Numerical Simulation and Experimental Research on Microstructural Evolution During Compact Hot Extrusion of Heavy Caliber Thick-Wall Pipe

Compact hot extrusion(CHE) process of heavy caliber thick-wall pipe is a new material-saving production process. In order to reveal the optimum hot extrusion parameters in CHE process, the e ects of the extrusion parameters on the microstructural evolution are investigated systematically. The metadynamic recrystallization(MDRX) kinetic models and grain size models of as-cast P91 steel are established for the first time according to the hot compression tests performed on the Gleeble-3500 thermal-simulation machine. Then a thermal-mechanical and micro-macro coupled hot extrusion finite element(FE) model is established and further developed in DEFORM software. The results indicated that the grain size of the extruded pipe increases with the increasing of initial temperature and extrusion speed, decreases when extrusion ratio increases. Moreover, the grain size is more sensitive to the initial temperature and the extrusion ratio. The optimum hot extrusion parameters are including that, the initial extrusion temperature of 1250 °C, the extrusion ratio of 9 and the extrusion speed of 50 mm/s. Furthermore, in order to verify the simulation precisions, hot extrusion experiment verification on the heavy caliber thick-wall pipe is carried out on the 500 MN vertical hot extrusion equipment. The load–displacement curve of the extrusion process and the grain sizes of the middle part extruded pipe are in good accuracy with the simulation results, which confirms that the hot extrusion FE models of as-cast P91 steel could estimate the hot extrusion behaviors. The proposed hot extrusion FE model can be used to guide the industrial production research of CHE process.

Strength differential effect and influence of strength criterion on burst pressure of thin-walled pipelines

In the framework of the finite deformation theory, the plastic collapse analysis of thin-walled pipes subjected to the internal pressure is conducted on the basis of the unified strength criterion （USC）. An analytical solution of the burst pressure for pipes with capped ends is derived, which includes the strength differential effect and takes the influence of strength criterion on the burst pressure into account. In addition, a USC- based analytical solution of the burst pressure for end-opened pipes under the internal pressure is obtained. By discussion, it is found that for the end-capped pipes, the influence of different yield criteria and the strength differential effect on the burst pressure are significant, while for the end-opened pipes, the burst pressure is independent of the specific form of the strength criterion and strength difference in tension and compression.

Manufacture of Extra-Thin Wall Steel Pipe by LD Cluster Mill

The manufacture of extra-thin wall steel pipe by LD cluster mill through suitable tool design and process design was described in detail.The defects in steel pipe produced during rolling were analysed and some measures were taken to improve them.Five kinds of extra-thin wall steel pipes have been produced successfully,which are as follows:φ18.5mm×0.25 mm,φ15.5mm×0.25 mm,φ11.4mm×0.2mm,φ14- 24mm×0.12 mm,φ21.74mm×0.12 mm.

Development of ToSPACE for Pipe Wall Thinning Management in Nuclear Power Plants

A number of piping components in the secondary system of nuclear power plants are exposed to aging mechanisms such as FAC (Flow-Accelerated Corrosion), cavitation, flashing, SPE (Solid Particle Erosion), LDIE (Liquid Droplet Impingement Erosion), etc. Those mechanisms may lead to thinning, leak, or rupture of the components. Due to the pipe ruptures caused by wall thinning in Surry unit 2 of USA in 1986 and in Mihama unit 3 of Japan in 1994, the pipe wall thinning management has emerged as one of the most important issues in nuclear power plants. To manage the pipe wall thinning in the secondary system, Korea has used a foreign program since 1996. As using the foreign country’s program for long term, it was necessary to improve from the perspective of the users. Accordingly, KEPCO-E & C has started to develop the 3D-based pipe wall thinning management program (ToSPACE, Total Solution for Piping And Component Engineering management) from eight years ago, and the development was successful. This paper describes the major functions included in ToSPACE program, such as 3D-based DB (Database) buildup, development of FAC and erosion evaluation theories, UT (Ultra-sonic Test) data reliability analysis, field connection with 3D, automatic establishment of long-term inspection plan, etc. ToSPACE program was developed to allow site engineers performing the selection of inspection quantity at each refueling outage, UT data reliability analysis, UT evaluation, determination of next inspection timing, identification of the inspecting and replacing components in 3D drawings, etc., to access easily.

Average temperature calculation for straight single-row-piped frozen soil wall

The average temperature of frozen soil wall is an essential parameter in the process of design, construction, and safety manage- ment of artificial ground freezing engineering. It is the basis of calculating frozen soil＇s mechanical parameters, fiarther prediction of bearing capacity and, ultimately, safety evaluation of the frozen soil wall. Regarding the average temperature of sin- gle-row-piped frozen soil wall, this paper summarizes several current calculation methods and their shortcomings. Furthermore, on the basis of Bakholdin＇s analytical solution for the temperature field under straight single-row-piped freezing, two new calcula- tion models, namely, the equivalent trapezoid model and the equivalent triangle model, are proposed. These two approaches are used to calculate the average temperature of a certain cross section which indicates the condition of the whole frozen soil wall. Considering the possible parameter range according to the freezing pipe layout that might be applied in actual construction, this paper compares the average temperatures of frozen soil walls obtained by the equivalent trapezoid method and the equivalent tri- angle method with that obtained by numerical integration of Bakholdin＇s analytical solution. The results show that the discrepancies are extremely small and these two new approaches are better than currently prevailing methods. However, the equivalent triangle method boasts higher accuracy and a simpler formula compared with the equivalent trapezoid method.

Automatic girth welding and performance evaluation of the joints of hot-induction-bend and line pipes with different wall thickness

During the process of laying long-distance oil and gas transmission pipelines, the hot-induction-bend method is extensively used when the direction has to be changed. By considering the pipeline＇ s ongoing processing and loading states during service, the pipeline that is generally used exhibits thicker walls than those that are observed in the line pipe. As such, during pipeline construction, hot-induction-bend and line pipes with different wall thickness are girth-welded. The chemical composition of hot-induction-bend and line pipes differs, with the carbon content being particularly higher in the hot-induction-bend pipe;it also depicts a higher carbon equivalent, which makes it possible to modify the girth of the pipe. In this study, using Baosteel＇ s standard X70M UOE hot- induction-bend and line pipes, solid-wire automatic gas-metal-arc girth welding was performed and the performance of the girth-welded joint was evaluated. Furthermore,the weldability of the pipeline girth and the microstructure of the girth-welded joint were analyzed. The results reveal that Baosteel＇ s standard UOE hot-induction-bend and line pipes exhibit good girth weldability, and their technical quality can be guaranteed in case of consumer field- construction applications.

Development of New Methodology for Distinguishing Local Pipe Wall Thinning in Nuclear Power Plants

To manage the wall thinning of carbon steel piping in nuclear power plants, the utility of Korea has performed thickness inspection for some quantity of pipe components during every refueling outage and determined whether repair or replacement after evaluating UT data. Generally used UT thickness data evaluation methods are Band, Blanket, and PTP (Point to Point) methods. Those may not desirable to identify wall thinning on local area caused by erosion. This is because the space between inspecting points of those methods are wide for covering full surface being inspected components. When the evaluation methods are applied to a certain pipe component, unnecessary re-inspection may also be generated even though wall thinning of components does not progress. In those cases, economical loss caused by repeated inspection and problems of maintaining the pipe integrity followed by decreasing the number of newly inspected components may be generated. EPRI (Electric Power Research Institute in USA) has suggested several statistical methods such as FRIEDMAN test method, ANOVA (Analysis of Variance) method, Monte Carlo method, and TPM (Total Point Method) to distinguish whether multiple inspecting components have been thinned or not. This paper presents the NAM (Near Area of Minimum) method developed by KEPCO-E & C for distinguishing whether multiple inspecting components have been thinned or not. In addition, this paper presents the analysis results for multiple inspecting ones over three times based on the NAM method compared with the other methods suggested by EPRI.

PipelinerⅡ自动焊系统在厚壁长输管道焊接中的应用

沙特阿美马尼法井场管道焊接工程的特点是:长输管道的口径大、管壁厚,但整体焊接工作量较少。文章在简要对比了几种常用的管道自动焊系统及工艺特点的基础上,论述了采用Pipeliner Ⅱ自动焊系统焊接中东地区厚壁长输管道的优点,并介绍了该系统在该工程中应用的要点,包括焊接工艺方案、对常见缺陷的分析及控制措施等。

Prediction of welding residual stress in multipass narrow gap welded pipes with large thickness

The objective of this study is to investigate the influence of post weld heat treatment （PWHT） on the distribution of residual stress in welded pipes with large thickness. The detailed pass-by-pass finite element simulation was developed to study the residual stress in narrow gap multipass welding of pipes with a wall thickness of 150 mm and 89 weld beads. The effect of PWHT on welding residual stress was also investigated by means of numerical analysis. The simulated results show that the hoop stress is tensile stress in the weld region and compressive stress in the parent metal areas adjacent to weld seam. After heat treatment, the residual stresses decrease substantially, and the simulated residual stress is validated by the experimental one. The distribution of the through-wall axial residual stress along the weld center line is a self-equilibrating type.

A Study on the Cause Analysis for the Wall Thinning and Leakage in Small Bore Piping Downstream of Orifice

A number of components installed in the secondary system of nuclear power plants are exposed to aging mechanisms such as FAC (Flow-Accelerated Corrosion), Cavitation, Flashing, and LDIE (Liquid Droplet Impingement Erosion). Those aging mechanisms can lead to thinning of the components. In April 2013, one inch small bore piping branched from the main steam line experienced leakage resulting from wall thinning in a 1000 MWe Korean PWR nuclear power plant. During the normal operation, extracted steam from the main steam line goes to condenser through the small bore piping. The leak occurred in the downstream of an orifice. A control valve with vertical flow path was placed in front of the orifice. This paper deals with UT thickness data, SEM images, and numerical simulation results in order to analyze the extent of damage and the cause of leakage in the small bore piping. As a result, it is concluded that the main cause of the small bore pipe wall thinning is liquid droplet impingement erosion. Moreover, it is observed that the leak occurred at the reattachment point of the vortex flow in the downstream side of the orifice.

锅炉水冷壁管失效分析

锅炉水冷壁管材料为20G钢,在320℃和10.3 MPa下使用约5年后外表面出现鼓包并泄漏。对失效的水冷壁管进行了宏观检查、化学成分分析、力学性能检测、金相检验、腐蚀产物分析及锅炉水质检测。结果表明:水冷壁管失效是由于锅炉水碱性超标从而发生高温碱腐蚀所致。

管道超声相控阵全聚焦成像仿真及算法优化

针对厚壁管道内部缺陷识别困难、可视化差等问题,提出基于超声相控阵理论和全聚焦算法对厚壁管道内部缺陷进行图像重构。并针对全聚焦成像效率低的缺点,采用有限元法对外径为550 mm,壁厚为65 mm的厚壁管道超声相控阵全聚焦成像进行仿真,模拟缺陷检测过程和成像结果,并使用稀疏矩阵对算法进行优化。结果表明:在基本满足成像质量要求的情况下,采用激发中心频率为5 MHz,阵元宽度为0.5 mm,阵元间距为1 mm,阵元数量为32时,稀疏激发矩阵比全矩阵全聚焦成像效率提高了74.81%,有效提高了成像速度,满足全聚焦快速成像的需求。

探讨分离胶促凝采血管的各组分对钾、钠、氯、钙、磷、镁离子检测结果的影响

目的了解分离胶促凝采血管的分离胶、胶塞和管壁涂层对钾、钠、氯、钙、磷、镁离子检测结果的影响。方法收集郑州大学第一附属医院2023年8月至9月100例献血者的混合血清,将其分装在不同试管中,试管进行不同的处理,试管分为4组:A组将血清放置在干燥玻璃管和黄色胶塞组成的试管中,并倒立放置;B组将血清放置在管壁涂有分离胶的干燥玻璃管中,并直立放置;C组将血清放置在红帽盖和去除分离胶的黄色管子中,并直立放置;D组将血清放置在红帽盖玻璃管中并直立放置作为实验对照组。以上各组试管均室温放置过夜并离心检测,以红帽盖干燥管的测定结果为参考,通过配对t检验分析,观察分离胶促凝采血管各组分对钾、钠、氯、钙、磷、镁离子检测结果的影响;以《临床生物化学检测常规项目分析质量指标》(WS/T403-2012)中允许总误差(TEa)的1/2评价分离胶采血管不同组分对检测结果的影响。结果胶塞对镁离子的检测结果影响差异有统计学意义(P<0.01)、对钾、钠、氯、钙、磷离子的检测结果影响差异无统计学意义(P>0.05);分离胶和管壁涂层对钾、钠、氯、钙、磷、镁离子检测结果影响差异均无统计学意义(P>0.05);当以1/2TEa作为可接受的偏移时,胶塞浸泡的血清镁离子的检测结果偏移超出了范围。结论分离胶采血管在临床检验中能发挥重要的作用,但在应用分离胶采血管前应根据检测项目选择合适的运输方式避免倒置以免影响镁离子的检测结果。

水冷壁管接头开裂原因

某电厂发生锅炉水冷壁管开裂现象。采用宏观观察、化学成分分析、金相检验、硬度测试等方法分析了水冷壁管开裂的原因。结果表明:水冷壁管接头对接环焊缝焊接产生了残余应力,材料中存在焊接缺陷,在高温、高压环境下,缺陷逐渐扩展为孔洞,并对其他管壁造成冲蚀破坏,最终导致水冷壁管开裂。

Hot-rolled strips of up to 19 mm in thickness and their processing to helically welded large diameter pipes of grade X80

Hot-rolled wide strip for production of large diameter,heavy gauged(up to 19 mm) helical line pipe grade X80 was a priority development over the last three years.Microstructure,texture and mechanical properties of strips have been characterised.Also the welding conditions have been simulated.The favourable microstructure is achieved by the proper selection of an appropriate chemical composition of low carbon content and increased niobium micro alloying in combination with suitable strictly controlled hot-rolling parameters.The addition of niobium in combination with the adjustment of other alloying elements increases the recrystallisation stop temperature and thus makes it possible to apply a high temperature processing(HTP) concept.The homogeneous bainitic microstructure across the strip gauge is then formed during accelerated cooling on the run-out table of the hot-rolling mill.All results indicated excellent properties of these hot strips which make it suitable for spiral pipes of grade X80 for example 18.9mm×Φ1 220 mm at dimension.

船闸单侧闸墙主廊道输水系统岔管水动力特性研究

船闸单侧闸墙主廊道输水系统具有结构简单、开挖量小、工程投资省等优点,在河谷狭窄、边坡陡峭等地形受限地区具有明显的技术优势,但工程应用难点之一在于如何保证廊道内断面流速的均匀性,避免出现严重的偏流、脱流现象。依托嘉陵江草街二线船闸工程,采用通用CFD软件FLUENT,对船闸单侧闸墙主廊道双阀门输水系统布置中的岔管水动力特性进行较为详细的研究,探讨岔管分岔角、墩头曲线形式以及外壁曲线形式对岔管水力特性的影响,提出外壁采用正弦曲线,内壁采用圆弧-直线-圆弧形曲线的单侧输水廊道阀门段岔管布置体形,可为类似工程设计提供参考。

基于磁各向异性的管壁应力集中区域检测方法

针对应力集中导致管壁发生屈服失效的问题,提出了利用磁各向异性检测管壁应力集中区域的方法。从能量角度出发,研究了应力导致管壁产生磁各向异性的机理,建立了管壁当量应力与磁各向异性探头输出电压信号的数学模型,通过计算管壁的当量应力判断其是否发生屈服失效,搭建了应力检测实验平台。实验结果表明,应力会导致管壁产生磁各向异性,磁各向异性检测方法能够检测出管壁当量应力的变化趋势和主应力方向所在延长线的角度,进而判断管壁是否产生应力集中区域。

基于可靠性方法的大口径天然气管段壁厚设计

我国陆上天然气管道规模庞大,管道路由地形、地貌和气候特征复杂多样。面对管道及管道所处环境的复杂性,提高油气管道的本质安全水平是行业和民众的共同需求,保证陆上天然气管道安全和可靠运行也越来越成为行业关注的焦点。为达到这个目标,可以采用从源头上对陆上天然气管道的设计方法进行改进的办法。目前天然气管道设计大多普遍利用传统的基于应力的设计方法,该方法由于采用单一的安全系数导致油气管道的安全裕度难以考量,针对此问题,基于可靠性的油气管道设计和评估方法(Reliability Based Design and Assessment,简称RBDA)正成为现代陆上天然气管道设计的趋向,该方法可量化管道全生命周期中的风险,避免采用不合理或过于保守的设计标准。故本研究综合CSAZ662《油气管道系统》标准规范的油气管道可靠性设计方法,并结合国内部分机构根据我国国情而修正的可靠性研究,利用RBDA方法流程,根据某段实际天然气管道确定该管道失效的主要原因(以腐蚀和第三方破坏为主),设计了管道在其生命周期内的极限状态,根据极限状态选择对应的极限状态方程类型,并利用多种数据统计分析方法和软件确定方程中所涉及各个随机变量参数的分布类型,之后利用蒙特卡洛法(Monte-Carlo法)计算设计壁厚条件下得到天然气管道失效概率,统筹考虑其他失效原因的权重,进而得到该管道的可靠度,将该可靠度数据与国内外标准规范确定的目标可靠度进行对比,检验是否满足可靠度目标。由此,对大口径天然气管段完成壁厚设计,实现了使用RBDA方法对1016 mm大口径天然气管道设计的整体流程。

冲击力下薄壁内衬复合管界面黏结强度效应分析

【目的】研究薄壁内衬复合管在受冲击力作用下的界面黏结强度对层间剥离屈曲的影响。【方法】建立薄壁内衬复合管在弹性阶段的非线性分析模型,对薄壁内衬复合管材模态试验与分析模型的分析结果进行对比,验证有限元分析模型可靠性。通过改变衬层与原基层管壁间的界面黏结强度,研究复合管在冲击力下的动态特征。【结果】研究结果表明,当冲击荷载较小、管道变形处于弹性阶段时,薄壁内衬复合管的损伤大都集中在层间界面处。界面黏结强度对层间剥离屈曲有较大的影响,随着层间界面黏结强度的增加,外基层管与内衬层的最大等效应力差值减少。此外,外基层管和内衬层的变形协调性能力随着黏结强度增加而增大,径向层间位移减小,增加了复合管的整体性和连续性。【结论】研究结果可为薄壁内衬修复管道设计方法及层间界面效应分析提供参考。

多冷媒非均质人工冻结壁弹塑性应力分析

【目的】受制冷媒介温度差异以及被冻地层与冻结管距离差异的影响,多冷媒联合双排管冻结壁的非均匀性较为显著,为了合理评价该类冻结壁的安全性,需开展考虑非均质性的多冷媒人工冻结壁弹塑性应力分析。【方法】选取距离1/4管距处的冻结壁作为特征截面,将该截面上的温度分布曲线等效成三段一次函数形式,并将冻结壁视为随温度成线性变化的非均质材料,分别基于4种冻土屈服准则,推导得出多冷媒联合双排管非均质冻结壁弹塑性应力解析表达式。基于该解析表达式,对多冷媒冻结壁的受力特性进行计算,并将该计算结果与均质冻结壁计算得出的结果进行对比。【结果和结论】研究发现:(1)在盐水-二氧化碳联合双排管冻结壁中,径向应力随着相对半径r的增加而上升,环向应力在不同冻结区间(Ⅰ、Ⅱ、Ⅲ)表现出不同的变化趋势。(2)基于均质冻结壁计算理论,弹性极限状态的冻结壁的环向应力最大值出现在冻结壁内侧,弹塑性状态的冻结壁的环向应力最大值出现在弹塑性分界面处,塑性极限状态的冻结壁的环向应力最大值出现在冻结壁最外侧;而基于非均质冻结壁计算理论,冻结壁环向应力最大值始终出现在冻结壁分区界线(r=2)处。(3)在考虑非均质特性后,冻结壁的弹性极限承载力降低1.8%,而塑性极限承载力提高8.1%。在弹塑性状态下,对应相同塑性区相对半径,非均质冻结壁具有更高的承载力,且这种现象随着塑性区相对半径的增大而愈发明显。研究成果对富水地层多冷媒联合冻结帷幕的设计具有重要的参考价值。