西部某轻烃厂球罐焊缝开裂原因分析及试验评价

李亚军; 吴超; 潘鸿; 安超; 方艳; 熊新民

doi:10.7643/ issn.1672-9242.2025.11.016

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装备环境工程 ›› 2025, Vol. 22 ›› Issue (11) : 151-159. DOI: 10.7643/ issn.1672-9242.2025.11.016

重大工程装备

西部某轻烃厂球罐焊缝开裂原因分析及试验评价

李亚军^1,2,3,4, 吴超^1,2,3,4, 潘鸿^5,*, 安超^1,2,3,4, 方艳^1,2,3,4, 熊新民^1,2,3,4

作者信息 +

Analysis of Cracking Causes and Experimental Evaluation of Welds on Spherical Tanks of a Light Hydrocarbon Plant in Western China

LI Yajun^1,2,3,4, WU Chao^1,2,3,4, PAN Hong^5,*, AN Chao^1,2,3,4, FANG Yan^1,2,3,4, XIONG Xinmin^1,2,3,4

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摘要

目的明确西部某轻烃厂球罐焊缝开裂的具体原因,以及焊接工艺和环境因素对焊缝抗裂性能的影响机制,为同类球罐的焊接工艺优化和施工控制提供支持。方法以失效Q345R钢球罐为对象,通过无损检测和理化检验,确定失效试样的损伤情况和模拟焊接样品在不同冷却速度下的残余应力大小和性能差异。结果球罐内焊缝有122处裂纹,最长达30 mm。1#和2#模拟焊缝样品残余应力分别为168、248 MPa,‒20 ℃下1#冲击功分别为110、93 J,热影响区硬度分别为276HV0.5和301HV0.5。1#模拟焊缝样品热影响区的马氏体含量较2#低,这是导致这2种样品残余应力和性能差异的根本原因。在低H₂S含量SCC试验中,2种样品均未开裂。结论该球罐焊缝裂纹是由于在较高残余应力作用下冷却速度过快,使硬脆相马氏体组织产生了冷裂纹,而不是低H₂S含量导致的应力腐蚀开裂。

Abstract

The work aims to clarify the specific causes of weld cracking in spherical tanks at a light hydrocarbon plant in western China, as well as the influence mechanism of welding process and environmental factors on the crack resistance of welds, and to provide support for the optimization of welding processes and construction control of similar spherical tanks. With a failed Q345R steel spherical tank as the research object, the damage status of the failed samples and the differences in residual stress magnitude and performance of simulated welded samples under different cooling rates were determined through non-destructive testing and physical and chemical inspection. The results showed that 122 cracks were found in the inner weld of the spherical tank, with the longest reaching 30 mm. The residual stresses of the simulated welded samples No. 1 and No. 2 were 168 MPa and 248 MPa respectively; their impact energies at ‒20 ℃ were 110 J and 93 J respectively, and the hardness values of their heat-affected zones (HAZ) were 276HV0.5 and 301HV0.5 respectively. The martensite content in the HAZ of simulated weld sample No. 1 was lower than that of sample No. 2, which was the fundamental reason for the differences in residual stress and performance between the two samples. Neither sample cracked in the stress corrosion cracking (SCC) test with low H₂S content. Therefore, the weld cracks in this spherical tank are cold cracks caused by the formation of hard and brittle martensite structure due to excessively fast cooling rate under the action of high residual stress, rather than stress corrosion cracking induced by low H₂S content.

导出引用

李亚军, 吴超, 潘鸿, 安超, 方艳, 熊新民. 西部某轻烃厂球罐焊缝开裂原因分析及试验评价[J]. 装备环境工程. 2025, 22(11): 151-159 https://doi.org/10.7643/ issn.1672-9242.2025.11.016

LI Yajun, WU Chao, PAN Hong, AN Chao, FANG Yan, XIONG Xinmin. Analysis of Cracking Causes and Experimental Evaluation of Welds on Spherical Tanks of a Light Hydrocarbon Plant in Western China[J]. Equipment Environmental Engineering. 2025, 22(11): 151-159 https://doi.org/10.7643/ issn.1672-9242.2025.11.016

中图分类号： TG404

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