Failure analysis and improvement measures of hydrogenation reactor flange sealing groove

doi:10.16265/j.cnki.issn1003-3033.2024.12.0102

Abstract

Abstract:

In order to prevent accidents caused by the failure of the flange sealing groove in the hydrogenation reactor, failure analysis methods such as macroscopic inspection, fracture analysis, ferrite detection, chemical composition analysis, hardness detection, metallographic detection, SEM analysis and operation process analysis were adopted. The influencing factors of damage mode, start-stop operation process, ferrite content in the weld overlay layer, material properties, and abnormal elements were studied, and the reasons for the failure of the flange sealing groove at the outlet of the hydrogenation reactor were analyzed. The results indicate that the failure of the sealing groove is mainly due to the high stress between the weld overlay layer and base metal of the sealing groove, which produces stress corrosion cracking under the action of a corrosive medium containing F, S and other elements. There is no weld overlay layer on the bottom surface of the cracked flange sealing groove, and the transgranular cracks started at the junction of the surface weld overlay layer and the non-weld overlay layer, mainly on the surface of the non-weld overlay layer side. According to the failure causes, the corresponding improvement measures are put forward from the aspects of manufacturing, material selection and maintenance.

Key words: hydrogenation reactor, flange sealing groove, failure causes, scanning electron microscope(SEM), weld overlay layer, stress corrosion cracking

CLC Number:

X937

ZHANG Chunyi, ZHU Ge, TIAN Zhiyong, SONG Ming, DU Liang, WU Yuanjian. Failure analysis and improvement measures of hydrogenation reactor flange sealing groove[J]. China Safety Science Journal, 2024, 34(12): 100-107.

Figures/Tables 12

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检测工件	A侧面铁素体均值	B槽底面铁素体均值	C侧面铁素体均值
开裂法兰	6.9	2.7	7.1
完好法兰	7.2	6.9	7.1

分析位置	化学成分质量分数/%
分析位置	碳	硅	锰	铬	镍	钼	钛	磷	硫
NB/T 47010—2017 标准要求	≤0.08	≤1.00	≤2.00	17.00~ 19.00	9.00~ 12.00	—	5×C~0.70	≤0.035	≤0.015
开裂法兰10号螺栓孔	0.06	0.72	1.64	18.52	10.76	0.10	0.30	0.031	0.004
开裂法兰2号螺栓孔	0.06	0.72	1.63	18.62	10.62	0.10	0.30	0.029	0.004
完好法兰11号螺栓孔	0.05	0.53	1.73	18.91	10.58	0.07	0.22	0.029	0.004
开裂法兰10号孔堆焊层(TP347L)	0.04	0.53	1.65	19.00	10.24	0.06	0.10	0.021	0.002

分析位置	元素Element	铁	氧	铬	镍	钙	锰	铝	硅	钛	镁	硫
10号螺栓孔 1号切片	质量分数/%	45.67	29	16.61	3.55	—	2.91	0.99	0.85	0.42	—	—
10号螺栓孔 1号切片	分数/At%	26.05	57.74	10.18	1.93	—	1.69	1.17	0.97	0.28	—	—
2号螺栓孔 3号切片	质量分数/%	45.64	41.68	8.34	—	1.93	1.61	—	—	—	0.42	0.4
2号螺栓孔 3号切片	原子分数/%	22.15	70.61	4.34	—	1.3	0.79	—	—	—	0.46	0.34