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Residual Service Lifetime of Furnaces in Petrochemical Industry
Horsák, Libor ; Vincour, Dušan (referee) ; Lukavský, Jiří (referee) ; Vejvoda, Stanislav (advisor)
The objectives of this work is residual lifetime of heaters in petrochemical industry. There is no comprehensive publication about this theme. This paper lists and describes the most of main phenomena that has to be taken into account in the process of determination of residual lifetime. This paper focuses on creep damage of a real heater based on deformation measurement. It describes some heater failures that could cause unplanned operation interruption however, appropriate intervention made possible safe heater operation until planned heater shutdown. No compact method is given how to determine heater residual lifetime, but a direction is given how a complex method of residual lifetime assessment of refinery heaters could be created.
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Oxide scales damaging evaluation
Audyová, Markéta ; Vejvoda, Stanislav (referee) ; Lošák, Pavel (advisor)
This work is focused on oxide scale failure and characteristics created in high temperature – supercritical processes. The presence of high temperature corrosion in supercritical processes is minimalised by selection of the right material. For this work was selected material X10CrMoVNb9-1, where formulas of present oxidation scales are Fe2O3, Fe3O4 and FeCr2O4. Each oxidation scale has its own mechanical properties thus it is important to notice scale arrangement, thickness and geometry. Oxide scale mechanical properties, scale failure mechanisms and oxidation scale growth is evaluated in this work. Tension and pressure oxide scale failure are determined by critical values, which are mentioned in this work. Thanks to these values there was possibility to verify the authenticity of the finite element model. Oxidation scales created in heat exchangers are badly accessible thus it is difficult to observe them or remove them mechanically. Tube finite element model with oxidation scales was created in this work. There are simulations of scales on selected steel in supercritical conditions (pressure 24 MPa, temperature 500 °C). Simulation and analytic results are compared. Failure operative conditions are searched for scale FeCr2O4 until its compleate delamination and separation from metal. Aim of this work is to create an oxidation scale model with a possibility of futher use.
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Life-Time Management of Process Devices in Industrial Practice
Lošák, Pavel ; Klemeš,, Jiří (referee) ; Ing. Zdeněk Jůza, Ph.D. MBA (referee) ; Vejvoda, Stanislav (advisor)
This dissertation examines life-time management of process and energetic devices in industrial practice, mainly in the area of steam power plants. Furthermore, it focuses on frequent damage mechanisms occurring in this area. It summarizes basics of damaging mechanisms occurring in the process industry area, their monitoring, evaluation and prediction. In the area of steam power plants, the main emphasize was placed on cumulative damage mechanisms. Within the dissertation, mechanisms of creep, fatigue, and their combinations were assessed. Major European standards were examined in order to discuss the amount of contained conservatism and their usability. Subsequently, attention was paid to the methods applicable for creep and fatigue combination evaluation. In the next step life-time monitoring and evaluation standard was discussed. The diagnostic software was created which includes creep, fatigue and creep-fatigue combination evaluation according to valid standards. For online life-time evaluation was proposed refined analytical solution for stress and strain calculation. To further extend the life-time management, the dissertation describes oxide scale damaging together with its evaluation and implementation into diagnostic software. The proposed software is extended by the material module which on the basis of defined materials allows easy and effective usage of material characteristics. For the purpose of refining life-time prediction accuracy, experimental device was schematically described. In addition, the device should be also able to verify used equations. Furthermore, the dissertation includes solution to industrially oriented cases. Firstly, a steam generator with damaged pipes was analyzed, afterwards damaged transferring pipeline. Further analyses deal with U-tube heat exchanger and its damaging. The causes of damage were discovered and corrective measures were proposed. The dissertation concludes with the summarization of potential activities for subsequent research in examined area.
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Flow Induced Vibration Fatigue Analysis of Tube Bundle
Buzík, Jiří ; Vincour, Dušan (referee) ; Lukavský, Jiří (referee) ; Vejvoda, Stanislav (advisor)
The aim of the dissertation thesis is the control of the tube bundle on the cyclic fatigue caused by the flow past tube bundle. Fatigue due to flow is caused by flow-induced vibrations. Examined vibrations are caused by the mutual interaction of two phases (solid and liquid). The present work is focused mainly on the interaction of tube bundles with fluid. The current level of knowledge in this field allows to predict mainly static respectively quazi-static loading. These predictions are based on methods of comparing key vibration variables such as frequencies, amplitudes or speeds (see TEMA [1]). In this way, it is possible to determine quickly and relatively precisely the occurrence of a vibrational phenomenon, but it is not possible to quantitatively assess the effect of these vibrations on the damage of to the tube beam and to predict its lifespan, which would require the determination of the temperature field and the distribution of forces from the fluid on the beam. The aim of the work is to evaluate the-state-of-the-art, to perform a numerical simulation of the flow of fluids in the area of shell side under the inlet nozzle. Current methods of numerical analyses very well solve this problem, but at the expense of computing time, devices and expensive licences. The benefit of this work is the use of user-defined function (UDF) as a method for simulating interaction with fluid and structure in ANSYS Fluent software. This work places great emphasis on using the current state of knowledge for verifying and validation. Verifying and validation of results include, for example, experimentally measured Reynolds and Strouhal numbers, the drag coefficients and for example magnitude of pressure coefficient around the tube. At the same time, it uses the finite element method as a tool for the stress-strain calculation of a key part on tube such as a pipe-tube joint. Another benefit of this work is the extension of the graphical design of heat exchanger according to Poddar and Polley by vibration damages control according to the method described in TEMA [1]. In this section, the author points out the enormous influence of flow velocity on both the tube side and the shell side for design of the heat exchanger to ensure faultless operation. As an etalon of damage, the author chose a heat exchanger designated 104 from the Heat Exchanger Tube Vibration Data Bank [3]. With this heat exchanger, vibrational damage has been proven to be due to cutting of the tubes over the baffles. The last part outlines the possibilities and limits of further work.
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Flow Induced Vibration Fatigue Analysis of Tube Bundle
Buzík, Jiří ; Vincour, Dušan (referee) ; Lukavský, Jiří (referee) ; Vejvoda, Stanislav (advisor)
The aim of the dissertation thesis is the control of the tube bundle on the cyclic fatigue caused by the flow past tube bundle. Fatigue due to flow is caused by flow-induced vibrations. Examined vibrations are caused by the mutual interaction of two phases (solid and liquid). The present work is focused mainly on the interaction of tube bundles with fluid. The current level of knowledge in this field allows to predict mainly static respectively quazi-static loading. These predictions are based on methods of comparing key vibration variables such as frequencies, amplitudes or speeds (see TEMA [1]). In this way, it is possible to determine quickly and relatively precisely the occurrence of a vibrational phenomenon, but it is not possible to quantitatively assess the effect of these vibrations on the damage of to the tube beam and to predict its lifespan, which would require the determination of the temperature field and the distribution of forces from the fluid on the beam. The aim of the work is to evaluate the-state-of-the-art, to perform a numerical simulation of the flow of fluids in the area of shell side under the inlet nozzle. Current methods of numerical analyses very well solve this problem, but at the expense of computing time, devices and expensive licences. The benefit of this work is the use of user-defined function (UDF) as a method for simulating interaction with fluid and structure in ANSYS Fluent software. This work places great emphasis on using the current state of knowledge for verifying and validation. Verifying and validation of results include, for example, experimentally measured Reynolds and Strouhal numbers, the drag coefficients and for example magnitude of pressure coefficient around the tube. At the same time, it uses the finite element method as a tool for the stress-strain calculation of a key part on tube such as a pipe-tube joint. Another benefit of this work is the extension of the graphical design of heat exchanger according to Poddar and Polley by vibration damages control according to the method described in TEMA [1]. In this section, the author points out the enormous influence of flow velocity on both the tube side and the shell side for design of the heat exchanger to ensure faultless operation. As an etalon of damage, the author chose a heat exchanger designated 104 from the Heat Exchanger Tube Vibration Data Bank [3]. With this heat exchanger, vibrational damage has been proven to be due to cutting of the tubes over the baffles. The last part outlines the possibilities and limits of further work.
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Residual Service Lifetime of Furnaces in Petrochemical Industry
Horsák, Libor ; Vincour, Dušan (referee) ; Lukavský, Jiří (referee) ; Vejvoda, Stanislav (advisor)
The objectives of this work is residual lifetime of heaters in petrochemical industry. There is no comprehensive publication about this theme. This paper lists and describes the most of main phenomena that has to be taken into account in the process of determination of residual lifetime. This paper focuses on creep damage of a real heater based on deformation measurement. It describes some heater failures that could cause unplanned operation interruption however, appropriate intervention made possible safe heater operation until planned heater shutdown. No compact method is given how to determine heater residual lifetime, but a direction is given how a complex method of residual lifetime assessment of refinery heaters could be created.
|
|
|
Oxide scales damaging evaluation
Audyová, Markéta ; Vejvoda, Stanislav (referee) ; Lošák, Pavel (advisor)
This work is focused on oxide scale failure and characteristics created in high temperature – supercritical processes. The presence of high temperature corrosion in supercritical processes is minimalised by selection of the right material. For this work was selected material X10CrMoVNb9-1, where formulas of present oxidation scales are Fe2O3, Fe3O4 and FeCr2O4. Each oxidation scale has its own mechanical properties thus it is important to notice scale arrangement, thickness and geometry. Oxide scale mechanical properties, scale failure mechanisms and oxidation scale growth is evaluated in this work. Tension and pressure oxide scale failure are determined by critical values, which are mentioned in this work. Thanks to these values there was possibility to verify the authenticity of the finite element model. Oxidation scales created in heat exchangers are badly accessible thus it is difficult to observe them or remove them mechanically. Tube finite element model with oxidation scales was created in this work. There are simulations of scales on selected steel in supercritical conditions (pressure 24 MPa, temperature 500 °C). Simulation and analytic results are compared. Failure operative conditions are searched for scale FeCr2O4 until its compleate delamination and separation from metal. Aim of this work is to create an oxidation scale model with a possibility of futher use.
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Life-Time Management of Process Devices in Industrial Practice
Lošák, Pavel ; Klemeš,, Jiří (referee) ; Ing. Zdeněk Jůza, Ph.D. MBA (referee) ; Vejvoda, Stanislav (advisor)
This dissertation examines life-time management of process and energetic devices in industrial practice, mainly in the area of steam power plants. Furthermore, it focuses on frequent damage mechanisms occurring in this area. It summarizes basics of damaging mechanisms occurring in the process industry area, their monitoring, evaluation and prediction. In the area of steam power plants, the main emphasize was placed on cumulative damage mechanisms. Within the dissertation, mechanisms of creep, fatigue, and their combinations were assessed. Major European standards were examined in order to discuss the amount of contained conservatism and their usability. Subsequently, attention was paid to the methods applicable for creep and fatigue combination evaluation. In the next step life-time monitoring and evaluation standard was discussed. The diagnostic software was created which includes creep, fatigue and creep-fatigue combination evaluation according to valid standards. For online life-time evaluation was proposed refined analytical solution for stress and strain calculation. To further extend the life-time management, the dissertation describes oxide scale damaging together with its evaluation and implementation into diagnostic software. The proposed software is extended by the material module which on the basis of defined materials allows easy and effective usage of material characteristics. For the purpose of refining life-time prediction accuracy, experimental device was schematically described. In addition, the device should be also able to verify used equations. Furthermore, the dissertation includes solution to industrially oriented cases. Firstly, a steam generator with damaged pipes was analyzed, afterwards damaged transferring pipeline. Further analyses deal with U-tube heat exchanger and its damaging. The causes of damage were discovered and corrective measures were proposed. The dissertation concludes with the summarization of potential activities for subsequent research in examined area.
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