螺栓法兰连接系统维修策略研究

南京工业大学硕士学位论文螺栓法兰连接系统维修策略研究姓名：胡少波申请学位级别：硕士专业：安全技术及工程指导教师：顾伯勤20060501IRCM123FMECA4FMECA:RCMABSTRACTIABSTRACTInprocessindustries,theleakageaccidentscausedbythefailureofsealingsystemstakeplacefrequentlyintheselatterdays.Byregardingallfactorsinfluencingthereliabilityoftheconnections,theappropriateboltedflangedconnectionscanbedesignedorselectedtodecreasetheriskoftheleakageaccidentsandimprovethesecurityoftheequipmentorpipeline.Itisnecessarytoinvestigatetheefficientmaintenancetechnologyfortheboltedflangedconnectionsinordertoreducethefailurerateoftheconnectionsandkeeptheequipmentorpipelineworkingreliably.Basedonthereliabilitytheory,thefuzzylogicinferencemethodandthelogicaldecisionmethod,thereliabilitycenteredmaintenance(RCM)intelligentdecisiontechnologyfortheboltedflangedconnectionsofsomekeyequipmentinYangtzePetrochemicalCorporationwasdevelopedinthisthesis.Themainresearchworkandconclusionsaresummarizedasfollows:(1)Theperformancesofthemetaloctagonalgasketsandthecreepcharacteristicoftheboltmaterialatelevatedtemperaturewereinvestigatedexperimentally.Thecorrespondingcharacterizationequationswereobtainedbyregressionanalysismethod.(2)Therandomdistributionregularityoftheparameterswereinvestigated,suchastheoperationpressureandtemperature,mainstructuraldimensionsofthepartsintheconnections,materialyieldingstressesofthepartsandthepretighteningloadsetc.Accordingtotheinterferencemodelofstressandstrength,thereliabilityevaluationmethodfortheboltedflangedconnectionswasbuilt,basedonthetightnessanalysismethod.Themaintenanceperiodofthesealingsystemscanbeascertainedbyusingthevisualcalculatingsoftwaredevelopedinthisthesis.(3)Inconsiderationofthevariationoftheoperationconditionsanddifferenttypesofthemedia,andonthebasisoftheexpertexperiences,thequalitativeanalysisofthefailurecausesandconsequencesoftheboltedflangedconnectionswascarriedoutbyusingthefailuremode,effectandcriticalityanalysis(FMECA)method.TheABSTRACTIIquantitativeanalysisforthefailureriskgradeoftheconnectionswasalsoperformedbasedonFMECAandfuzzylogicinferencemethod.(4)Accordingtothelogicaldecisionmethod,themaintenancestrategiesfordifferentfailuremodeswereputforwardbasedonFMECAandtheexistedmaintenancemethods.Furthermore,themaintenancestrategyofahydrogenationreactionchamberwasworkedout,adoptingthereliabilityandthefailureriskanalysis.Keywords:Boltedflangedconnections;Reliabilitycenteredmaintenance;Reliabilityanalysis;Fuzzylogicinferencemethod;Maintenancestrategy11.11984198970%O[1]12345[2~6]21.21.2.1GB1501998GB1501998ASMEaybm[7~10]ybDWmπ=11.1pDbpDWmmππ2422+=1.2Waters1.2.2()RFFBBGKDDDllDD+−+−=−121221.3SG[10]1.33[11~13]1.2.3DIN2505[14]ASME[7]DIN2505ASMEGbaGS[15,16]1.31.3.1rss,r1-1Fig.1-1Intervenesketchofstress-intensionfr(r)fs(s)fs(s),fr(r)04[17]1-1sry−=ydssfsyfyfsrsy)()()(+=∫1.40ydydssfsyfdyyftRsry∫∫∫∞∞∞+==000)()()()(1.5MonteCarloMonteCarloMonteCarlo011r2r[17]212cosln2rrxπσµ−+=212sinln2rrxπσµ−+=1.6)2cosln2exp(21rrxπσµ−+=)2sinln2exp(21rrxπσµ−+=1.7()kkkarbxk+−=11ln1.8[17]MonteCarloMonteCarlors51.3.2[18]Bach()hDDDpryFFBfπ−−=31.9[29]()2104CbdCWWryπ+−=1.10[20]1.10[21]1.3.3[22~24][21]04779.01835.290exp0866.0expLtTL⋅−=1.11LC64779.0101835.290exp0866.0ln−=TLLJC1.121.4[25]RuntoFailureRTFPreventiveMaintenancePMPredictiveMaintenancePDMCondition-basedMaintenanceCBM[26]RCM[27,28]1.4.1RCM1.2.3.4.5.6.7.1-2RCMFig.1-2FlowchartofRCManalysesofsystem7NowlanHeap[29]RCM1978MSG-3MaintenanceSteeringGroup-3RCM[27,28]RCM1-2RCMSocietyofAutomotiveEngineersSAERCM[30~31]M.Rausand[32]RCMRCM13RCMRCM1-31-3Fig.1-3Age-relatedfailureratecurve1-4Fig.1-4Effectofplannedmaintenanceonfailureratecurve1-5Fig.1-5Developingprocessoffailure1-6P-FFig.1-6P-Fintervaloffailure81-41-51-6RCMJCrockerUDKumarUD[33]RCMRCMHauge[34]RCMReicksetc[35]RCM[36,37]RCMWong[38]EisingerRakowsky[39]RCMFoxetc[40]ThreeMileIslandRCM13428RCM8020[32]RCMRCM[41,42][43]RCMRCMRCM[44]RCM91.4.21231.5FMECAFMECARCMFMECARausandMOienK[45][36,37]RCM10FMECAFailureModeandEffectsAnalysis─FMEACriticalityAnalysis—CAFMECA1RiskPriorityNumberRPN[46]2[47]FMECA1965L.A.Zadeh40[48,49]K.Xu[50][51~53]FMECARCM1.611125Cr2MoVA2GB15019983FailureMode,EffectsandCriticalityAnalysis,FMECA4FMECARCM5122.12-1[54]2-22.1.12-1Fig.2-1Testdeviceforgasketperformances123456789101112123675891210411132.1.20.5%500kN0.5~5kN/s2.1.37MPa2-2Fig.2-2Flowchartoftestequipmentforgasketperformances12345678910111213∼1516∼181920∼2612435679810111213151416181724221921232620142.1.421T1T2T3V1V2V31RTnpV11=222RTnpV=2.1333RTnpV=∑==++=31321iiiTVRpnnnn2.2p15∑=∆=∆31iiiTVRpn2.3∑=∆=∆=∆31iiiaaaaTVppTnRpTV2.4L∑=∆=∆=3100ππiiiaaTVptpDTtDVL2.52.1.5―2.22-13042-1Table2-1GeometricparametersoftheoctagonalgasketDGmmhmmammwmmα°123.8217.467.7511.1123°2.2.1AB3120016001800N/mm16AB2.2.2150300400500480012001600N/mm2.2.31100±21h234220V530V67890V9q040N/mm1011XY12222625242626—17132.2.4ABBAB2-31600N/mm2-31230.00.10.20.30.40.50.60.70.80200400600800100012001400160018002-3Fig.2-3CompressiveandresilientcurvesatdifferenttemperaturesandunderthesameseatingstressDGmm20150300400500qGN/mm182.2.4.1CNKCCKDTBAq)(−=(2.6)AC9085.23