基于JB 4732—1995《钢制压力容器——分析设计标准》多年的实施情况,介绍了该标准修订的必要性和迫切性,并重点阐述了新制定的压力容器分析设计国家标准的结构变化、适用范围的调整、主要技术内容的变化等.以基于失效模式的设计理念为统领,实现该系列标准的有机结合,阐明标准制定的意义和现实作用.该标准作为TSG 21《固定式压力容器安全技术监察规程》的协调标准将对法规提供有效的技术支撑.

储气井是压缩天然气汽车加气站的核心设备,用于高压天然气的存储,工作压力高达25 MP a.文章以某公司一套天然气高压地下储气井为例,从风险识别及控制,主要承压元件选材,井口以及井身和井底结构设计,应力分析及疲劳评定,建造过程中的钻井、井管组装以及固井过程控制、固井质量检测、耐压及泄漏试验等方面,详细阐述了设计过程,分析研究了各个环节的控制要点和难点,并有针对性地提出了解决方案和对策,明确了各项技术要求,为此类设备的设计、制造提供技术参考.

压力容器作为承压类特种设备,其高性能制造涵盖了产品全生命周期,是反映压力容器本质安全性、工艺适用性、产品绿色性和智能性等综合性能指标的制造模式.本文简要回顾了"十三五"以来我国压力容器设计制造与维护技术进展,包括标准体系建设、基于风险与寿命的设计制造、在役长周期安全保障等,面向"十四五"和2035远景目标以及制造强国、质量强国和碳达峰、碳中和重大部署,提出了我国压力容器高性能制造技术发展面临的若干需求与挑战.

该文开发了一种高压容器新型端部密封结构,采用抗剪钢球代替了现有的抗剪元件.分析了其结构特点,并对抗剪钢球进行了强度计算.研制了一台试验容器,通过液压试验对结构强度及密封性能进行了验证.理论分析和试验研究表明该结构可适用于快开高压容器的端部密封.

In recent years, with the gradual expansion of units scale for energy industries such as oil refining, chemical and natural gas, etc. in China, pressure vessels are developing toward the large and heavy direction with the maximum wall thickness reaching hundreds of millimeters and weight exceeding one thousand tons. It not only causes huge material consumption, difficulty in manufacture and processing (even beyond current capability), but probably also lead to new failure modes and mechanisms, and significant safety risks thereby. Therefore, the lightweight design and manufacture under the premise of inherent safety has become an urgent need to break through the bottleneck of manufacturing capability and realize the material and energy conservation. In this paper, the progress of lightweight design and manufacturing technology of heavy-duty pressure vessels in recent years in China is introduced from the aspects of adjustment of material allowable strength, application of high strength steel and matching of strength and toughness, cold stretch of austenitic stainless steel, structure optimization design with multi-parameter coupling, and application of composite materials. Application cases in the construction of pressure equipments such as large hydrogenating reactors, low temperature ethylene spherical tanks, austenitic stainless steel cryogenic vessels, butyl octanol heat exchangers, etc. are also included. Finally, some suggestions on the future research are proposed including composite pressure vessels in cryogenic environment, materials genome and additive manufacturing technologies for pressure vessels.

Several techniques for fabricating large-scale zirconium-steel clad plate reactors,including narrow gap submerged arc welding,gas tungsten arc welding and plasma arc welding,were presented in this paper.The applications,advantages and shortcomings for each method were critically evaluated.Conventional methods,namely radiographic inspection,penetrate testing and ultrasonic NDT were performed on the welded joints of clad plates.Hydrostatic test,air tightness detection,thermal cycling study and helium leakage detection were also conducted to examine defects and assess their propagation behavior under designed working temperature and pressure for the purpose of ensuring the safety and prolonging the remaining lifetime of the reactors.

Since the beginning of this century,Chinese scientific and technical workers in the field of pressure vessels have solved many technical problems brought by production scale upsizing,harsh medium environment and long-term safe operation of process industries,and established the technological methods of design,manufacturing and maintenance based on life-cycle risk control.Based on these achievements,the important pressure vessels in China are no longer depend on importation,and the failure rate per ten thousand sets of equipment is decreasing year by year.However,the problem of heavy-duty trend of pressure vessels due to scale upsizing of the process industry plants becomes increasingly prominent,which not only causes large material,energy and labor consumption,and makes processing and manufacturing difficult,but also there may exist certain safety risks.The lightweighting,green design and manufacturing of pressure vessels under the premise of ensuring their inherent safety,and the reduction of environmental pollution caused by the failure of pressure vessels subjected to disasters,are two outstanding problems that need to be solved focally during China's "12th Five-Year Plan" period.At the same time,in recent years,the rapid development of modern information technology,such as Internet of Things,big data etc.and artificial intelligence technology has brought unprecedented opportunities and challenges to the traditional technology of pressure vessels in China.Another important problem that Chinese pressure vessel technical workers began to explore and solve in the "12th Five-Year Plan" period,is to deeply integrate with modern information and artificial intelligence technology so as to promote the development of Chinese pressure vessel technology toward the direction of digitalization,networking and intelligentization.This paper briefly reviews the progress of the green design,manufacturing and maintenance,network-based remote operation and maintenance technology of Chinese pressure vessels since the "12th Five-Year Plan".In combination with the strategic requirements of "Made in China 2025",this paper also proposes some research suggestions during the "13th Five-Year Plan" period and in the future,including the genome program of pressure vessel materials and additive manufacturing,network-based collaborative manufacturing and intelligent factory,intelligent operation and maintenance,etc.

The influence of plastic deformation and welding on the ultra-low temperature impact toughness of 304 and 304L austenitic stainless steel welded joints was investigated by using Charpy V-notch impact test,X-ray diffraction.The paper also explored the relationship between the impact absorbed energy and the lateral expansion.The results showed that both of the material′s impact absorbed energy and lateral expansion decreased with increasing of the deformation rate.The plastic energy consumed by the plastic deformation showed a similar trend with the impact absorbed energy,and the crack propagation energy was small and stayed unchanged basically.The plastic deformation of 304 and 304L stainless steel induced martensitic transformation to generate martensitic of ε and α′.The welding not only decreased the plastic energy but also reduced the crack propagation energy.There was a similar linear relationship between impact absorbed energy of base metal and heat affected zone,in addition the welding had no obvious influence on the linear relationship.Both of impact absorbed energy and lateral expansion can be a decision index to judge the ultra-low temperature vessels qualified.

Plasma arc welding has powerful penetrative ability.It is able to penetrate a thicker plate with I grooved in single bead.Therefore,the plasma arc welding is regarded as a high quality and effective meth-od in the manufacturing of high-alloy steel or non-ferrous alloy material pressure vessels.It has been wide-ly used in the industry.Longitudinal girth welding of stainless steel,nickel base alloy,titanium,zirconium and other metal equipments were token as examples.From the groove processing,group of quality control and welding parameters,the application of plasma arc welding technology was introduced,and satisfactory results were obtained in multiple product manufacturing.

In recent years, Chinese petrochemical plants have been continuously developing towards the direction of extreme conditions such as high temperature, high pressure, aggressive medium, large scale, etc. Once the seal structure of the pressure equipments for petrochemical plants leaks, it will not only cause material loss and nonscheduled shutdown, but also may cause disastrous accidents such as fire, poisoning, environment pollution, personal casualties, etc. This paper focuses on the flange seal structure of pressure equipment for petrochemical plants, makes comparison analysis of the standards/codes of different countries, points out the deficiency of Chinese current standards/codes and gives the advice that controlling leak rate of volatile organic compounds (VOCs) to 2×10−5mg/s • mm as the target to conduct relevant research on design, manufacture, installation and maintenance of flange seal that satisfies leakage rate control requirement and improvement of design standard.

The skirt support structure of the hydrogenation reactor has big mechanical stress and thermal stress, and poor stress state. This paper analyzes the temperature field of the skirt support structure of the hydrogenation reactor and the thermal stress through indirect analysis method of adding the temperature field to the structure. Based on the one directional tensile test of different temperature points, the stress-strain curve of material under different temperature points is obtained, and materials constitutive of linear elastic and elastic-plastic are used to carry out the finite element calculation of the skirt support structure of the hydrogenation reactor. Comparison and analysis of the results show that the calculation result of elastic-plastic finite element is more accurate. Besides, based on the failure evaluation content of these two methods in ASME Ⅷ-2 2007, this paper evaluates and calculates the possibility of local failure in this structure. The research in this paper indicates that the calculation results based on linear elastic finite element can be used in the engineering design, but the most stress position may not be the same position in the actual situation, which means that there is still margin for the improvement of the analysis and design calculation method.(6 Figures, 1 Table, 10 References)

The skirt support structure of hydrogenation reactor works in the conditions of high temperature and high pressure. There is not only high mechanical stress but also high temperature difference stress in this zone. The service environment of the structure is in poor conditions. In this paper, temperature field analysis on the local structure of skirt hot box is carried out. The stress classification method and direct route method are used to calculate the skirt support structure of hydrogenation reactor. The calculation results are compared. Results of these two analysis and design methods are both meet with the requirements of relevant standards. The results obtained by two methods are discussed. Some meaningful conclusions are obtained.

With the rapid development of Chinese economy, the pressure vessels are developing towards the direction of high parameters and have at least one of the following characteristics, one is the use of advanced technology and process, diversification and deterioration of raw stock, causing extremalization of service conditions, which is represented by higher pressure, higher or lower temperature, stronger medium corrosiveness; the other is promoting presence of pressure vessels with extreme dimensions in order to improve economic benefit, which is represented by increased diameter, wall thickness, length or height. Service environment and high parameterization of equipment dimensions cause expansion of design boundary, whereas expansion of design boundary will cause changes in failure modes and design criteria. Therefore, a group of Chinese scholars have conducted effective exploration on design, manufacturing and maintenance of high-parameter pressure vessels. This paper describes the expansion of design boundary and changes in failure modes brought by extramalization of service environment and high parameterization of large-sized equipment, reviews technical advancement in design, manufacture and maintenance of Chinese pressure vessels in recent decade, and forecasts recent opportunities and challenges for high-parameter pressure vessel.

超高压管式反应器是管式超高压聚乙烯装置的关键设备,其端部通常为夹套与反应管的过盈配合连接结构。利用电阻应变测量技术,针对某石化厂发生疲劳断裂的超高压管式反应器端部结构应力场开展试验研究,采用应力释放法获得过盈配合后的局部应力场数据,在此基础上,建立基于ANSYS软件的有限元模型,并与试验数据进行对比分析。结果表明,端部结构的过盈配合边缘局部范围内存在较高的轴向拉应力,且大于环向应力,应力水平随过盈量增加而提高;接触刚度对应力场数值模拟结果影响较大,在保证收敛的前提下应尽量增大接触刚度以提高模拟精度,有限元模拟结果与试验数据符合得较好。研究结果对后期的数值模拟以及结构失效原因的分析提供重要参考依据。

Nowadays,lightweight technology of heavy pressure vessel is regarded as an important measure for resource conservation in production all over the world.The research progress of lightweight technology of heavy pressure vessels in China is introduced in this paper in three aspects.Firstly,Chinese government revised TSG R0004—2009 Supervision Regulation on Safety Technology for Stationary Vessel in 2009,where the safety factor of tensile strength in conventional design is reduced from 3.0 to 2.7.Meanwhile,corresponding revision was also made to GB 150—2011 Pressure Vessels.The influence possibly brought by these adjustments on safety of pressure vessels is analyzed and associated resolutions are proposed in this paper.Secondly,the research progress of application of high strength steels in pressure vessel construction,the technical difficulties and their resolution ways are introduced.The typical case is introduced which is the application of 490 MPa grade high strength steel with low weld cracking sensitivity in the construction of large-sized cryogenic ethylene spherical tank.Finally,the research progress of strain strengthening technology for austenitic stainless steel is introduced,including the suitability of Chinese domestic steels and the effect of strain strengthening process on pressure vessel life and reliability.

In recent years, with the rapid change of global economic situation, quality deterioration of resources and adjustment of energy structure, the pressure-bearing equipments are developing gradually to the extreme direction of high temperature, cryogenic temperature, complex medium corrosion, ultrabig volume, ultrabig wall thickness, etc. It becomes an important subject confronted by Chinese scientific and technical workers of processing equipment to research breaking through the key design, manufacture and maintenance technology of important pressure equipments under extreme conditions and realize localization of important equipment and ensure long-cycle safe operation. The current main development trends of pressure equipment in process industry is described, the deficiency existing in the past standards and codes and technical methods for design, manufacture and operation management of Chinese pressure equipments are analyzed, and the main achievements obtained in the aspects of design, manufacture and maintenance of important pressure equipment under extreme conditions such as high temperature, cryogenic temperature, complex corrosion, ultrabig volume, ultrabig wall thickness, etc. and several technical difficulties solved are introduced, and the main research works requiring further development are prospected.

GB Vessels(2011 Revision,hereinafter is referred to as New edition of GB 150) has been published in November 2011 and will be officially enforced in replacement of GB 150—1998 in March 2012,The new edition of GB 150 is consistent with Supervision Regulation on Safety Technology for Stationary Pressure Vessel implemented in December 2009.It adapts to the progress of safety management concept and technology on pressure vessels at home and abroad in recent ten years,and absorbs some mature research achievements to ensure intrinsic safety of pressure vessels and improve economy of them.In the new edition,the design and manufacture technology for controlling failure likelihood and failure consequence based on risk assessment is an important feature.Entrusted by the standard drafting group,a brief description with respect to relevant clauses in the standard is given in combination with the achievements and application practice of national scientific research projects in recent ten years in this paper.

Over the last ten years of the new century,great progress and improvement in the capacity and level of the design,fabrication and maintenance of pressure vessels in China has been made.In this paper,the technical development about the design,fabrication and maintenance for pressure vessels in China is summarized and reviewed.Based on this,the prospect of the opportunity and challenge of the future technical development for pressure vessels is conducted.

Numerical simulation was carried out on the end structure of the ultrahigh pressure polyethylene tubular reactor in which fatigue fracture occurred based on the finite element program—ANSYS.The local stress field of the reactor was analyzed after its shrink-fit,autofrettage treatment and under the on-service startup and shutdown cyclic loading.The results show that axial tensile stress is high on the location at the edge of the shrink-fit under the shrink-fit and the startup and shutdown cyclic loading,and it′s larger than hoop stress;The local axial stress increases with the increase of shrink range and autofrettage stress;The reactor with 0.05 mm shrink range are analyzed,the maximal local axial mean stress is 86.71 MPa,the maximal local axial alternating stress amplitude is 62.2 MPa,which indicates that the crack driving force perpendicular to the axial direction is relative larger.The simulated results can provide some insight into the reason of failure and the improvement of the end structure.

Zirconium have high corrosion resistant,but for its low toughness,head forming is difficult,and cracking is often occurred.A high temperature forming way is usually used for forming zirconium head to prevent cracking in china now.There were some papers introducing it before,but is simple.A more complete discussing will be introduced in this paper by original results of test,relate analysis and zirconium head forming.