Research And Development Of High Temperature Pressure Process Piping Petrochemical Plant Safety Assessment Decision Support System

The project is about the research and development of decision-making system for safety assessment of high temperature tubes in petro-chemical industry in cooperation with Dalian Petro-chemical Company(DLPEC), which takes 1Cr5Mo, 12CrlMoV and 20# as research objects. 1Cr5Mo, 12CrlMoV and 20# are three types of pearlitic heat resistant steel and widely used for high temperature tubes in petro-chemical industry, so their safety assessments are necessary for the sake of operation safety in high temperature condition. On the basis of our former work, the decision-making system(FES-DP) has been developed by means of database and object-oriented programming technology. The purpose of the research and development of FES-DP is to provide a new approach to safety assessment of radiation tubes related with the three types of steel in several dozen of sets of heating furnace of DLPEC.The relationships between microstructure feature and residual life of the three types of steel in different states have been founded according to the data from the experiments, former failure analysis and safety assessment for other petro-chemical corporations. In term of the correlative standards and a great of information, the standard grades of microstructure degradation of the three types of steel have been established and the basic residual life assessment strategy by evaluating the grade of microstructure degradation has been brought forward.FES-DP mainly consists of four modules: the module of operation parameters and materials database, the module of metallographic photos, the module of the equipment operation rules and the assessment module. The function of the first module is data maintenance and management, and in the second one actual metallographic photos can be graded according to the standard metallographic photos. Users can inquire and maintain the equipment operation rules in the third one. The last one is the most important part of FES-DP, by which residual life of a single furnace tube or a group of tubes can be assessed and their operation states can be inquired. The four modules have been effectively integrated into FES-DP which have user-friendly interfaces and effectual data maintenance and management function, so safety assessment of correlative tubes can be done expediently and reliably.FES-DP is in use now and provides reliable decision-making information to equipment operation and management, which passed the qualification of DLPEC on December ,2003.