obtaining test data based on non-destructive testing and material performance characterization of the hot-pressure separator; determining whether there are excessive defects or irreversible material degradation based on the test data; and when the determination result indicates that there are no excessive defects and the material has not undergone irreversible material degradation, obtaining the stress field distribution data of the hot-pressure separator under over-temperature conditions.

[0010] Optionally, in the above-mentioned method for detecting the structural integrity of a hot high-pressure separator, the method further includes: when the metallographic analysis results show that the microstructure of the base material, weld and heat-affected zone does not show high-temperature deterioration characteristics, and the degree of microstructure aging does not exceed the preset microstructure stability level threshold, it is determined that the material has not undergone irreversible microstructure degradation.

[0011] In the above-mentioned method for detecting the structural integrity of a thermal high-pressure separator, optionally, obtaining the stress field distribution data of the thermal high-pressure separator under over-temperature conditions includes: establishing a finite element analysis model based on the design parameters of the thermal high-pressure separator and the temperature and pressure parameters of the over-temperature conditions; applying loads to the finite element analysis model and solving the finite element analysis model to obtain stress field distribution data incorporating the loads; wherein the loads include internal pressure, gravity loads, and lateral loads equivalent to wind loads and seismic loads.

[0012] In the above-mentioned method for detecting the structural integrity of a high-pressure separation tank, optionally, generating the cumulative creep damage amount through a creep damage tolerance assessment model includes: constructing the creep damage tolerance assessment model based on the ratio between exposure time and remaining creep life using the remaining lifetime fraction method; calculating the remaining creep life based on the stress field distribution data; and obtaining the cumulative creep damage amount using the creep damage tolerance assessment model based on the remaining creep life and the exposure time.

[0013] In the above-mentioned method for detecting the structural integrity of a high-pressure separator, optionally, calculating the remaining creep life based on the stress field distribution data includes: extracting three principal stresses characterizing the triaxial stress state from the stress field distribution data; calculating multiaxial damage parameters reflecting the triaxial stress state based on the three principal stresses; and using the multiaxial damage parameters to correct the uniaxial creep data to obtain the remaining creep life corresponding to the actual stress state.

[0014] Optionally, in the above-mentioned method for detecting the structural integrity of a hot high-pressure separator, the method may further include: setting the temperature during the entire duration of the short-term overheating event as the highest overheating temperature in the short-term overheating event, and using this period as the exposure time.

[0015] In the above-mentioned method for detecting the structural integrity of a hot-pressure separator, optionally, determining the structural integrity detection result of the hot-pressure separator further includes: comparing the stress verification result with the allowable stress threshold, and comparing the cumulative creep damage with the allowable creep damage threshold to obtain a stress and creep assessment conclusion; judging whether there are excessive defects or material performance degradation based on the wall thickness measurement result, hardness test result, and non-destructive testing result of the hot-pressure separator to obtain a material condition conclusion; and determining the structural integrity detection result of the hot-pressure separator based on the stress and creep assessment conclusion and the material condition conclusion.

[0016] In the above-mentioned method for detecting the structural integrity of a hot high-pressure separator, optionally, determining whether there is material performance degradation based on the hardness test result includes: comparing the hardness test result with the strength level determined based on the stress verification result; when the deviation between the hardness test result and the strength level exceeds a preset range, determining that the material state conclusion is unreliable, and triggering a re-verification of the boundary conditions of the stress field distribution data to update the stress and creep assessment conclusion.

[0017] This application also provides a structural integrity testing device for a hot high-pressure separator, including a stress analysis module, a strength verification module, a creep assessment module, and a detection analysis module. The stress analysis module is used to acquire stress field distribution data of the hot high-pressure separator under over-temperature conditions, and generate classified stress intensity values ​​based on the stress field distribution data through stress linearization processing. The strength verification module is used to receive the classified stress intensity values ​​and generate stress verification results based on the comparison between the classified stress intensity values ​​and the allowable stress intensity of the material. The creep assessment module is used to receive the stress field distribution data and generate cumulative creep damage based on the stress field distribution data and the process parameters of the over-temperature conditions through a creep damage tolerance assessment model. The detection analysis module is used to receive the stress verification results and the cumulative creep damage, and determine the structural integrity testing results of the hot high-pressure separator based on the stress verification results and the cumulative creep damage.

[0018] This application also provides an electronic device, including 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 above-described method.

[0019] This application also provides a computer-readable storage medium storing a computer program that performs the above-described methods.

[0020] This application also provides a computer program product, including a computer program / instructions that, when executed by a processor, implement the steps of the above-described method.

[0021] The beneficial technical effects of this application are as follows: It is the first to construct a three-in-one structural integrity testing method integrating on-site non-destructive testing and material performance characterization, finite element stress analysis under over-temperature conditions, and creep damage tolerance assessment based on fracture mechanics, achieving a leap from traditional qualitative experience-based judgment to quantitative data-driven decision-making. By acquiring stress field distribution data under over-temperature conditions and performing stress linearization classification verification, and simultaneously calculating cumulative creep damage based on the remaining life fraction method and multiaxial stress correction, the creep damage caused by short-term over-temperature can be scientifically quantified, accurately defining the critical boundary between "short-term over-temperature" and "irreversible structural damage." This method avoids unnecessary equipment replacement or post-weld heat treatment due to overly conservative assessments, significantly reducing enterprise operation and maintenance costs, and also eliminates potential safety accidents caused by insufficient assessment. Furthermore, by cross-validating the material performance characterization results such as metallographic analysis and hardness testing with the stress analysis and creep assessment results, the reliability of the assessment conclusions is further improved. This method is not only applicable to high-pressure separators but can also be extended to other pressure-bearing special equipment operating under high-temperature and high-pressure conditions and potentially experiencing short-term over-temperature events. Attached Figure Description

[0022] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic flowchart of a method for detecting the structural integrity of a high-pressure separator provided in an embodiment of this application. Figure 2 This is a schematic diagram of the pre-detection process before obtaining stress field distribution data provided in an embodiment of this application; Figure 3 This is a schematic diagram of the process for obtaining stress field distribution data under over-temperature conditions according to an embodiment of this application; Figure 4 This is a schematic diagram of the process for generating cumulative creep damage using a creep damage tolerance assessment model according to an embodiment of this application. Figure 5 This is a schematic diagram of the process for calculating the remaining creep life based on stress field distribution data, provided in an embodiment of this application. Figure 6 This is a schematic diagram of the comprehensive judgment process for determining the structural integrity test results provided in an embodiment of this application; Figure 7 This is a schematic diagram of a process for judging the deterioration of material properties based on hardness test results, provided in an embodiment of this application. Figure 8 This is a schematic diagram of the structure of an electronic device provided in an embodiment of this application; Figure 9 This is a schematic diagram of the distribution of wall thickness measuring points provided in an embodiment of this application; Figures 10A to 10C This is a schematic diagram of the metallographic structure provided in an embodiment of this application; Figure 11 This is a schematic diagram of metallographic measurement points at the overheated location provided in an embodiment of this application; Figure 12 This is a schematic diagram of the magnetic particle testing and ultrasonic testing areas provided in an embodiment of this application; Figure 13 This is a schematic diagram of magnetic particle detection for overheated parts provided in an embodiment of this application; Figure 14 This is a schematic diagram of the device geometric model provided in an embodiment of this application; Figures 15A to 15C This is a schematic diagram of finite element mesh generation provided in an embodiment of this application; Figure 16A and Figure 16B This is a schematic diagram of load and boundary condition settings provided in an embodiment of this application; Figure 17 This is a schematic diagram of the lateral load distribution provided in an embodiment of this application; Figure 18 This is a schematic diagram of the overall stress intensity distribution cloud provided in an embodiment of this application; Figure 19A and Figure 19B This is a schematic diagram of the path linearization result at the point of maximum stress provided in an embodiment of this application. Detailed Implementation

[0023] The following will describe in detail the implementation methods of this application with reference to the accompanying drawings and embodiments, so as to fully understand how this application uses technical means to solve technical problems and achieve technical effects, and to implement it accordingly. It should be noted that, as long as there is no conflict, the various embodiments and features in each embodiment of this application can be combined with each other, and the resulting technical solutions are all within the protection scope of this application.

[0024] Furthermore, the steps shown in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions, and although a logical order is shown in the flowchart, in some cases the steps shown or described may be executed in a different order than that shown here.

[0025] This application provides a method and apparatus for detecting the structural integrity of a thermal high-pressure separator based on a short-term over-temperature scenario. This method addresses the structural integrity of in-service thermal high-pressure separators after they have experienced short-term over-temperature abnormal conditions by integrating material performance characterization, over-temperature stress analysis, and creep damage tolerance assessment.

[0026] In modern chemical refining units, the high-pressure separator, as the core pressure-bearing equipment of the hydrogenation reaction system, operates under harsh conditions of high temperature, high pressure, and proximity to hydrogen for extended periods. Its main body is typically constructed of Cr-Mo series heat-resistant steel. In emergency shutdowns or process disturbances, the equipment may experience unplanned short-term overheating events. The instantaneous high temperature combined with structural stress can lead to the peeling of the fire-retardant coating, degradation of the material's microstructure, and cumulative creep damage. Current technologies lack systematic and quantitative assessment methods for short-term overheating scenarios, making it impossible to scientifically define the critical boundary between "short-term overheating" and "irreversible structural damage."

[0027] Taking a high-pressure separator in a refining and chemical enterprise as an example, its main body is made of Cr-Mo heat-resistant steel, with a stainless steel cladding layer welded to the inner wall. Under normal operating conditions, the equipment operates at a temperature lower than the design temperature. During multiple emergency shutdowns, it experienced overheating, exceeding the design temperature, accompanied by localized peeling of the fire-retardant coating. The following detailed explanation of the method described in this application is based on this example.

[0028] Please refer to Figure 1 As shown, the structural integrity testing method for the hot high-pressure separator provided in this application specifically includes: S101 Obtains stress field distribution data of the hot high-pressure separator under over-temperature conditions, and generates classified stress intensity values ​​based on the stress field distribution data through stress linearization processing. S102 generates stress verification results based on the comparison between the classified stress intensity values ​​and the allowable stress intensity of the material; S103 generates the cumulative creep damage amount based on the stress field distribution data and the process parameters of the over-temperature condition using a creep damage tolerance assessment model. S104 determines the structural integrity test result of the hot high-pressure separator based on the stress verification result and the cumulative creep damage amount.

[0029] In the above embodiments, determining the structural integrity test result of the hot-pressure separator includes: when the stress verification result meets the strength criteria specified in the pressure vessel analysis and design standard, and the cumulative creep damage is less than the allowable creep damage threshold, it is determined that the ability of the hot-pressure separator to maintain structural integrity after a short-term overheating is unaffected. The allowable creep damage threshold is determined according to the applicability assessment standard and is typically taken as 0.25. To facilitate a clearer understanding of the structural integrity test method for the hot-pressure separator provided in this application, the implementation logic of each step will be further explained below.

[0030] Before obtaining stress field distribution data, this application comprehensively understands the current material state of the equipment through on-site non-destructive testing and material property characterization. Subsequent stress verification and creep assessment are only of engineering significance when the material does not exhibit irreversible microstructural degradation or excessive defects. Please refer to [reference needed]. Figure 2 As shown, in one embodiment of this application, before obtaining the stress field distribution data of the hot high-pressure separator under over-temperature conditions, the method further includes: S201 Obtain test data based on non-destructive testing and material property characterization of the hot high-pressure separator; S202 determines, based on the test data, whether there are defects exceeding the standard or irreversible material degradation; S203 When the judgment result shows that there are no defects exceeding the standard and the material has not undergone irreversible structural degradation, obtain the stress field distribution data of the hot high-pressure separator under the ultra-high temperature condition.

[0031] Among them: when the metallographic analysis results show no high-temperature deterioration characteristics in the microstructure of the base material, weld and heat-affected zone, and the degree of microstructure aging does not exceed the preset microstructure stability level threshold, it is determined that the material has not undergone irreversible microstructure degradation.

[0032] Specifically, in actual work, the data detection process is as follows: Wall thickness measurement: For systematic wall thickness testing of the hot high-pressure separator shell, please refer to [reference needed]. Figure 9 As shown, the measuring points cover the key stress areas of the cylinder and the head to ensure the representativeness of the test results. The actual measurement results show that the wall thickness at each measuring point is within the design allowable range, and no significant thinning was found.

[0033] Hardness testing: Surface hardness tests were conducted on the base material, weld, and heat-affected zone. The test results showed that the hardness values ​​of each region were within the acceptable range specified in the material standard, and no significant hardening or softening characteristics were observed.

[0034] Metallographic testing: Metallographic examination is a crucial method for assessing the stability of the microstructure of heat-resistant steel after long-term high-temperature or ultra-high-temperature service. Samples were taken from the base material, welds, and heat-affected zone of the high-pressure separator, prepared according to the standards for metal microstructure testing, and observed under an optical microscope. Please refer to [reference needed]. Figures 10A to 10C As shown, where Figure 10A Metallographic structure of the parent material region. Figure 10B The metallographic structure of the weld area is as follows: Figure 10CThe microstructure of the heat-affected zone (HAZ) was determined. Results showed that the microstructure in the base metal region consisted of ferrite and pearlite, while the weld zone primarily consisted of bainite. The HAZ maintained a ferrite and pearlite structure, and no martensite, Widmanstätten, or other abnormal phases were observed. Based on a comprehensive evaluation according to the technical guidelines for metallographic inspection and evaluation in thermal power plants, the degree of microstructure aging was low and did not exceed the preset threshold for microstructure stability.

[0035] Please refer to Figure 11 As shown, the measuring points were arranged in the shell base material, welds, and heat-affected zone within the overtemperature region. No high-temperature degradation characteristics such as pearlite spheroidization, graphitization, carbide aggregation along grain boundaries, or grain coarsening were found in any of the inspected areas. The pearlite agglomerates remained intact, and the carbide distribution was uniform. This indicates that under the current overtemperature amplitude and duration conditions, the material has not yet entered the critical range of irreversible microstructural degradation.

[0036] In the above embodiments, when the metallographic analysis results show that the microstructure of the base material, weld and heat-affected zone does not show high-temperature deterioration characteristics and the degree of microstructure aging does not exceed the preset microstructure stability level threshold, it is determined that the material has not undergone irreversible microstructure degradation.

[0037] Magnetic particle testing and ultrasonic testing: To comprehensively investigate surface and near-surface defects, magnetic particle testing and ultrasonic testing were performed on key components of the hot high-pressure separator in accordance with relevant non-destructive testing standards. Please refer to [reference needed]. Figure 12 , Figure 12 This diagram illustrates the areas tested using magnetic particle inspection and ultrasonic testing. The testing areas cover stress concentration and overheating locations such as the cylinder, end caps, and weld joints. Please refer to this diagram. Figure 13 , Figure 13 This is a schematic diagram of magnetic particle testing of the over-temperature area. The test results show that neither magnetic particle nor ultrasonic testing revealed any defects exceeding the standard acceptance level. After experiencing over-temperature operation, the main structure of the equipment still maintained good integrity, with no cracks, lack of fusion, or other harmful defects observed.

[0038] After characterizing the material properties and confirming that the material condition is acceptable, this application establishes a finite element model to calculate the stress distribution under overtemperature conditions, providing input for strength verification and creep damage calculation; please refer to Figure 3 As shown, in one embodiment of this application, obtaining the stress field distribution data of the hot high-pressure separator under ultra-high temperature conditions includes: S301 establishes a finite element analysis model based on the design parameters of the hot high-pressure separator and the temperature and pressure parameters of the over-temperature condition; S302 applies a load to the finite element analysis model and solves the finite element analysis model to obtain stress field distribution data taking into account the load; The loads include internal pressure, gravity loads, and lateral loads that are equivalent to wind loads and seismic loads.

[0039] The following detailed description of this embodiment is based on the specific implementation of the above steps.

[0040] In step S301, based on the design drawings and considering structural symmetry and computational efficiency, a partial geometric solid model is established. Please refer to... Figure 14 , Figure 14 This is a geometric model diagram of the equipment. Three-dimensional isoparametric elements were used for mesh generation, with mesh refinement applied to the head transition zone and the end of the cylinder to ensure calculation accuracy. Please refer to... Figures 15A to 15C As shown, where Figure 15A The grid is for the upper end cap and the cylindrical section. Figure 15B For the cylindrical section mesh, Figure 15C The mesh is for the lower head and cylinder section. The mesh quality meets the independence requirement.

[0041] In step S302, loads and boundary conditions are applied. Please refer to... Figures 16A to 16B As shown, where Figure 16A For loads and boundary conditions, Figure 16B The load is temperature-dependent. The applied loads include internal pressure and gravitational acceleration, and the mass of the packing and accessories is converted to an equivalent uniformly distributed density and applied to the shell. Displacement constraints are applied at the bottom of the model, and frictionless support constraints are applied on the symmetry plane. The material model adopts a linear elastic constitutive relation, and the material mechanical property parameters are taken at the corresponding temperatures according to the pressure vessel analysis and design standards.

[0042] For handling lateral loads, please refer to [reference needed]. Figure 17 , Figure 17 This diagram illustrates the distribution of lateral loads. Wind and seismic loads generate bending moments at the tangential section between the cylinder and the head. Bending stresses are calculated using the section modulus, and edge stresses are derived based on the principle of geometric similarity. The lateral loads are decomposed into membrane stress components and bending stress components, which are respectively included in the primary membrane stress and primary bending stress for subsequent structural strength checks.

[0043] For stress calculation and strength verification, please refer to [reference needed]. Figure 18 , Figure 18 This is a cloud map showing the overall stress intensity distribution. A linearized path was drawn, passing through the point of maximum stress and along the wall thickness. Please refer to [reference needed]. Figure 19A and Figure 19B As shown, where Figure 19A A schematic diagram for selecting a linearization path. Figure 19B This is a diagram showing the distribution of stress components.

[0044] According to the standards for pressure vessel analysis and design, the stress in the structure should meet the following criteria: SI = P m ≤ KS m ; S II = P L ≤1.5 KS m ; S III = P L + P b ≤1.5 KS m ; S IV = P L + P b + Q ≤3 S m ; To prevent failure due to localized excessive strain, the algebraic sum of the three principal stresses at any point on the structure must not exceed 4S. m Wherein: P m The total membrane stress is P. L This represents a localized membrane stress; P b Q is the primary bending stress; S is the secondary stress; m This represents the allowable stress at the material's calculation temperature.

[0045] Based on the stress classification method and the third strength theory, the path stress is decomposed into primary local membrane stress, primary membrane plus primary bending stress, and secondary stress, and the stress component generated by the transverse load is also included. The verification results show that all types of stress are below the allowable values, meeting the requirements for preventing plastic collapse and local failure.

[0046] Although the duration of each overtemperature event was short, from the perspective of structural integrity assessment, it is still necessary to quantify the irreversible cumulative creep damage to the material caused by high temperatures. This invention uses the remaining lifetime fraction method to assess creep damage tolerance based on suitability assessment criteria.

[0047] Please refer to Figure 4 As shown in one embodiment of this application, generating the cumulative creep damage amount through the creep damage tolerance assessment model includes: S401 constructs the creep damage tolerance assessment model based on the ratio between exposure time and remaining creep lifetime using the remaining lifetime fraction method; S402 calculates the remaining creep life based on the stress field distribution data, and obtains the cumulative creep damage amount using the creep damage tolerance assessment model based on the remaining creep life and the exposure time.

[0048] In one embodiment of this application, the method further includes: setting the temperature during the entire duration of the short-term overheating event as the highest overheating temperature in the short-term overheating event, and using this period as the exposure time.

[0049] The following detailed description of this embodiment is based on the specific implementation of the above steps.

[0050] In step S401, the remaining life fraction method used to construct the creep damage tolerance assessment model has the following core formula: ; In the formula: t is the actual exposure time; L is the remaining creep life under given stress and temperature. This model takes the exposure time and remaining creep life as inputs, and the ratio of the two as the output cumulative creep damage. If the calculated... If the value is less than the allowable threshold (usually 0.25), the device is considered to have passed the creep assessment.

[0051] To ensure a safety margin under the worst-case conditions, in one embodiment, the exposure time is determined using a conservative setting method. Specifically, the temperature throughout the entire duration of the short-term overheating event is set as the highest overheating temperature during the short-term overheating event, and this period is taken as the exposure time. The equivalent stress is calculated based on the finite element analysis results and the yield criterion.

[0052] In step S402, the calculation of the remaining creep life further incorporates multiaxial stress correction. Please refer to... Figure 5 As shown, in one embodiment of this application, calculating the remaining creep life based on the stress field distribution data includes: S501 extracts three principal stresses characterizing the triaxial stress state based on the stress field distribution data; S502 calculates multiaxial damage parameters that reflect the triaxial stress state based on the three principal stresses; S503 uses the multiaxial damage parameters to correct the uniaxial creep data and obtain the remaining creep life corresponding to the actual stress state.

[0053] Specifically, based on the creep damage model of heat-resistant steel provided by the applicability assessment standard, a multiaxial stress correction factor and a material degradation factor are introduced. The material parameters are obtained from the standard material parameter table based on the chemical composition and heat treatment state of the material.

[0054] The core formulas for calculating damage parameters are as follows. The formula for calculating the remaining life L is: ; in, The initial creep strain rate is... This is a multiaxial damage parameter.

[0055] ; ; ; ; ; ; ; ; In the formula: For damage parameters, based on the three principal stresses σ 1. σ 2. σ 3 and equivalent stress calculate, Take the lower limit value -0.5. Take the lower limit value -0.3; coefficient α and β The data was obtained by fitting the creep rupture test data of Cr-Mo steel.

[0056] Substituting the above parameters into the remaining life prediction model, the cumulative creep damage is calculated. The results showed that... The values ​​are far below the permissible limit of 0.25, and even below the negligible damage threshold. This indicates that although the equipment experienced multiple short-term overheating events, the grain boundary slip and void aggregation mechanisms within the material have not yet significantly occurred because the overheating peaks are far below the material's tempering temperature and the duration is short. From the perspective of creep damage mechanics, the equipment passes the overheating evaluation and does not require post-weld heat treatment or replacement due to short-term overheating.

[0057] After completing the above-mentioned sub-item evaluations, this invention comprehensively analyzes the stress verification results, creep evaluation results, and material property characterization results to generate the final test results. Please refer to... Figure 6 As shown, in one embodiment of this application, determining the structural integrity test result of the hot high-pressure separator further includes: S601 compares the stress verification result with the allowable stress threshold and compares the cumulative creep damage with the allowable creep damage threshold to obtain the stress and creep assessment conclusion. S602 determines whether there are excessive defects or material performance deterioration based on the wall thickness measurement results, hardness test results and non-destructive test results of the hot high-pressure separator, and obtains a material condition conclusion. S603 determines the structural integrity test result of the hot high-pressure separator based on the stress and creep assessment conclusion and the material state conclusion.

[0058] The following detailed description of this embodiment is based on the specific implementation of the above steps.

[0059] In step S601, the stress verification result is compared with the allowable stress threshold specified in the pressure vessel analysis and design standard, and the cumulative creep damage is compared with the allowable creep damage threshold. When both requirements are met, the stress and creep assessment conclusion is deemed qualified.

[0060] In step S602, the wall thickness measurement results, hardness test results and non-destructive testing results obtained in Example 1 are combined to comprehensively determine whether there are defects exceeding the standard or material performance deterioration, and a conclusion on the material condition is drawn.

[0061] Furthermore, in step S602, the hardness test results not only serve as an independent basis for determining the material condition, but can also be cross-validated with the stress analysis results. Please refer to [link / reference needed]. Figure 7 As shown, in one embodiment of this application, determining whether there is material performance degradation based on the hardness test results includes: S701 compares the hardness test result with the strength level determined based on the stress verification result for consistency. S702 When the deviation between the hardness test result and the strength level exceeds a preset range, the material state conclusion is determined to be unreliable, and a re-verification of the boundary conditions of the stress field distribution data is triggered to update the stress and creep assessment conclusion.

[0062] The purpose of the aforementioned cross-validation mechanism is as follows: hardness is a direct characterization of the mechanical properties of a material, while the strength level converted from the stress verification result is based on the calculated value of the theoretical model. When the deviation between the two is too large, it indicates that there may be a deviation in the boundary condition setting of the stress analysis, which needs to be corrected retrospectively, thereby forming a self-correcting evaluation closed loop and improving the reliability of the final test results.

[0063] In step S603, a comprehensive judgment is made based on the stress and creep assessment conclusions obtained in step S601 and the material condition conclusions obtained in step S602. If the stress check meets the strength criteria, the cumulative creep damage is less than the allowable threshold, and the material condition conclusion indicates no defects exceeding the standard and no irreversible structural degradation, it is determined that the equipment's ability to maintain structural integrity after a short-term overheating is unaffected and it can continue to serve. Simultaneously, based on the assessment conclusions, the following handling recommendations are output: repair the detached fire-retardant coating; conduct a focused re-inspection of the shell base material and adjacent welds in the overheated area during the next shutdown maintenance window; and strengthen operating temperature management during subsequent service.

[0064] This application also provides a device for detecting the structural integrity of a hot high-pressure separator, including a stress analysis module, a strength verification module, a creep assessment module, and a detection and analysis module; The stress analysis module is used to acquire stress field distribution data of the hot high-pressure separator under over-temperature conditions, and generate classified stress intensity values ​​based on the stress field distribution data through stress linearization processing; wherein, the stress analysis module is also used to: establish a finite element analysis model based on design parameters and temperature and pressure parameters under over-temperature conditions; apply loads to the model, the loads including internal pressure, gravity loads, and lateral loads equivalent to wind loads and seismic loads; and obtain stress field distribution data taking into account the loads by solving.

[0065] The strength verification module is used to receive the classified stress intensity value and generate a stress verification result based on the comparison between the classified stress intensity value and the allowable stress intensity of the material. The creep assessment module is used to receive the stress field distribution data and generate the cumulative creep damage amount through the creep damage tolerance assessment model based on the stress field distribution data and the process parameters of the over-temperature condition. The creep assessment module constructs the creep damage tolerance assessment model based on the remaining life fraction method, calculates the remaining creep life based on the stress field distribution data, and obtains the cumulative creep damage amount based on the remaining creep life and the exposure time.

[0066] The detection and analysis module receives the stress verification result and the cumulative creep damage amount, and determines the structural integrity detection result of the hot-pressure separator based on the stress verification result and the cumulative creep damage amount. When the stress verification result meets the strength criteria specified in the pressure vessel analysis and design standard, and the cumulative creep damage amount is less than the allowable creep damage threshold, the detection and analysis module determines that the ability of the hot-pressure separator to maintain structural integrity after a short-term overheating is not affected.

[0067] Furthermore, the detection and analysis module is also used to: compare the stress verification results with the allowable stress threshold, compare the cumulative creep damage with the allowable creep damage threshold, and obtain stress and creep assessment conclusions; determine whether there are excessive defects or material performance degradation based on the wall thickness measurement results, hardness test results, and non-destructive testing results, and obtain material condition conclusions; and determine the structural integrity test results based on the stress and creep assessment conclusions and the material condition conclusions.

[0068] In one embodiment, the detection and analysis module is further configured to: compare the hardness test results with the strength level determined based on the stress verification results; when the deviation exceeds a preset range, determine that the material state conclusion is unreliable, and trigger a re-verification of the boundary conditions of the stress field distribution data to update the stress and creep assessment conclusion.

[0069] The above-described apparatus and method embodiments are based on the same inventive concept, and their specific implementation details can be found in the corresponding descriptions in the method embodiments, which will not be repeated here.

[0070] The beneficial technical effects of this application are as follows: It is the first to construct a three-in-one structural integrity testing method integrating on-site non-destructive testing and material performance characterization, finite element stress analysis under over-temperature conditions, and creep damage tolerance assessment based on fracture mechanics, achieving a leap from traditional qualitative experience-based judgment to quantitative data-driven decision-making. By acquiring stress field distribution data under over-temperature conditions and performing stress linearization classification verification, and simultaneously calculating cumulative creep damage based on the remaining life fraction method and multiaxial stress correction, the creep damage caused by short-term over-temperature can be scientifically quantified, accurately defining the critical boundary between "short-term over-temperature" and "irreversible structural damage." This method avoids unnecessary equipment replacement or post-weld heat treatment due to overly conservative assessments, significantly reducing enterprise operation and maintenance costs, and also eliminates potential safety accidents caused by insufficient assessment. Furthermore, by cross-validating the material performance characterization results such as metallographic analysis and hardness testing with the stress analysis and creep assessment results, the reliability of the assessment conclusions is further improved. This method is not only applicable to high-pressure separators but can also be extended to other pressure-bearing special equipment operating under high-temperature and high-pressure conditions and potentially experiencing short-term over-temperature events.

[0071] This application also provides an electronic device, including 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 above-described method.

[0072] This application also provides a computer-readable storage medium storing a computer program that performs the above-described methods.

[0073] This application also provides a computer program product, including a computer program / instructions that, when executed by a processor, implement the steps of the above-described method.

[0074] like Figure 8 As shown, the electronic device 600 may also include: a communication module 110, an input unit 120, an audio processor 130, a display 160, and a power supply 170. It is worth noting that the electronic device 600 does not necessarily need to include these components. Figure 8 All components shown; in addition, the electronic device 600 may also include Figure 8 For components not shown, please refer to existing technologies.

[0075] like Figure 8 As shown, the central processing unit 100, sometimes also referred to as a controller or operating control, may include a microprocessor or other processor device and / or logic device. The central processing unit 100 receives inputs and controls the operation of various components of the electronic device 600.

[0076] The memory 140 may be, for example, one or more of a cache, flash memory, hard drive, removable media, volatile memory, non-volatile memory, or other suitable devices. It may store the aforementioned failure-related information, and also store a program for executing that information. The central processing unit 100 may execute the program stored in the memory 140 to perform information storage or processing, etc.

[0077] Input unit 120 provides input to central processing unit 100. Input unit 120 may be, for example, a keypad or touch input device. Power supply 170 provides power to electronic device 600. Display 160 displays images and text. Display may be, for example, an LCD display, but is not limited thereto.

[0078] The memory 140 can be a solid-state memory, such as a read-only memory (ROM), random access memory (RAM), a SIM card, etc. It can also be a memory that retains information even when power is off, can be selectively erased, and contains more data; examples of this type of memory are sometimes referred to as EPROMs. The memory 140 can also be some other type of device. The memory 140 includes a buffer memory 141 (sometimes referred to as a buffer). The memory 140 may include an application / function storage unit 142 for storing application programs and function programs or processes for executing the operation of the electronic device 600 via the central processing unit 100.

[0079] The memory 140 may also include a data storage unit (data 143) for storing data, such as contacts, digital data, pictures, sounds, and / or any other data used by the electronic device. The driver storage unit (driver 144) of the memory 140 may include various drivers for the electronic device's communication functions and / or for performing other functions of the electronic device (such as messaging applications, address book applications, etc.).

[0080] The communication module 110 is a transmitter / receiver 110 that transmits and receives signals via antenna 111. The communication module (transmitter / receiver) 110 is coupled to the central processing unit 100 to provide input signals and receive output signals, which can be the same as in a conventional mobile communication terminal.

[0081] Based on different communication technologies, multiple communication modules 110 can be configured in the same electronic device, such as cellular network modules, Bluetooth modules, and / or wireless LAN modules. The communication module (transmitter / receiver) 110 is also coupled to a speaker 131 and a microphone 132 via an audio processor 130 to provide audio output via the speaker 131 and receive audio input from the microphone 132, thereby enabling typical telecommunications functions. The audio processor 130 may include any suitable buffer, decoder, amplifier, etc. Additionally, the audio processor 130 is coupled to a central processing unit 100, enabling on-device recording via the microphone 132 and on-device playback of stored audio via the speaker 131.

[0082] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0083] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0084] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0085] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0086] The various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to interchangeably. Each embodiment focuses on describing the differences from other embodiments. In the description of this specification, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the embodiments in this specification. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0087] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this application. It should be understood that the above descriptions are merely specific embodiments of this application and are not intended to limit the scope of protection of this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method for detecting the structural integrity of a high-pressure thermal separator, characterized in that, The method includes: Acquire stress field distribution data of the hot high-pressure separator under over-temperature conditions, and generate classified stress intensity values ​​based on the stress field distribution data through stress linearization processing. Based on the comparison between the classified stress intensity values ​​and the allowable stress intensity of the material, stress verification results are generated; Based on the stress field distribution data and the process parameters of the over-temperature condition, the cumulative creep damage is generated through the creep damage tolerance assessment model. Based on the stress verification results and the cumulative creep damage, the structural integrity test results of the hot high-pressure separator are determined.

2. The method for detecting the structural integrity of a high-pressure thermal separator according to claim 1, characterized in that, The results of the structural integrity test of the hot high-pressure separator include: When the stress verification result meets the strength criteria specified in the pressure vessel analysis and design standard, and the cumulative creep damage is less than the allowable creep damage threshold, it is determined that the ability of the hot high-pressure separator to maintain structural integrity after a short-term overheating is not affected.

3. The method for detecting the structural integrity of a high-pressure thermal separator according to claim 1, characterized in that, Before obtaining the stress field distribution data of the hot high-pressure separator under over-temperature conditions, the following steps are also included: Test data were obtained based on non-destructive testing and material property characterization of the hot high-pressure separator. Based on the test data, determine whether there are defects exceeding the standard or irreversible material degradation. When the judgment result indicates that there are no defects exceeding the standard and the material has not undergone irreversible structural degradation, the stress field distribution data of the hot high-pressure separator under ultra-high temperature conditions are obtained.

4. The method for detecting the structural integrity of a high-pressure thermal separator according to claim 3, characterized in that, The method further includes: When the metallographic analysis results show no high-temperature degradation characteristics in the microstructure of the base material, weld, and heat-affected zone, and the degree of microstructure aging does not exceed the preset microstructure stability level threshold, it is determined that the material has not undergone irreversible microstructure degradation.

5. The method for detecting the structural integrity of a high-pressure thermal separator according to claim 1, characterized in that, Obtaining the stress field distribution data of the hot high-pressure separator under ultra-high temperature conditions includes: A finite element analysis model is established based on the design parameters of the hot high-pressure separator and the temperature and pressure parameters of the over-temperature condition. A load is applied to the finite element analysis model, and the finite element analysis model is solved to obtain stress field distribution data that takes the load into account. The loads include internal pressure, gravity loads, and lateral loads that are equivalent to wind loads and seismic loads.

6. The method for detecting the structural integrity of a high-pressure thermal separator according to claim 2, characterized in that, The cumulative creep damage amount generated by the creep damage tolerance assessment model includes: The creep damage tolerance assessment model is constructed based on the ratio between exposure time and remaining creep lifetime using the remaining lifetime fraction method. The remaining creep life is calculated based on the stress field distribution data, and the cumulative creep damage is obtained using the creep damage tolerance assessment model based on the remaining creep life and the exposure time.

7. The method for detecting the structural integrity of a high-pressure thermal separator according to claim 6, characterized in that, Calculating the remaining creep life based on the stress field distribution data includes: Based on the stress field distribution data, three principal stresses characterizing the triaxial stress state are extracted; Multiaxial damage parameters reflecting the triaxial stress state are calculated based on the three principal stresses. The uniaxial creep data is corrected using the multiaxial damage parameters to obtain the remaining creep life corresponding to the actual stress state.

8. The method for detecting the structural integrity of a high-pressure thermal separator according to claim 6, characterized in that, The method further includes: The temperature during the entire duration of the short-term overheating event is set as the highest overheating temperature in the short-term overheating event, and this period is taken as the exposure time.

9. The method for detecting the structural integrity of a high-pressure thermal separator according to claim 1, characterized in that, Determining the structural integrity test results of the hot high-pressure separator also includes: The stress verification result is compared with the allowable stress threshold, and the cumulative creep damage is compared with the allowable creep damage threshold to obtain the stress and creep assessment conclusion. Based on the wall thickness measurement results, hardness test results, and non-destructive testing results of the hot high-pressure separator, it is determined whether there are excessive defects or material performance deterioration, and a conclusion on the material condition is obtained. Based on the stress and creep assessment conclusions and the material condition conclusions, the structural integrity test results of the thermal high-pressure separator are determined.

10. The method for detecting the structural integrity of a high-pressure thermal separator according to claim 9, characterized in that, Determining whether material properties have deteriorated based on the hardness test results includes: The hardness test results are compared with the strength level determined based on the stress verification results for consistency. When the deviation between the hardness test result and the strength level exceeds a preset range, the material state conclusion is determined to be unreliable, and a re-verification of the boundary conditions of the stress field distribution data is triggered to update the stress and creep assessment conclusion.

11. A device for detecting the structural integrity of a high-pressure thermal separator, characterized in that, It includes a stress analysis module, a strength verification module, a creep assessment module, and a detection and analysis module; The stress analysis module is used to obtain stress field distribution data of the hot high-pressure separator under over-temperature conditions, and generate classified stress intensity values ​​based on the stress field distribution data through stress linearization processing. The strength verification module is used to receive the classified stress intensity value and generate a stress verification result based on the comparison between the classified stress intensity value and the allowable stress intensity of the material. The creep assessment module is used to receive the stress field distribution data and generate the cumulative creep damage amount based on the stress field distribution data and the process parameters of the over-temperature condition through the creep damage tolerance assessment model. The detection and analysis module is used to receive the stress verification result and the cumulative creep damage amount, and to determine the structural integrity detection result of the hot high-pressure separator based on the stress verification result and the cumulative creep damage amount.

12. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method of any one of claims 1 to 10.

13. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program that, when executed by a processor, implements the method of any one of claims 1 to 10.

14. A computer program product comprising a computer program / instructions, characterized in that, When the computer program / instructions are executed by the processor, they implement the steps of the method described in any one of claims 1 to 10.

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