Evaluating the Residual Life of Long-Term Equipment Made of Structural and Heat-Resistant Steel by Using the Structural–Mechanical Criterion
Abstract
:1. Introduction
2. Materials and Methods
3. Theoretical Part
4. Calculation of the Structural–Mechanical Criterion and Residual Operating Time
5. Discussion
6. Conclusions
- A structural–mechanical criterion Ks.-m was developed based on the established relationships between the structural state, internal stress fields and stable localization of deformations with the characteristics of non-destructive tests in the metal of long-term power equipment made of structural 0.2 C steel and heat-resistant 0.12C-1Cr-1Mo-1V steel.
- It has been established that with the values of the structural–mechanical criterion Ks.-m ≤ 0.75 for structural steel 20 and Ks.-m ≤ 0.78 for heat-resistant 0.12C-1Cr-1Mo-1V steel, corresponding to the moment of stable deformation localization, it is recommended to replace the checked equipment components due to the exhaustion of the resource. However, the structural–mechanical criterion requires a large number of calculations that can be automated using intelligent systems.
- The proposed and justified approach to assessing and predicting the performance and residual life of long-running power equipment, based on the identified relationships between the structural and substructural states, internal stress fields and stable localization of deformations with the characteristics of non-destructive tests and the calculation of the structural–mechanical criterion, was applied at a number of power plants in the Kemerovo region—Kuzbass.
- When comparing the results of calculating the residual life of power equipment in an automated system, a high convergence was established with the results obtained when directly calculating the parameters of the microstructure (electron microscopy) and deformation parameters.
- An automated system for predicting the performance and evaluating the residual life of long-term power equipment has been developed, the basis of which is the structural–mechanical criterion, and has been tested in industrial conditions on a number of sections of steam and hot water steam pipelines made of structural 0.2 C steel and heat-resistant 0.12C-1Cr-1Mo-1V steel. The results of the calculation of the residual life according to the structural–mechanical criterion were compared with the results obtained by the expert organization during the examination of industrial safety. The discrepancy between the residual life assessment results did not exceed 5%.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Steel | Mass Fraction of Elements, % | |||||||||
---|---|---|---|---|---|---|---|---|---|---|
C | Si | Mn | Cr | Ni | Mo | S | P | V | Fe | |
0.2 C steel | 0.17–0.24 | 0.17–0.37 | 0.35–0.65 | Up to 0.25 | Up to 0.25 | Up to 0.25 | Up to 0.04 | Up to 0.035 | Up to 0.08 | ~98 |
0.12C-1Cr-1Mo-1V | 0.08–0.15 | 0.17–0.37 | 0.4–0.7 | 0.9–1.2 | Up to 0.3 | 0.25–0.35 | Up to 0.025 | Up to 0.03 | 0.15–0.3 | ~96 |
Steel | Pipe Size, mm | Operating Time, Thousand Hours | Quantity, pcs. | Residual Resource, Thousand Hours |
---|---|---|---|---|
Automated system (calculation duration—70.5 h) | ||||
0.2 C steel | Ø133.0 × 13.0 | 219–242 | 26 | 51.2–74.6 |
0.2 C steel | Ø133.0 × 13.0 | 219–242 | 7 | 25.3–48.5 |
0.2 C steel | Ø133.0 × 13.0 | 219 | 3 | less 25 |
0.12C-1Cr-1Mo-1V | Ø133.0 × 17.0 | 180–360 | 19 | 52.6–72.8 |
0.12C-1Cr-1Mo-1V | Ø325.0 × 43.0 | 305–343 | 6 | 26.4–49.1 |
0.12C-1Cr-1Mo-1V | Ø133.0 × 17.0 | 284–318 | 4 | <25 |
Expert organization (calculation duration—112 h) | ||||
0.2 C steel | Ø133.0 × 13.0 | 219–242 | 25 | 50.4–77.8 |
0.2 C steel | Ø133.0 × 13.0 | 219–242 | 8 | 25.2–49.1 |
0.2 C steel | Ø133.0 × 13.0 | 219 | 3 | <25 |
0.12C-1Cr-1Mo-1V | Ø133.0 × 17.0 | 180–360 | 19 | 52.1–74.7 |
0.12C-1Cr-1Mo-1V | Ø325.0 × 43.0 | 305–343 | 6 | 25.9–49.4 |
0.12C-1Cr-1Mo-1V | Ø133.0 × 17.0 | 284–318 | 4 | <25 |
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Ababkov, N.; Smirnov, A.; Danilov, V. Evaluating the Residual Life of Long-Term Equipment Made of Structural and Heat-Resistant Steel by Using the Structural–Mechanical Criterion. Metals 2023, 13, 1075. https://doi.org/10.3390/met13061075
Ababkov N, Smirnov A, Danilov V. Evaluating the Residual Life of Long-Term Equipment Made of Structural and Heat-Resistant Steel by Using the Structural–Mechanical Criterion. Metals. 2023; 13(6):1075. https://doi.org/10.3390/met13061075
Chicago/Turabian StyleAbabkov, Nikolay, Alexandr Smirnov, and Vladimir Danilov. 2023. "Evaluating the Residual Life of Long-Term Equipment Made of Structural and Heat-Resistant Steel by Using the Structural–Mechanical Criterion" Metals 13, no. 6: 1075. https://doi.org/10.3390/met13061075