1、探讨压力容器制造中材料代用的分析论文摘要：压力容器设计中最重要的部分之一便是材料的选择，它直接关系到压力容器的质量和安全性，但由于设备制造过程中采购困难等因素的影响，材料代用现象普遍发生，常见的代用问题有：以优代劣、以厚代薄及其他问题，这些问题直接关系到容器的质量和安全以及投资建设方的经济和管理问题，值得我们重视。Abstract: one of the most important part in the design of pressure vessels is the choice of materials, it is directly related to the quality a
2、nd safety of pressure vessel, but as a result of equipment procurement difficulties during the process of manufacturing, the influence of such factors as material substitution phenomenon occurs frequently, common alternative questions are: generation to better, with thick and thin, and other issues,
3、 these issues directly related to the quality of the container and safe construction and investment of economic and management issues, worthy of our attention. 如何进行正确的选材是压力容器设计和创造中的第一步，也是直观重要的一步。在压力容器的设计和制造过程中，一旦材料选取不合适，会对容器的安全使用留下重大隐患。所以，在压力容器选材上，要根据容器的具体使用条件，如设计的压力和温度、操作特http:/ http:/ to make the
4、right selection is the first step in pressure vessel design and creation, and intuitive important step. In pressure vessel design and manufacture process, once the material selection is not appropriate, will use left significant hidden danger for the security of the container. So, on the pressure ve
5、ssel materials, according to the working conditions of the container, such as the design pressure and temperature, operating characteristics, characteristic of medium etc, have to select suitable mechanical, welding and corrosion resistance and other physical properties of the material. In addition,
6、 when select material will also give full consideration to the specific processing technology and economy, and other factors. 1 材料代用的具体规定1 material to substitute the specific provisions 在设备的设计和制造过程中，常常会出现材料采购困难或者出于经济上的考虑，材料代用的现象经常出现在压力容器的设计过程http:/ http:/ 固定式压力容器安全技术监督规程（TSG R0004-2009） 以及钢制压力容器（GB1
7、50-1998） 对材料代用做了相关规定。一般来讲，主要要求如下：压力容器的承压部件在代用材料的选择上，应和被代用材料有着相同或者相似的外形质量、化学成分、尺寸公差、性能指标、检验项目和检验率等。材料代用最基本的原则是：要绝对保证，在技术要求上，代用材料不得低于被代用材料，个别在检测率或性能项目上要求不严格的代用材料，可以采取检验、测试的方式来选择合适的代用材料。材料代用的手续要求为：（1）容器承压部件的代用要严格进行，须经由代用单位技术部门的批准并上报代用材料的复检报告或质量证明，由主管负责人核准批复；（2）必须在获得原设计单位的允许并拿到证明文件后，才可以在压力容器制造时进行材料代用；（3
8、）压力容器的设计图、施工图以及出厂时的质量证明书中要细致标注代用材料的规格部位、材质和规格。In equipment design and manufacturing process, often there will be a material procurement difficult or out of economic considerations, material substitution phenomenon often appears in the process of pressure vessel design. The stationary pressure vessel
9、s safety technology supervision regulation (TSG R0004-2009) “and“ steel pressure vessel (GB150-1998) “made rules for material substitution. Generally speaking, the main requirements are as follows: pressure vessel pressure parts in the http:/ http:/ of alternative material, should be substitute mate
10、rial has the appearance of the same or similar quality, chemical composition, dimensional tolerance, performance index, rate of inspection items and inspection, etc. Material to substitute the most basic principle is: to absolutely guarantee that, on the technical requirements, alternative materials
11、 shall not be less than be substitute material, individual projects or performance in detection rate on the alternative material is not strict, can adopt the method of inspection, testing, to choose suitable alternative material. Material alternative procedures for: (1) container compression part al
12、ternative to strict, must through the alternative unit approved by the technical department and report to substitute material review report or quality certificate, subject to approval by the supervisor, head of the approval; (2) must be in the permission of the original design unit and after to get
13、the documents, can on when the pressure vessel manufacturing materials substitute; (3) of the pressure vessel design, shop drawing and factory in the certificate of quality to detailed annotation of the specifications of the alternative material parts, materials and specifications. 2 以优代劣Generation
14、2 in order to better http:/ http:/ metal materials used in the pressure vessel with excellent performance, including the material mechanical properties, corrosion resistance, high temperature resistance and production process, etc. Each kind of material performance is fixed, from the perspective of
15、performance comparison, will often appear between material “optimal“ and “bad“ problem. But for each pressure vessel material performance requirements under different circumstances is also different, so material substitute of the “best“ and “bad“ judge from set out actually, specific issue concrete
16、analysis. Here, the author based on their own work experience, mainly discusses several typical generation “in order to better“. 2.1 压力容器制作中，在强度、力学特征等机械性能方面，其http:/ http:/ pressure vessel production, in terms of strength and mechanical properties such as mechanical characteristics, the commonly used
17、 in low alloy steel although is better than carbon steel, but its cold working performance and weldability are better than carbon steel. Generally speaking, the high level of intensity, the cold working performance and poor weldability, negative correlation between them. So in this aspect of the alt
18、ernative, should correspondingly adjust the welding process, when the heat treatment may also have corresponding change, should give full attention. 2.2 材料代用时进行细致、周全的考虑，否则压力容器实际使用中可能会出现各种安全隐患。比如处于湿硫化氢环境下及存在应力腐蚀开裂风险的设备中，容器对应力腐蚀开裂地敏感性随容器使用的钢材的强度级别的提高而增大，二者正相关。此时若将 20R 和Q235 和 20R 系列的钢材用 16MnR 等低合金钢待用就
19、极易产生问题，因此，此类“以优代劣”行径在原则是行不通的，应当被禁止。镇静钢在许多性能方面上，镇静钢都比沸腾钢要更占优势，但在搪玻http:/ http:/ material substitute a detailed and comprehensive consideration, otherwise the pressure vessel may appear all kinds of potential safety problems in practical use. For example and there is stress corrosion cracking in wet h
20、ydrogen sulfide environment risk of equipment, containers with susceptibility to stress corrosion cracking in use of the strength of the steel increases with the increase of the level, the two are related. At this point if the 20 r and Q235 and 20 r series of 16 MNR steel with low alloy steel for us
21、e is easy to cause problems, as a result, this kind of “generation“ in order to better behavior in principle doesnt work, should be banned. Killed steel in many performance, calm steel all is more dominant than the steel, but the glass lining container manufacturing, sedative effect as rimming steel
22、 instead of the enamel steel well. 2.3 一般来说，不锈钢的耐腐蚀性较出色，但在含有氯离子的环境下，其耐腐蚀性却不如低合金钢和碳素钢。2.3 in general, the corrosion resistance of stainless steel is good, but in containing chloride ion environment, its corrosion resistance is better than low alloy steel and carbon steel. http:/ http:/ 和普通不锈钢相比，超低碳不锈
23、钢虽然具有价格优势和良好的耐腐蚀性，但前者的高温热强性却更为出色。一般情况下，为了提高耐腐蚀性，需降低含量，而为了提高高温性，则要提高炭的含量。故而，此种情况下的 “以优代劣” ，要尤其精确设计设备温度，如有必要，应当重新计算。2.4 compared with the ordinary stainless steel, ultra-low carbon stainless steel although has the price advantage and good corrosion resistance, but the former strong high temperature ho
24、t sex is superior. Under normal circumstances, in order to improve the corrosion resistance, need to lower levels, and in order to improve high temperature resistance, to increase the carbon content. So, this case of “generation“ in order to better, be especially accurate temperature design equipmen
25、t, if necessary, shall be recalculated. 2.5 原则上，膨胀节、爆破片、挠性管板及这类零件不能进行以优代劣，特殊情况下必须代用时应以代用的材料为重新进行精密计算，根据结果，适当调整零件厚度，以防止这类零件及其相邻部位出现故障或者失效。2.5 in principle, expansion joint, blasting, flexible tube plate and the parts http:/ http:/ be in optimal generation of carrier, when special circumstances must s
26、ubstitute with substitute material for precision calculated again, according to the results, appropriate adjustments to part thickness, and its adjacent areas in order to prevent this kind of parts malfunction or failure. 2.6 对热换器管板而言，锻件的总体性能比板材要好，所以通常情况下采用锻件，但当管板厚度小于 6cm 时也可以用板材代替锻件，但此时要注意，即使锻件和板材的
27、厚度、材质及设计温度都相同，但两者的许应用力却不相同，前者的许应用力稍低于后者。故如需锻件代用板材，应重新核准管板厚度。2.6 for heat exchange in tube sheet forgings overall performance is better than plate, so usually USES the forgings, but when the tube plate thickness less than 6 cm plate can also be used instead of the forgings, but at this point to note
28、that even if the forgings and the thickness of the plate temperature, material and design are the same, but the applied force is not the same, xu applied force of the former was slightly lower than the latter. So if you want to substitute plate forgings, shall be approved to tube plate thickness. 对钢
29、材来说，其化学成份上的微小差异都可能对其性能造成重大影响，所以要对待任何类型压力容器钢材的“以优代劣”问题都http:/ http:/ steel, its chemical composition on the tiny differences may have a significant impact on its performance, so to treat any type of pressure vessel steel problem of “generation in order to better“ to give full attention, so as not to
30、cause the product and the original design. 3 以厚代薄3 with thick and thin “以厚代薄”常常使从平面应力状壳体的受力态转变为平面应变状态，这对容器受力状态来说，是有百害而无一利的，通常情况下，厚壁容器比薄壁容器更容易产生三向拉应力，进而产生平面应变脆性断裂。“Thick and thin“ often make the transition from plane stress of shell stress state for plane strain state, this stress state, the containe
31、r is a vile and, under normal circumstances, thick wall vessel easier than thin walled containers to produce three to tensile stress, thus produce plane strain of brittle fracture.3.1 对原设计中封头和筒体间等厚焊接的容器，若对容器壳体的个http:/ http:/ on the original design of head and shell thickness of welding between conta
32、iners, if individual parts into the container shell with thick and thin, easy to increase shell geometric discontinuity, so that the head and cylinder connections between parts of local stress increase, at this point, for the container has a tendency to stress corrosion, and can cause great damage.
33、May lead to fatigue crack, serious can cause fatigue fracture. 3.2 在厚板替代薄板时，常常导致连接结构发生相应改变，例如，筒体与加厚的封头连接时，通常需要对封头进行削边处理。对以管道为主要筒体构成的设备，若增加筒壁厚度，在封头与筒体的连接部位也须对筒体侧实施内削边处理。在厚度增加较大时，往往也关系到焊接工艺的变化。3.2 in thick plate replacement sheet, often leads to connection corresponding changes in the structure, for e
34、xample, cylinder head and thickening, connection, usually need to edge the head. For pipe as the main cylinder composed of equipment, if increase the wall thickness, in http:/ http:/ head and the connection parts of cylinder should be within the cylinder side implementation on edge processing. Large
35、 increases in thickness, also often related to changes in the welding process. 3.3 容器壳体整体层面上的“以厚代薄” ，虽然并不会造成筒体连接处和封头的局部应力增加，但不了避免地，仍会导致一下不良影响。1）厚度增加后，原来的壳体设计中的探伤方式和焊接工艺也要进行相应的改变，增加难度；2）壳体厚度的增加必然使容器的重量加大，当容器重量增加过大时，必然会对容器的基础和支座产生不利影响；3）对壳体同时具有传热作用的容器，壳体厚度的增加肯定会影响其传热效果。3.3 container shell overall leve
36、l “by the thick and thin“, although not cause cylinder and head of the local stress increases, but not the inevitable, still can cause a bad influence. 1) thickness increases, the testing way and the welding technology in the design of the original shell also must carry on the corresponding change,
37、increase the difficulty; 2) the thickness of the shell increase will make up the weight of the container, the container weight increase is too large, will inevitably impact of and support for container; 3) for shell have heat transfer effect of containers at the same time, increase the thickness of
38、shell is bound to affect the heat transfer effect. http:/ http:/ 钢板的许应用力和其厚度紧密相连， 钢制压力容器（GB150-1998） 指出，钢材的许应用力随着其板厚的增大而减小，二者负相关。例如 20-150环境下，16MnR 板厚由 16mm 变为18mm 时，其许应用力则从 170MPa 降为 167MPa，150时，20R的板厚由 16mm 变为 18mm 时，其许应用力则从 135MPa 降为125MPa。由此可知，以厚代薄很可能导致强度不够，故而，对处于临界状态的以厚代薄，必须对验算其强度。3.4 steel pla
39、te applied force and its thickness is closely linked, “steel pressure vessel (GB150-1998)“ pointed out that steel xu applied force with decreases with the increasing of the thickness, the negative correlation between them. For example at 20 to 150 environment, 16 MNR thickness changed from 16 mm to
40、18 mm, its application strength from 170 mpa to 167 mpa, 150 , 20 r thickness changed from 16 mm to 18 mm, its application strength from 135 mpa to 125 mpa. “Accordingly, with thick and thin is likely to lead to strength is not enough, so, for in the critical state of thick and thin, need to check i
41、ts strength. 3.5 因为原件厚度与其刚性是成正比的，厚度越大，刚性越强，所以原则上不允许对挠性薄管板、波纹管和膨胀节等元件实行以厚http:/ http:/ because the original thickness and its stiffness is proportional to the, the greater the thickness, the stronger rigidity, so in principle does not allow for flexible and thin tube sheet, corrugated pipe and expans
42、ion joint element with thick and thin, in order to prevent the weakening deformation compensation effect. 3.6 由于换热器的特殊性，对热换器的主要元件进行以厚代薄很容易破坏原来的平衡力系，原则上不可以厚代薄，特殊情况下，必须代用时，需要重新设计计算。3.6 due to the particularity of the heat exchanger, the heat changer of the main components for thick and thin is easy to
43、 destroy the original balance state, in principle can not thick and thin, special circumstances, must be substitute, you need to design and calculation. 综上所述，以厚代薄的利弊问题是很复杂的，在进行代用时，要由相关设计单位对代用的可行性和影响进行综合考虑后，方可决定其是否可行。对可采取以厚代薄类型的容器，应对其焊接工艺、支座和等进行相应的调整，以尽可能的消除不利影响。http:/ http:/ all, to the pros and con
44、s of thick and thin problem is very complicated, in the alternative, should by the relevant design units and the feasibility of substitute effect, after comprehensive consideration to decide whether it is feasible. Can take to thick and thin type of container, to deal with the welding process, beari
45、ng and etc to adjust accordingly, as much as possible to eliminate adverse effects. 4 其他注意事项4 other considerations 进行材料代用时，应根据实际用材情况对焊接工艺进行适当的调整，一般调整原则为：用高级材料替代低级材料时，实验和验收仍可采用低级材料的标准，不用提高标准；不同材料的耐高温性、韧度等性能不同时，进行最低水压实验时，其相应的温度也可能发生改变，此时，要严格按 GB150 的相关规定执行；当板厚增加超过GB150 所规定的冷卷厚度时，一定要对筒体进行消除应力的热处理；钢板的厚度
46、达到一定水平时，还需要进行超声探伤，必要时，提高水试验的压力。For material substitution, should according to the actual material for welding technology for the proper adjustment, general adjustment http:/ http:/ is: use advanced materials instead of inferior materials, the experiment still can use inferior materials and acceptance standard, without an increase in the standard; Different material properties such as
