Disclosure of Invention
The invention provides a method for measuring and repairing the defects of a flange sealing surface of a reactor pressure vessel, which aims to solve the technical problems that defects are difficult to avoid on a surfacing layer of the flange sealing surface in the prior art, a defect measuring area is not clear, and related area defects influence the sealing reliability of an RPV, so that the safety and stability of the operation of the reactor are influenced.
The invention solves the technical problems by the following technical proposal:
The invention provides a method for measuring defects of a flange sealing surface of a reactor pressure vessel, which is characterized by comprising the following steps of S 1, measuring and calculating the minimum diameter and the maximum diameter of an annular belt formed by an indentation range of a sealing ring, S 2, taking the center of the vessel flange as the center of a circle, checking the defects on the vessel flange falling into the annular belt range between the minimum diameter and the maximum diameter, and measuring and recording the sizes and the directions of the defects.
According to one or more embodiments of the invention, the step S 1 comprises the following substeps of S 11, determining the maximum value of the indentation width of the sealing ring through measurement and calculation, determining the maximum installation deviation of the central axis of the sealing ring relative to the center of the ring groove through the design of the dimensional tolerance of the interface between the sealing ring and the ring groove through calculation, determining the maximum installation deviation of the center of the top cover relative to the center of the flange of the cylinder through the tolerance value of the center alignment when the top cover and the cylinder are installed, S 12, and calculating the minimum diameter C min and the maximum diameter C max of the ring belt formed by the indentation range of the sealing ring according to the maximum value t max of the indentation width of the sealing ring, the maximum installation deviation delta 1max of the central axis of the sealing ring relative to the center of the ring groove and the maximum installation deviation delta 2max of the center of the top cover relative to the center of the flange of the cylinder, wherein D i is the nominal diameter of the ring in the calculation formula as follows : Cmin=Di – (tmax + 2δ1max + 2δ2max); Cmax=Di + (tmax + 2δ1max + 2δ2max);.
According to one or more embodiments of the present invention, in said step S 11, the maximum value of the seal ring indentation width is determined from actual measurements on the pressure vessel flange face and/or from the seal ring material, seal ring cross-sectional dimensions, seal ring plating requirements, seal ring compression, by trial or by simulation analysis.
According to one or more embodiments of the present invention, the dimensions of the defect include a defect depth, a defect radial width, and a defect circumferential length.
According to one or more embodiments of the present invention, the defect depth measurement accuracy is not less than 0.001mm, the defect radial width measurement accuracy is not less than 0.02mm, and the defect circumferential length measurement accuracy is not less than 0.1mm.
The invention also provides a method for repairing the defects of the flange sealing surface of the reactor pressure vessel, which is characterized in that the repairing method is carried out by adopting different schemes based on the result of the method for measuring the defects of the flange sealing surface of the reactor pressure vessel, and comprises the following steps of P 1, determining a defect treatment scheme according to the types and the defect sizes of the defects on the flange of the vessel, wherein the types and the defect sizes of the defects fall into the range of an annular area between the minimum diameter and the maximum diameter, the defect treatment scheme comprises the steps of temporarily not carrying out treatment or adopting the defect repairing scheme, and the defect repairing scheme comprises the polishing repairing scheme and the repair welding repairing scheme when the types and the defect sizes of the defects meet the set conditions, and P 2 is carried out according to the determined defect treatment scheme.
In accordance with one or more embodiments of the present invention, the defects include pits, scratches, pitting and corrosion, and in the step P 1, a defect treatment scheme is determined according to a repair criterion, in which when the defect depth of the defect is < H 1, the defect is temporarily left untreated, recorded and tracked, when the defect depth of the defect is greater than or equal to H 1 and greater than or equal to H 2 and the radial width is greater than or equal to W 1, the defect is repaired by a polishing repair scheme, in which when the defect depth of the defect is greater than or equal to H 2 and the radial width is greater than or equal to W 1, the defect is temporarily left untreated, recorded and tracked, and in which when the defect depth of the defect is greater than or equal to H 2, the repair scheme by polishing or repair welding is determined after evaluation.
According to one or more embodiments of the present invention, the repair criterion is determined according to the result of artificially manufacturing defects on the sealing flange of the test piece, performing a sealing test on the test piece, and finally determining according to the result of the sealing test.
According to one or more embodiments of the invention, H 1 has a value of 0.08mm, H 2 has a value of 0.16mm, and W 1 has a value of 0.86mm.
According to one or more embodiments of the present invention, when repair welding repair is performed, the defective portion is cleaned and/or polished before repair welding, and polished to be flat after repair welding is completed, and in step P 2, polishing is performed using a polishing material of at least 400 mesh when polishing is performed after repair welding using the repair welding repair scheme or the repair welding repair scheme, and polishing is performed along the circumferential direction of the flange of the container when polishing.
According to one or more embodiments of the invention, the quality requirements after polishing are that the surface roughness of the polished area is less than or equal to Ra0.8, the gradient after polishing is less than or equal to 1:100 for polishing with a polishing repair scheme, and the flatness after polishing is less than or equal to 0.1mm for polishing after repair welding repair.
According to one or more embodiments of the present invention, in the step P 2, if a repair welding repair scheme is adopted, manual argon tungsten-arc welding or manual arc welding is adopted, a straight stainless steel welding wire or electrode is used for repair welding, and a welding process evaluation test is required, wherein the welding process evaluation is required to consider factors of defect removal depth and residual thickness of the corrosion-resistant alloy surfacing layer, and the welding process evaluation test items comprise nondestructive testing, hardness testing, chemical composition analysis, ferrite content analysis, bending test, impact test, intergranular corrosion test and metallographic test.
The invention has the positive progress effects that:
The method for measuring the defect of the flange sealing surface of the reactor pressure vessel and the method for repairing the defect of the flange sealing surface of the Reactor Pressure Vessel (RPV) fill the blank of the systematic method for repairing the defect of the flange sealing surface of the Reactor Pressure Vessel (RPV), and the provided method for determining the range of the sealing line, the measuring requirement, the repairing criterion and the repairing method are convenient to execute on the nuclear power site, can be used for guiding the implementation of the overhaul of the flange sealing surface of the Reactor Pressure Vessel (RPV) of the nuclear power station, effectively reduce the repairing workload, reduce the personnel irradiation dose, improve the efficiency of operation and maintenance overhaul, further ensure the safe and stable operation of a nuclear power unit and improve the economic benefit of the operation of a power station.
Detailed Description
In order to make the above objects, features and advantages of the present invention more comprehensible, embodiments accompanied with figures are described in detail below.
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Furthermore, although terms used in the present invention are selected from publicly known and commonly used terms, some terms mentioned in the present specification may be selected by the applicant at his or her discretion, the detailed meanings of which are described in relevant parts of the description herein. Furthermore, it is required that the present invention is understood, not simply by the actual terms used but by the meaning of each term lying within. Meanwhile, for convenience of description, the sizes of the respective parts shown in the drawings are not drawn to actual scale.
The invention provides a method for measuring the defect of a flange sealing surface of a reactor pressure vessel, which comprises the following steps:
Step S 1, measuring and calculating the minimum diameter and the maximum diameter of the annular band formed by the seal ring indentation range.
And S 2, taking the center of the container flange as the center of the circle, checking the defects on the container flange falling into the ring belt range between the minimum diameter and the maximum diameter, and measuring and recording the sizes and the orientations of the defects.
It should be noted that, as shown in fig. 1a and 1b, a typical flange sealing structure of a Reactor Pressure Vessel (RPV) includes an upper flange 11 and a lower flange 12, and screw holes 13 for fixing are formed in the upper flange 11 and the lower flange 12. One or two seal ring grooves 100 are arranged on one of the flanges, the seal ring grooves 100 are sealed by adopting a metal seal ring 200, the metal seal ring 200 can be an O-shaped ring or a C-shaped ring, and the flange sealing surface 300 in FIG. 1b is the surface of the metal seal ring 200 contacted with the upper surface of the lower flange 12. The annular contact surface of the seal ring and the flange, which is called a seal line or seal ring indentation, includes the lower surface of the upper flange 11, the upper surface of the lower flange 12, and the side surface of the seal ring groove 100, but the defect of the upper surface of the lower flange 12 is most likely to occur because the upper surface of the lower flange 12 is in close contact with the metal seal ring 200 and is affected by gravity. The seal line or seal ring indentation here is thus the subject of the present invention. Half the difference between the inner and outer diameters of the annular band formed by the seal line is referred to as the indentation width.
Defects in the seal line or seal ring indentation range are critical to the seal of a Reactor Pressure Vessel (RPV). Before determining what repair measures to take, it is necessary to determine whether the defect is within the seal ring indentation range. Thus, sizing of seal ring indentations is particularly important for practical service.
The method for measuring the defects of the flange sealing surface of the reactor pressure vessel is designed for detecting the defects of the flange sealing surface of the Reactor Pressure Vessel (RPV), can be used for guiding the implementation of the overhaul of the Reactor Pressure Vessel (RPV) of a nuclear power station, ensures the safe operation of a nuclear power unit, and improves the efficiency and economic benefit of operation, maintenance and overhaul.
As a preferred embodiment of the method for measuring the defect of the flange sealing surface of the reactor pressure vessel according to the present invention, the step S 1 includes the following sub-steps:
S 11, determining the maximum value of the indentation width of the sealing ring through measurement and calculation, determining the maximum installation deviation of the central shaft of the sealing ring relative to the center of the ring groove through the design of the dimensional tolerance of the interface of the sealing ring and the ring groove, and determining the maximum installation deviation of the center of the top cover relative to the center of the flange of the cylinder through the tolerance value of the center alignment when the top cover and the cylinder are installed.
Step S 12, calculating the minimum diameter C min and the maximum diameter C max of the ring belt formed by the indentation range of the sealing ring according to the maximum value t max of the indentation width of the sealing ring, the maximum installation deviation delta 1max of the central shaft of the sealing ring relative to the center of the ring groove, and the maximum installation deviation delta 2max of the center of the top cover relative to the center of the flange of the cylinder body, wherein the calculation formula is as follows:
wherein D i is the nominal diameter of the diameter circle in the seal ring as shown in fig. 2.
Preferably, the maximum mounting deviation of the central axis of the seal ring with respect to the center of the ring groove can be determined according to the tolerance (outer sidewall clearance) of the interface size of the seal ring with the ring groove, and the maximum mounting deviation of the center of the top cover with respect to the center of the flange of the cylinder can be determined according to the tolerance value of the center alignment when the top cover is mounted with the cylinder (i.e., the upper flange 11 and the lower flange 12).
T max can be determined according to engineering or experimental measurement and combined with simulation results, delta 1max can be determined according to dimensional tolerance (outer sidewall clearance) of an interface between the sealing ring and the ring groove, and delta 2max can be determined according to tolerance values in center alignment when the top cover and the cylinder body (namely the upper flange 11 and the lower flange 12) are installed.
The minimum diameter C min and the maximum diameter C max of the annulus formed by the size range of the seal line are calculated using the center of the flange (typically, the lower flange 12) to which the Reactor Pressure Vessel (RPV) is fixed as a theoretical base point in the calculation.
The nominal diameter of the sealing ring pitch circle in fig. 2 refers to the nominal diameter of the circumference formed by the center points of innumerable sealing ring cross sections in the theoretical design state, and the metal sealing ring 200 can be an O-ring or a C-ring. The outside of the cross-section of the sealing ring in fig. 2 is therefore indicated by a broken line to indicate that the cross-section may be either a closed O-shape or a C-shape with an opening on the outside. As another embodiment, the opening of the C-ring may also be provided on the inner side.
As a preferred embodiment of the method for measuring defects of a flange sealing surface of a reactor pressure vessel according to the present invention, in the step S 11, the maximum value of the seal ring indentation width is determined according to actual measurement on the flange surface of the pressure vessel, and/or according to the material of the seal ring, the cross-sectional size of the seal ring, the plating requirements of the seal ring (including plating material and thickness), the compression amount of the seal ring, by test or by simulation analysis.
As a preferred embodiment of the method for measuring the defects of the flange sealing surface of the reactor pressure vessel according to the present invention, the sizes of the defects include a defect depth, a defect radial width and a defect circumferential length.
A schematic of the defect radial width L 1 and the defect circumferential length L 2 is shown in fig. 3.
As a preferred embodiment of the method for measuring the defects of the flange sealing surface of the reactor pressure vessel, the measurement accuracy of the depth of the defects is not less than 0.001mm. The measurement accuracy of the radial width of the defect is not lower than 0.02mm. The measurement accuracy of the circumferential length of the defect is not lower than 0.1mm.
When the cylinder flange of the reactor pressure vessel of the nuclear power plant is actually overhauled, defects falling in the range (C min, Cmax) on the cylinder flange are checked, and the sizes (defect sizes comprise depth multiplied by radial width multiplied by circumferential length) and the orientations of the recorded defects are measured, wherein the orientations are usually expressed in terms of relative angles. As shown in fig. 3, the screw holes on both sides of the defect are a first screw hole 13a and a second screw hole 13b, respectively, and the defect is located at an angle of about 2 ° from the first screw hole 13a to the second screw hole 13 b. The depth of the defect is measured with the recommended precision of 0.001mm, the radial width of the defect is measured with the recommended precision of not less than 0.02mm, and the circumferential length of the defect is measured with the precision of not less than 0.1mm.
The invention also provides a method for repairing the defects of the flange sealing surface of the reactor pressure vessel, which is executed by adopting different schemes based on the results of the method for measuring the defects of the flange sealing surface of the reactor pressure vessel, and comprises the following steps:
Step P 1, determining a defect treatment scheme according to the defect type and defect size of the container flange falling within the range of the annular area between the minimum diameter and the maximum diameter. Defect management schemes include temporary no treatment or employing defect repair schemes. And when the defect type and the defect size meet the set conditions, adopting a defect repair scheme, wherein the defect repair scheme comprises a polishing repair scheme and a repair welding repair scheme.
Step P 2 is performed according to the determined defect handling scheme.
As a preferred embodiment of the method for repairing a flange sealing surface defect of a reactor pressure vessel according to the present invention, the defect includes pits, scratches, pitting and corrosion, and in the step P 1, the defect treatment scheme is determined according to the following repair criteria:
when the defect depth of the defect is smaller than H 1, the processing is not performed, and recording and tracking are performed.
When the defect depth of the defect is more than or equal to H 1 and less than or equal to H 2 and the radial width is more than W 1, repairing by adopting a polishing repairing scheme.
When the defect depth of the defect is less than or equal to H 2 and the radial width is less than or equal to W 1, the processing is not performed temporarily, and recording and tracking are performed.
When the defect depth of the defect > H 2, a repair scheme using grinding or repair welding is determined after evaluation.
As a preferred embodiment of the method for repairing the defects of the flange sealing surface of the reactor pressure vessel, the repairing criterion is determined according to the result of the sealing test according to the artificial defects on the sealing flange of the test piece and the sealing test of the test piece.
As a preferred embodiment of the method for repairing the defects of the flange sealing surface of the reactor pressure vessel, H 1 has a value of 0.08mm, H 2 has a value of 0.16mm and W 1 has a value of 0.86mm.
The defect type generally includes pits, scratches, pitting, corrosion, and the like. For relevant defects in the sealing line, corresponding measures should be taken according to the above criteria. For flange seal face defects (i.e., defects in the non-seal line) that are not within the minimum diameter and maximum diameter ranges, the above criteria can be referenced for processing.
In one embodiment, the repair criteria is set to:
a) When the defect depth is <0.08mm, the processing can be temporarily stopped, and the recording and tracking should be performed.
B) When the defect depth is more than or equal to 0.08mm and less than or equal to 0.16mm and the radial width is more than 0.86mm, repairing by adopting a polishing mode is recommended.
C) When the depth of the defect is less than or equal to 0.16mm and the radial width of the defect is less than or equal to 0.86mm, the defect can be temporarily left untreated and is recorded and tracked.
D) When the defect depth is >0.16mm, the repair scheme using grinding or repair welding should be determined after evaluation.
Note that the above-described temporary defects may be repaired in principle using a sanding repair scheme. The defects adopting the polishing repair scheme can be repaired by adopting a repair welding repair scheme in principle.
The invention provides corresponding recommended repair methods for defects of different scales according to repair criteria, and can be used for guiding implementation of maintenance of RPV sealing surfaces of nuclear power stations, ensuring safe operation of a nuclear power unit and improving efficiency and economy of operation and maintenance.
In the repair welding repair scheme, the defect part is cleaned and/or polished before repair welding, repair welding is performed after the metal natural color is exposed at the defect part and the repair welding groove is smoothly treated, and polishing is also required after repair welding is finished. In the step P 2, polishing is performed by using an abrasive material with at least 400 meshes when polishing is performed after repair welding by using a polishing repair scheme or a repair welding repair scheme. And polishing along the circumferential direction of the container flange during polishing.
As a preferred implementation mode of the method for repairing the defects of the flange sealing surface of the reactor pressure vessel, the quality requirements after polishing are required to be met:
The surface roughness of the polished area is less than or equal to Ra0.8 (namely Ra0.8 or better). For polishing by adopting a polishing repair scheme, the inclination after polishing is less than or equal to 1:100. For polishing after repair welding repair, the flatness after polishing is less than or equal to 0.1mm (namely Ra0.8 or better).
When polishing repair or final polishing after repair welding is performed, it is recommended to use a polishing material such as sandpaper or abrasive cloth or abrasive strip with finer particles, at least 400 mesh or more. If the grinding agent or the grinding paste used for assisting the grinding is adopted in the grinding process, the material containing carbon steel or other halogen which can pollute the corrosion resistant alloy is not allowed to be used, and the material is not allowed to be used on the corrosion resistant alloy after being used on the carbon steel or the materials.
The polishing trace should be along the circumference of the flange, and there should be no polishing texture along the radial direction. The polished area should have a surface roughness satisfying Ra0.8 or better. For post repair polishing, the final flatness requirement should be 0.1mm or better. For polishing repair for shallow defect removal, the slope after polishing should be less than or equal to 1:100, with 1:300 or less being recommended.
As a preferred implementation mode of the method for repairing the defects of the flange sealing surface of the reactor pressure vessel, in the step P 2, if a repair welding repair scheme is adopted, tungsten electrode manual argon arc welding or manual arc welding is adopted, a straight stainless steel welding wire or welding rod is used for repair welding, a welding process assessment test is required, and the factors of defect removal depth and residual corrosion resistant alloy thickness are required to be considered in welding process assessment.
The welding process evaluation test items comprise nondestructive testing, hardness testing, chemical component analysis, ferrite content analysis, bending test, impact test, intergranular corrosion test and metallographic test.
When the repair welding repair scheme is adopted, as the sealing surface of the reactor pressure vessel is a 309L+308L combined stainless steel overlaying layer, the repair welding can be performed by tungsten electrode manual argon arc welding (GTAW) or manual arc welding (SMAW) and by adopting a straight stainless steel welding wire or welding rod. The repair welding process should be rated as acceptable and meet the requirements associated with either the ASME Specification volume IX or the RCC-M Specification volume IV.
The welding process evaluation test items comprise nondestructive testing, hardness testing, chemical component analysis, ferrite content analysis, bending test, impact test, intergranular corrosion test, metallographic test and the like. In addition, the repair welding process can meet the related requirements of ASME NB-4622.9 section or RCC-M IV volumes S3000 and S7000 according to the conditions of the depth of defect removal, the thickness of the residual weld overlay and the like. After a qualified repair welding process and repair scheme are formulated, the repair welding repair can be carried out formally.
The scheme of the invention prescribes a measuring range determining method and a measuring requirement, and sets a repairing criterion, a polishing repairing method and a repair welding repairing requirement.
In summary, the method fills the blank of a systematic method for repairing the flange sealing surface defects of the Reactor Pressure Vessel (RPV) under the background that the maximum service life exceeds 30 years when the domestic nuclear power plant runs nearly 60 nuclear power plants, and the method for determining the sealing line range, measuring the requirement, repairing the sealing line and repairing the sealing surface of the Reactor Pressure Vessel (RPV) can be used for guiding the implementation of repairing the sealing surface of the nuclear power plant, effectively reducing the repairing workload, reducing the personnel irradiation dose, improving the efficiency of operation, maintenance and repair, further ensuring the safe and stable operation of the nuclear power unit and improving the economic benefit of the operation of the power plant.
While specific embodiments of the invention have been described above, it will be appreciated by those skilled in the art that these are by way of example only, and the scope of the invention is defined by the appended claims. Various changes and modifications to these embodiments may be made by those skilled in the art without departing from the principles and spirit of the invention, but such changes and modifications fall within the scope of the invention.