基于蠕变的高温法兰连接系统寿命预测方法

长期工作在高温下的法兰连接系统 ,由于密封垫片和螺栓的蠕变松弛 ,使得垫片上的残余压紧应力逐渐减小 ,并最终导致连接系统的泄漏失效。在考虑垫片和螺栓蠕变的基础上 ,对连接系统进行变形协调分析 ,建立了高温下法兰连接系统的变形协调方程 ;进而导出了垫片残余应力与时间的关系式 ,即变形协调率型方程 ;根据紧密性概念 ,以最大允许泄漏率为失效准则 ,提出了高温法兰连接系统的寿命预测方法     

高温异种钢管道焊缝开裂原因分析及解决措施

石化装置中,异种钢连接常见。在高温工况下,异种钢管道焊接焊缝质量要求高,管道强度及管道应力应满足高温工况条件,控制不好焊缝处易发生开裂。结合高温异种钢管道焊缝开裂的实际案例,分析开裂原因,并提出处理方案,即高温工况下,异种钢通过法兰连接,但应核算异种钢法兰密封面的膨胀量。     

长颈法兰偏转角的解析算法

螺栓法兰连接是石油、化工、核能、电力等部门压力容器和管道广泛采用的一种连接形式,其密封连接是否可靠直接关系到生产装置的安全运行和现场操作人员的安危。其失效极少是因强度不足引起的,泄漏是连接系统失效的主要原因。在真实螺栓法兰连接结构中,螺栓载荷和内压的作用使法兰发生偏转,法兰偏转引起垫片接触应力分布不均匀,垫片的局部接触应力对螺栓法兰连接结构密封性能的影响较垫片的平均压紧应力更大。文章在Warters法的基础上,考虑了操作压力的影响,对法兰变形进行理论分析,推导了法兰偏转角的计算公式,这为垫片接触应力分布的解析计算研究奠定基础。     

螺栓法兰接头安全密封技术(四)——垫片应力

虽然垫片成本相对较低,但在保证法兰接头的密封性能、控制泄漏方面却起着关键的作用。当法兰接头发生泄漏时,人们往往容易归因于垫片,其中固然有垫片本身的原因,但更多的是法兰连接系统的设计或安装使用中存在的问题,最终通过垫片密封失效的形式表现了出来。在法兰接头安装后到投入使用,垫片应力受到众多因素的影响而发生改变直至减小。当垫片应力降低到低于设计密封要求时,将导致法兰接头的密封失效、发生泄漏。分析了影响垫片应力的因素及其原因,提出从螺栓预紧后直至维持长期运行过程中,垫片应力经历了一个逐渐衰减的过程。要弥补或减小这样的影响,维持法兰接头的密封状态,在垫片和螺栓许用强度范围内,安装垫片应力应尽可能大,即安装螺栓载荷应足够大。     

焊接密封元件的应力计算和强度分析简

根据“螺栓＋法兰＋焊接密封”密封结构的密封原理和结构特点,建立了密封元件-Ω形密封环的有限元计算模型;基于静力学平衡原理,推导出了一种简单、可靠的法兰密封面对Ω形密封环元件产 生的压应力的计算公式,且对计算模型的位移和载荷边界条件进行了合理的处理;应用ANSYS程序计算获得了Ω形密封环的应力分布场,得到了最大应力的数值和出现的部位;根据应力的性质和对结构强度的影响程度,给出了Ω形密封环元件的强度评价条件和评价结果。     

螺纹锁紧环密封结构的有限元分析

加氢换热器中经常使用螺纹锁紧环密封,由于其结构中连接件间的接触以及垫片的非线性性质难以采用常规计算,文章借助ANSYS软件强大的非线性分析功能对螺纹锁紧环密封结构进行了有限元分析。通过分析,得到此密封结构在工况下各个部件的应力分布,分析结果表明:在工况条件下,壳体、螺纹锁紧环、平盖都满足应力强度要求,密封结构连接安全、密封可靠。壳体是主要的受压元件,最大应力出现在壳体和锁紧环互相啮合的螺纹上,危险截面出现在主螺纹的齿根处。由此得出的结论可以为密封结构的优化设计提供参考。     

试验压力下容器法兰强度的探讨

采用设备法兰联接压力容器.在选用设备法兰时,不仅要考虑容器的设计压力、允许工作压力,还必须确定试验压力下的法兰强度,以保证满足工况条件下设备法兰的强度和密封要求.     

提高法兰连接密封可靠性的最大螺栓安装载荷控制技术

确定螺栓安装载荷是走出法兰设计选用的认识误区,解决法兰接头泄漏的核心问题。螺栓材料抗松弛适用温度应大大低于螺栓材料最高设计温度,螺栓安装应力应大大高于螺栓材料许用应力。垫片蠕变松弛是螺栓安装载荷(垫片应力)降低,并导致泄漏的重要因素。最大螺栓安装载荷只要控制螺栓不发生屈服、垫片不压溃、法兰不发生影响垫片密封的过大变形。按WRC 538或ASME压力容器规范进行法兰安装工况下的应力和转角(应变)评估。     

螺栓法兰接头安全密封技术(三)——法兰的设计选用及其承载能力评估

Taylor-Waters法与相应的设计工况下载荷确定规则及其应力判据三者构成一个完整规则,被各国规范应用于非标法兰的强度校核。标准法兰按标准规定的压力-温度额定值选用是安全的。最大螺栓预紧力是控制法兰接头泄漏的关键,而法兰的承载能力评估是决定最大螺栓预紧力的重要因素。法兰承载能力评估可采用公式计算、弹性应力分析、弹-塑性有限元分析等方法,并建立相应的应力分类判据、应变或转角判据。     

化工装置换热器密封泄漏的处理

以E1451设备密封泄漏处理为基础通过图谱对比论述如何选用适当的连接螺栓形式及密封材料、增加螺栓预紧力等以增强在高温、交变工况下设备、管线法兰连接的密封性能。     

FEM stress analysis and sealing performance improvement of box-shaped bolted flanged joints using silicone sealant under internal pressure and thermal conduction conditions

Interface stresses and sealing performance of thin-wall box-shaped bolted flanged joints using silicone sealant under internal pressure and thermal conduction conditions are analyzed by the thermo-elastic finite element method. The flexible flanges were fastened by M8 bolts and nuts with an initial clamping force (bolt preload) after being joined with the silicone sealant. In the elastic and thermo-elastic Finite Element Method (FEM) calculations, the effects of the bolt pitch distance, flange rigidity and flange thickness were examined on the interface stress distributions. In addition, the effects of the linear thermal expansion coefficient and Young's modulus of the silicone sealant in the steady temperature state were also examined from a design standpoint. In the experiments, leakage pressure was measured when the silicone sealant was applied between an aluminum flexible flange with 1 mm thickness and an aluminum flange (body) with 10 mm thickness. Measurements of sealing performance with the silicone sealant and a sheet gasket were also conducted. In addition, strains in the joint in steady temperature states were also measured by strain gauges to understand the effect of the operative temperature on the sealing performance. The experimental results were found to be in fairly good agreement with the calculated results. From the results, it was found that the effect of the thermal conduction condition was greater than that of the internal pressure on both the interface stress distributions and the sealing performance. In addition, the sealing performance was found to be better in the joint with the silicone sealant than that with the sheet gasket.     

The Effects of High Contact Pressures and Temperatures on the Adhesion of Amorphous Polystyrene to Borosilicate (Pyrex) Glass

The effects on adhesive joint strength of four pressure-temperature histories, each over the range of pressures from 1 to 1500 bars and temperatures from 25 to 200°C, has been investigated with polystyrene-Pyrex glass butt joint specimens. The various pressure-temperature histories were designed to show the separate effects of permanent stresses, transient stresses and interfacial contact on joint strength. This strength increased as the number of stress concentration loci were reduced through application of high contact pressures on the melt. However, isobaric solidification of the polymer led to a maximum in fracture stress as a function of applied molding pressure because of the existence of a critical pressure at which permanent thermal stresses were minimized. A series of isothermal compression-decompression molding operations showed fracture stress to increase with interfacial contact area until maximum contact was achieved. A 100 per cent gain in bond strength was realized when interfacial contact was maximized concurrent with minimizing both the permanent and transient stresses which normally develop when the adhesive joint is formed. Microscopic observations of interfaces in both non-fractured and fractured butt joints established a qualitative relationship between debonding, the mechanism of fracture, and joint strength.     

The Effects of High Contact Pressures and Temperatures on the Adhesion of Amorphous Polystyrene to Borosilicate (Pyrex) Glass

The effects on adhesive joint strength of four pressure-temperature histories, each over the range of pressures from 1 to 1500 bars and temperatures from 25 to 200°C, has been investigated with polystyrene-Pyrex glass butt joint specimens. The various pressure-temperature histories were designed to show the separate effects of permanent stresses, transient stresses and interfacial contact on joint strength. This strength increased as the number of stress concentration loci were reduced through application of high contact pressures on the melt. However, isobaric solidification of the polymer led to a maximum in fracture stress as a function of applied molding pressure because of the existence of a critical pressure at which permanent thermal stresses were minimized. A series of isothermal compression-decompression molding operations showed fracture stress to increase with interfacial contact area until maximum contact was achieved. A 100 per cent gain in bond strength was realized when interfacial contact was maximized concurrent with minimizing both the permanent and transient stresses which normally develop when the adhesive joint is formed. Microscopic observations of interfaces in both non-fractured and fractured butt joints established a qualitative relationship between debonding, the mechanism of fracture, and joint strength.     

法兰接头预紧力密封接触分析

法兰接头在石油化工、压力容器等领域有着广泛的应用,而其一旦发生泄漏则会造成严重的事故。利用Workbench,对法兰接头在一定螺栓预紧力和内部压强作用下的强度和变形进行了分析,同时对其密封性能进行了验证。     

基于有限单元法的法兰连接中的接触分析

应用ANSYS软件对法兰接头结构进行建模和网格划分,并且对法兰与螺栓接触处做了非线性接触分析,得到了在设计压力下螺栓结构的应力分布和变形。之后分别对整体模型和螺栓模型做出了应力强度分析。按照JB4732—1995《钢制压力容器-分析设计标准》对危险截面进行应力强度评定。分析结果表明,强度满足要求。     

固定管板釜式再沸器壳程斜锥应力分析

以某固定管板釜式再沸器为例,忽略局部结构,建立整体应力分析模型,利用ANSYS软件对各工况下的应力进行了计算;同时,仅取设备壳程筒体建立局部应力分析模型,对比分析了斜锥最大倾角路径上的轴向应力和薄膜应力.结果显示：前者的最大应力强度位于斜锥大端内壁处,而后者的最大应力强度位于斜锥小端外壁处;对比同时表明采用整体模型分析所得斜锥各项应力强度水平均远低于局部模型分析结果,以此为基础进行设计可大大降低斜锥壁厚.     

LNG接收站用低温球阀阀座唇形密封圈接触特性分析

低温球阀是液化天然气(LNG)接收站中必不可少的流体管道控制装置之一,其在低温工况下工作时阀座密封易发生泄露,严重威胁工业生产的正常运行。本工作基于热固耦合方法研究了LNG接收站用低温球阀唇形密封圈与阀体和阀座的接触特性,包括接触间隙和接触压力。结果表明,受低温介质的影响,唇形密封圈上存在较大温差,导致密封圈上的Mises应力大幅增加,最大Mises应力达到204.92 MPa。相比于常温工况时,低温工况时唇形密封圈的接触间隙变大,接触压力减小,最大接触间隙值达到-0.72 mm。增大弹簧预紧力在一定程度上可以改善低温工况时唇形密封圈的密封性能,增大接触压力。本工作对低温球阀的阀座密封设计和研究具有一定参考价值。     

Fatigue Failure Criterion of Adhesively-Bonded Joints Under Combined Stress Conditions

A study was conducted to investigate fatigue failure criteria for adhesively-bonded joints under combined stress conditions. Two types of adhesively-bonded joint specimens were used: the scarf joint and the butterfly-type butt joint. Both types of joints have considerably uniform combined stress distributions in the adhesive layer. Furthermore, the stress distributions of these joints were analyzed by a finite element method. The results showed that the maximum principal, the von Mises equivalent and the maximum shear stresses in the uniform stress region of the adhesive layer at the endurance limit are correlated with the principal stress ratio.     

锆制压力容器活套法兰接管的结构分析

针对锆制压力容器活套法兰接管不同的衬环结构,利用ANSYS 11.0软件进行应力分析,得到其最大的应力区域.根据衬环的应力分布情况,对其各种结构的优劣性进行分析,并提出在不同工况条件下衬环结构的选择建议,可为工程设计提供参考依据.