نشریه فناوری آزمون‌های غیرمخرب

نشریه فناوری آزمون‌های غیرمخرب

ارزیابی نوع و شدت خرابی لوله‌های ریفورمر بخار با استفاده از جریان گردابی

نوع مقاله : مقاله پژوهشی

نویسندگان
1 دانشکده مهندسی مواد و صنایع، دانشگاه صنعتی نوشیروانی بابل، بابل، ایران
2 دانشکده مهندسی مواد و صنایع، دانشگاه صنعتی نوشیروانی بابل، بابل، ایران،
3 واحد تحقیق و توسعه ادی وایز ان‌دی‌تی، ازمیر، ترکیه
چکیده
در این مقاله، روشی نوین جهت ارزیابی غیرمخرب نوع و شدت خرابی در لوله‌های ریفرمر بخار از جنس HP40Nb بر پایه روش جریان گردابی ارائه شده است. این روش فراتر از تشخیص ساده نقص‌ها، انواع مختلف آسیب‌های ریزساختاری را به صورت عددی ارائه می‌کند. بازرسی به صورت میدانی و آزمایشگاهی روی لوله‌هایی از سه واحد ریفرمر یک واحد صنعتی پتروشیمی ایران با عمرهای بهره‌برداری اسمی 5، 13 و 16 سال انجام شد. بازرسی جریان گردابی به روش روبش نقطه‌ای و با حسگر الکترومغناطیسی با هسته‌ای به شکل T در فرکانس 60 کیلوهرتز توسط یک دستگاه قابل حمل دستی انجام شد. بررسی‌های ریزساختاری نمونه‌هایی از این لوله‌ها با میکروسکوپ‌های نوری و الکترونی روبشی مجهز به پردازش عنصری انجام شد. نتایج مطالعات آزمایشگاهی ریزساختاری نشان داد که آسیب‌های اصلی در لوله‌های آسیب دیده شامل تغییرات در مقدار و نوع کاربیدها، کاهش مقدار کروم زمینه، کربوره‌شدن، اکسیداسیون و ریزترک‌ها است. ارزیابی‌های جریان گردابی نشان داد که تغییرات ریزساختاری و تغییرات داده‌های آزمون جریان گردابی را می‌توان با شاخصهای مناسبی مشخص کرد. آسیب ذاتی (DI) ناشی از کربوریزاسیون و اکسیداسیون را با استفاده از شاخص تغییرات زاویه فاز جریان گردابی و آسیب ناشی از خزش (DII) که با ایجاد حفره‌ها و ترک‌ها نمایان می‌شود را با استفاده از شاخص تغییرات امپدانس می‌توان ارزیابی کرد. مشاهده شده است که با افزاش میزان کربوره شدن و تبدیل کاربیدهای M23C6 به M7C3 و کاهش مقدار کروم فاز زمینه، شاخص زاویه فازی از عدد 18.7 به حداکثر 63.2 درجه افزایش می‌یابد. همچنین همزمان با افزایش عمر لوله‌ها و جوانه‌زنی و رشد ترک‌های خزشی، شاخص امپدانس از مقدار بدون بعد 655 به مقدار 1064 افزایش می‌یابد. در پایان، با ترکیب دو شاخص الکترومغناطیس با یکدیگر و ارائه یک رابطه تجربی، شاخص میزان خرابی کل (Dtotal) هر لوله ارائه شده است.
کلیدواژه‌ها
موضوعات

عنوان مقاله English

Evaluation of Severity and Type of Damages in Steam ‎Reformer Tubes using Nondestructive Eddy Current Method

نویسندگان English

Ruaa Alshareefi 1
Majid Abbasi 2
Maryam Shamgholi 3
1 Faculty of Materials and Industrial Engineering, Babol Noshirvani University of Technology, Babol, Iran
2 Faculty of Materials and Industrial Engineering, Babol Noshirvani University of Technology, Babol, Iran.
3 R&D Manager of EDDYWISE NDT, Izmir, Türkiye.
چکیده English

In this paper, a novel method for non-destructive evaluation of the type and severity of damage in HP40Nb steam reformer tubes is presented based on the eddy current method. Beyond simple defect detection, this method provides numerical representation of various types of microstructural damage. Field and laboratory inspections were performed on tubes from three reformer units of an Iranian petrochemical industrial unit with nominal operating lives of 5, 13, and 16 years. Eddy current inspection was performed by the point scanning method with an electromagnetic sensor with a T-shaped core at a frequency of 60 kHz using a handheld portable device. Microstructural studies of samples of these tubes were performed with optical and scanning electron microscopes equipped with EDS analysis. The results of the microstructural laboratory studies showed that the main damages in the damaged pipes include changes in the amount and type of carbides, reduction in the chromium content of the matrix, carburization, oxidation, and microcracking. Eddy current evaluations showed that the microstructural and the eddy current variations can be characterized by appropriate parameters. Intrinsic damage (DI) due to carburization and oxidation can be evaluated using the phase angle index and creep damage (DII), which is manifested by the formation of holes and cracks and can be evaluated using the impedance index. It has been observed that by increasing the amount of carburization and the conversion of M23C6 carbides to M7C3 and reducing the chromium content of the matrix, the phase angle index increases from 18.7 to a maximum of 63.2 degrees. Also, as the pipes' life increases and the creep cracks' nucleation and growth occur, the impedance index increases from a dimensionless value of 655 to 1064. Finally, by combining the two electromagnetic indices and presenting an empirical relationship, the total failure rate index (Dtotal) of each pipe is presented.

کلیدواژه‌ها English

Eddy Current Testing
Steam Reformer Tube
HP40Nb
Life Assessment
Damage
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  • تاریخ دریافت 07 فروردین 1404
  • تاریخ بازنگری 31 فروردین 1404
  • تاریخ پذیرش 09 خرداد 1404