目的 明确西部某天然气处理厂注气压缩机组燃料气换热器管束投运7个月后突发泄漏的根本原因,避免同类失效事故重复发生,保障设备连续稳定运行。方法 采用宏观检测、化学成分分析、金相组织观察、显微硬度测试、扫描电镜（SEM）及能谱（EDS）分析、XRD物相分析等多种系统检测手段,对失效管束开展全面失效分析。结果 管束材质为纯铜（Cu的质量分数≥99.5%）,泄漏与未泄漏管束金相组织形貌一致,晶粒呈不规则状,晶粒度等级达9.0级,属加工态特征,显微维氏硬度平均值为88.4HV0.02,材质无明显缺陷。管束内壁光洁,无腐蚀痕迹,XRD分析仅检测到壳体碳钢的腐蚀产物（Fe2O3、FeS、FeCO3）,未发现管束相关腐蚀产物,说明腐蚀并非失效主因。宏观及微观观察表明,管束与挡流板接触部位均存在不同程度磨损和变形,挡流板因厚度仅0.8 mm、固定点不足,在气流冲击下发生扰动和畸变失稳,导致管束与挡流板持续摩擦、壁厚减薄,同时产生附加弯曲应力使管束弯曲变形,两处减薄叠加后,当剩余壁厚无法承受 1.2~1.5 MPa（壳程）与0.2 MPa（管程）的内外压差时,最终发生穿孔泄漏,泄漏形式分为弯曲变形穿孔和磨损穿孔两类。结论 换热器挡流板结构设计缺陷是管束失效的核心诱因,本文提出的结构优化、材质升级、采购技术协议完善及强化材质检验等针对性建议,可为同类工况下燃料气换热器的设计、采购与运维提供科学参考,对提升天然气处理设备运行可靠性具有重要工程价值。
Abstract
The work aims identify the root cause of leakage of the tube bundle in the fuel gas heat exchanger of a gas injection compressor unit in a natural gas processing plant in western China, which occurred only 7 months after commissioning, avoid the recurrence of similar accidents, and ensure the continuous and stable operation of the equipment. A comprehensive set of detection and analysis methods was adopted, including macro inspection, chemical composition analysis, metallographic structure observation, microhardness testing, scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) analysis, as well as X-ray diffraction (XRD) phase analysis. The test results showed that the tube bundle was made of pure copper with a Cu content of ≥99.5 wt%. The metallographic structure of both leaking and non-leaking tube bundles was similar, with irregular grains and a grain size grade of 9.0, which was characteristic of the as-worked state. The average micro-Vickers hardness of the tube bundle was 88.4HV0.02, and there were no obvious material defects. The inner wall of the tube bundle was smooth without corrosion traces, and XRD analysis only detected corrosion products of the carbon steel shell (Fe2O3, FeS, FeCO3), with no obvious corrosion products related to the tube bundle, indicating that corrosion was not the main cause of failure. Macroscopic and microscopic observations revealed varying degrees of wear and deformation at the contact positions between the tube bundles and the baffle plates. Due to the structural design defects of the baffle plates (thickness only 0.8 mm and insufficient fixed points), they were disturbed and distorted unstably under the impact of gas flow. This not only caused continuous friction between the tube bundles and the baffle plates, leading to severe wear and wall thickness reduction of the tube bundle outer wall, but also generated additional bending stress that induced bending deformation of the tube bundles, further thinning the wall thickness at the bent positions. When the residual wall thickness, thinned by wear and bending, was insufficient to withstand the internal and external pressure difference (0.2 MPa for the tube side and 1.2-1.5 MPa for the shell side), the tube bundles suffered perforation and leakage at the weak parts, which were manifested in two forms: bending deformation-induced perforation and wear-induced perforation. The research conclusions indicate that the structural design defects in the baffle plates of the heat exchanger are the core inducement for the tube bundle failure. The targeted suggestions proposed in this study, including structural optimization, material upgrading, improvement of procurement technical agreements, and strengthening of material inspection, can provide scientific references for the design, procurement, operation and maintenance of fuel gas heat exchangers under similar operating conditions, and hold significant engineering value for enhancing the operational reliability of natural gas processing equipment.
关键词
注气压缩机 /
燃料气换热器 /
管束 /
泄露 /
失效分析 /
挡流板
Key words
gas injection compressor /
fuel gas heat exchanger /
tube bundle /
leakage /
failure analysis /
baffle plate
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] 冯刚. 换热器管束流体诱导振动机理与防振研究进展[J]. 化工进展, 2012, 31(3): 508-512.
FENG G.Research Progress in the Flow Induced Vibration Mechanism of Tube Bundles in Heat Exchangers and Precautionary Measures[J]. Chemical Industry and Engineering Progress, 2012, 31(3): 508-512.
[2] 夏春杰, 陈永东, 吴晓红, 等. 关于GB/T 151和TEMA标准中流体诱发振动的分析[J]. 压力容器, 2021, 38(4): 64-71.
XIA C J, CHEN Y D, WU X H, et al.Analysis of Flow-induced Vibration in GB/T 151 and TEMA Standard[J]. Pressure Vessel Technology, 2021, 38(4): 64-71.
[3] 程剑锋. 一次机五段后冷器失效分析及处理措施[J]. 石油化工设备技术, 2015, 36(6): 47-49.
CHENG J F.Failure Analysis on the fifth-section after- Cooler of the Primary Compressor and Treatment Measures[J]. Petro-Chemical Equipment Technology, 2015, 36(6): 47-49.
[4] 曾晓波, 符鹏飞. 一段炉燃料气预热器内漏原因分析及处理[J]. 化工设计通讯, 2012, 38(1): 35-38.
ZENG X B, FU P F.Analysis and Treatment for Fuel Gas Preheater Leakage in Primary Reformer[J]. Chemical Engineering Design Communications, 2012, 38(1): 35-38.
[5] 段兴梅, 张一钧. 换热器泄漏综合分析与处理[J]. 中国机械, 2014(18): 216-217.
DUAN X M, ZHANG Y J.Comprehensive Analysis and Treatment of Heat Exchanger Leakage[J]. Machine China, 2014(18): 216-217.
[6] ALLAHKARAM S R, ZAKERSAFAEE P, HAGHGOO S A M. Failure Analysis of Heat Exchanger Tubes of Four Gas Coolers[J]. Engineering Failure Analysis, 2011, 18(3): 1108-1114.
[7] SHAHRANI S, AL-SUBAI S.Failure Analysis of Heat Exchanger Tubes[J]. Journal of Failure Analysis and Prevention, 2014, 14(6): 790-800.
[8] SAFFIUDEEN M F, SYED A, MOHAMMED F T.Failure Analysis of Heat Exchanger Tubes[J]. Journal of Failure Analysis and Prevention, 2023, 23(3): 1259-1264.
[9] 苏国庆, 李彦, 张建文, 等. 低温甲醇洗装置换热器腐蚀泄漏原因分析[J]. 压力容器, 2025, 42(3): 71-78.
SU G Q, LI Y, ZHANG J W, et al.Analysis of Corrosion and Leakage Causes in Heat Exchangers of Low-temperature Methanol Washing Units[J]. Pressure Vessel Technology, 2025, 42(3): 71-78.[10] 雷顺权, 张国彬, 潘从锦, 等. 酸性水汽提装置原料水/净化水换热器的腐蚀分析与管控[J]. 石油化工建设, 2025, 47(3): 107-109. LEI S Q, ZHANG G B, PAN C J, et al. Corrosion Analysis and Control of Raw Water/Purified Water Heat Exchangers in the Acidic Water Stripping Unit[J]. Petroleum & Chemical Construction, 2025, 47(3): 107-109.
[11] 徐拥军, 呼立红, 郑丽群, 等. 化学清洗造成的换热器管束失效分析[J]. 石油化工腐蚀与防护, 2019, 36(1): 61-64.
XU Y J, HU L H, ZHENG L Q, et al.Analysis of Heat Exchanger Tube Bundle Failure Caused by Chemical Cleaning[J]. Corrosion & Protection in Petrochemical Industry, 2019, 36(1): 61-64.
[12] 刘舫辰, 石岩, 李元鲁, 等. 用于燃煤电厂的低温省煤器前烟道流动及磨损特性[J]. 山东大学学报(工学版), 2022, 52(3): 100-108.
LIU F C, SHI Y, LI Y L, et al.Flow and Wear Characteristics in Front Flue of Low-Temperature Economizer Used in Coal-Fired Power Plant[J]. Journal of Shandong University (Engineering Science), 2022, 52(3): 100-108.
[13] HERNANDEZ S, HARDELL J, WINKELMANN H, et al. Influence of Temperature on Abrasive Wear of Boron Steel and Hot Forming Tool Steels[J]. Wear, 2015, 338/339: 27-35.
[14] 国家市场监督管理总局, 中国国家标准化管理委员会. 铜及铜合金化学分析方法. 第27部分: 电感耦合等离子体原子发射光谱法: GB/T 5121.27—2008[S]. 北京: 中国标准出版社, 2008.
State Administration for Market Regulation, National Standardization Administration. Methods for Chemical Analysis of Copper and Copper Alloys. Part 27: The Inductively Coupled Plasma Atomic Emission Spectromertric Method: GB/T 5121.27—2008[S]. Beijing: Standards Press of China, 2008.
[15] 国家市场监督管理总局, 中国国家标准化管理委员会. 加工铜及铜合金牌号和化学成分: GB/T 5231—2022[S]. 北京: 中国标准出版社, 2022.
State Administration for Market Regulation, National Standardization Administration. Designation and Chemical Composition of Wrought Copper and Copper Alloys: GB/T 5231—2022[S]. Beijing: Standards Press of China, 2022.
[16] VAISI A, MOOSAVI R, LASHKARI M, et al.Experimental Investigation of Perforated Twisted Tapes Turbulator on Thermal Performance in Double Pipe Heat Exchangers[J]. Chemical Engineering and Processing-Process Intensification, 2020, 154: 108028.
[17] 倪增磊, 马江松, 王星星, 等. 纯铜表面梯度结构层的微观组织演化及力学行为[J]. 中国有色金属学报, 2025, 35(6): 2022-2036.
NI Z L, MA J S, WANG X X, et al.Microstructure Evolution and Mechanical Behavior of Gradient-structured Layer on Pure Copper Surface[J]. The Chinese Journal of Nonferrous Metals, 2025, 35(6): 2022-2036.
[18] 毛泽宁. 纯铜塑性行为的晶粒尺寸与应变速率效应研究[D]. 南京: 南京理工大学, 2018.
MAO Z N.Effect of Grain Size and Strain Rate on Plastic Behavior of Pure Copper[D]. Nanjing: Nanjing University of Science and Technology, 2018.
[19] 刘孟杰, 查佳朋, 邹成科. 环境中硫元素物质对换热器铜管腐蚀影响[J]. 日用电器, 2021(3): 64-67.
LIU M J, ZHA J P, ZOU C K.Influence of Sulfur Substance in Environment on Copper Tube Corrosion of Heat Exchanger[J]. Electrical Appliances, 2021(3): 64-67.
[20] 杨开利, 张盼盼, 蒲阳峰, 等. 陕北某气田集气站管线腐蚀机理研究[J]. 热加工工艺, 2024, 53(6): 128-132.
YANG K L, ZHANG P P, PU Y F, et al.Study on Corrosion Mechanism of Gas Gathering Station Pipeline in Gas Field in Northern Shaanxi[J]. Hot Working Technology, 2024, 53(6): 128-132.
[21] 浦晖, 陈杰. 绕管式换热器在大型天然气液化装置中的应用及国产化技术分析[J]. 制冷技术, 2011, 31(3): 26-29.
PU H, CHEN J.Application and Technical Analysis on Localization of Spiral-wound Heat Exchanger in Large-scale Natural Gas Liquefaction Plant[J]. Refrigeration Technology, 2011, 31(3): 26-29.
[22] 汪关锋, 石伟, 孙燕. 固定板式换热器使用效果分析[J]. 化工管理, 2022(5): 107-109.
WANG G F, SHI W, SUN Y.Analysis of the Use Effect of the Fixed Plate Heat Exchanger[J]. Chemical Enterprise Management, 2022(5): 107-109.
[23] 高秋英, 汪洋, 张浩, 等. 塔河油田换热设备腐蚀与防护措施探讨[J]. 石油化工腐蚀与防护, 2021, 38(4): 29-33.
GAO Q Y, WANG Y, ZHANG H, et al.Discussion on Corrosion and Anti-corrosion Measures of Heat Exchange Equipment in Tahe Oil Field[J]. Corrosion & Protection in Petrochemical Industry, 2021, 38(4): 29-33.
[24] 王浩, 史永征, 刘蓉, 等. 天然气管道加热用浸没燃烧换热器设计及应用分析[J]. 石油与天然气化工, 2019, 48(4): 50-56.
WANG H, SHI Y Z, LIU R, et al.Design and Application Analysis of Submerged Combustion Heat Exchanger for Natural Gas Pipeline Heating[J]. Chemical Engineering of Oil & Gas, 2019, 48(4): 50-56.
[25] 苏清博, 鹿来运, 陈杰, 等. 天然气液化用绕管换热器建造技术标准分析[J]. 化工设计通讯, 2021, 47(6): 73-74.
SU Q B, LU L Y, CHEN J, et al.Analysis of Technical Standards for Construction of Coiled Tube Heat Exchanger for Natural Gas Liquefaction[J]. Chemical Engineering Design Communications, 2021, 47(6): 73-74.
PDF(16057 KB)
