重大危险源泄漏机理及应急封堵技术研究
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摘要
随着我国经济的飞速发展和改革开放的不断深入,煤化工行业得到了高速发展。在过程工业生产中,大量有毒、有害、易燃和易爆的危险化学品通常存储在管道及压力容器中,这些管道及压力容器往往会因为管理不慎、设备老化和人为破坏等因素而产生破裂,导致泄漏事故的发生。因此,迫切需要应用现代设计理论与方法对危险源泄漏机理及应急封堵技术进行研究,当危险源发生泄漏时,能够利用有效封堵设备快速进行应急处理处置,来降低或消除事故造成的重大危害。
本文对危险源管道、储罐及储运过程泄漏的成因及影响因素进行了分析,确定了管道、高压容器的主要泄漏部位,并对重大危险源的泄漏模式进行了研究,建立了危险源储罐及管道等泄漏模型以及三种介质流泄漏状态的数学模型；分析了七种影响泄漏扩散的主要因素,研究了15种泄漏模式的产生机理及条件,并建立了危险源管道的动力学模型。通过管道流体的CFD动力学仿真,对管道泄漏处流量和压力状态做出理论性评估,并得出在管道长度相同、主管道压力变化、泄漏小孔直径不同及入口压力变化的情况下泄漏平均总压力大小与泄漏孔尺寸变化的关系以及小孔泄漏平均压力跃变的情况,为封堵装置的设计提出了具体的性能指标。
本文设计的快速封堵装置是针对现有封堵装置效率低,难以适应复杂多变的工况和特定的泄漏状态而研发的快速有效的新型封堵装置。本文对适用于管道、储罐等压力容器泄漏时实施封堵的危险源管道内封堵导流气囊、管口应急封堵导流装置、管道泄漏外封堵气囊、自适应万向强磁封堵导流装置以及带压封堵装置的机械结构进行了详细剖析。当危险源管道及储罐发生断裂、裂纹或者孔洞泄漏时,确定以内封法、外封法及磁压法为主要封堵实施方法,详细设计了四种新型封堵装置,为危险源泄漏的应急处理处置增添了新手段。
本文针对封堵实验系统进行了研究,并研发了直管口泄漏与弯管小孔泄漏的综合封堵实验平台。利用自行研制的内封堵装置、外封堵装置及其改进装置在平台上进行实验。实验结果表明,在内封堵装置的密封橡胶气囊套长度增加20mm、气囊外圆的密封环数量增加5圈、充气和导流口侧的中空轴端盖直径增加24mm后的封堵效果非常明显,最大封堵压力几乎增加45%；在外封堵装置的充气橡胶气囊带的长度增加2m、气囊带外表面上复合细密的密封圈以及缠绕在管道上的气囊带匝数增加3匝时,封堵压力也有了较大的提升。同时对两种封堵装置与管道的面--面接触问题进行了有限元分析,验证了封堵装置的封堵性能。
另外,本文还对主要危险源发生泄漏的多种应急封堵技术和方法库的应用进行了研究,并以实物图的形式说明了应急封堵装置在处理处置平台上的运用；提出了八种主要应急封堵工具,并以导图形式说明危险源直弯管道、管线连接法兰及储罐发生泄漏时封堵工具的实际应用；提出了危险源应急封堵方法库的核心架构,对五种典型危险物的物化特性、泄漏分类及特性、泄漏处置要点、封堵方法及封堵工具等主要数据库模块进行了详细总结。分析了16种封堵方法及对应封堵装置的处置步骤,为危险源泄漏应急处理处置提供了重要依据。为企业安全生产提供了重要的技术保障。
With the rapidly development of our country's economy and the deepening of reform and opening up, the coal chemical industry has made a high-speed development in past decades. In the industrial processes, the pressure vessels and storage areas, which store a lot of dangerous chemicals such as poisonous, harmful, inflammable and explosive matters. As a result of careless management of such chemicals, together with the ageing equipment and man-made destruction can easily cause ruptures of pressure vessels or pipes, and lead to leakage accidents. Therefore, there is an emerging need to apply the Modern design theory and method to research the hazard's leakage, and select appropriate sealing devices to avoid such leakage accidents. When in the worse case hazard leakage occurs, we can take emergency treatment quickly and effectively to reduce or eliminate the resulting damage.
This thesis analyzes causes and affecting factors of possible leakages in hazard pipelines, tanks, as well as the leakages during the process of storage or transportation. The proposed method can locate the main leakage location in pipelines or pressure vessels. Furthermore, this thesis studies the mathematical models of significant hazard's leakages and establishes models of hazard's storage tanks and pipelines through three kinds of mathematical representations of medium flow leakage states. This thesis also analyzes seven main factors which affect the spreading of the leakages, researches fifteen types of mechanisms and conditions of leakage models, and establishes the dynamic model of the hazard pipeline. Through the CFD dynamics simulation of pipeline's fluid, the author makes theoretical evaluations of pipeline leakage's flow and pressure, and obtaines the variation of the inlet pressures in the case of main line pressure change with the same pipe length and different diameter of leakage's small hole. The author also presents the relationships between the average of total pressures and the change of leakage's size and variations of aperture leak's average pressure jump. Additionally the author puts forward specific performance indicators for sealing device' s working characteristic.
Rapidly sealing device is a fast and effective new-type device. It is developes for some plugging device with low efficiency but high difficulty to adapt to the complex conditions and certain leakage state. This thesis carries on the detailed analysis for risk source pipeline inner wall diversion airbag which applies to plugging in case of pressure vessel leakage, the emergency sealing mouth guiding device, the pipeline leak sealing air bages, adaptive universal strong magnetic closure guiding device and mechanical structure of take pressure sealing device. When hazards pipe and tank fractures, cracks or leaks, the proposed framework can determine the appropriate method among the sealing method, the outer method and the magnetic pressure method as the main sealing method. It designs four kinds of new type of rapid sealing device, and adds new content for method library of hazards leakage's emergency treatment and disposal technology.
This thesis studies the plugging experiment system, researches and develops the plugging experiment system in the situation of straight pipe leakage or hole leakage. Under the condition of straight pipe leakage and bent pipe leakage, with the experiment with sealed plugging device, outer sealing device and its improving device, we can see that, when sealing rubber sleeve's length in internal blocking increased20mm, the seal ring of air bag's outer circle increased5ring and the diameter of inflatable and diversion's hollow shaft cover increased24mm, the achieved plugging is quite effective. Maxinum sealing pressure increased almost45%; inflatable rubber bag band's length in external plugging device increased2m, airbag's appearance coated sealing convex circle, when winding circle number increased to3turns, the sealing pressure had more obvious improvement. The thesis then uses ANSYS to analyze the surface contact problems of two types of plugging devices and pipes, and validates the plugging device sealing performance in accordance with ecperimental results.
Based on the above research, this thesis studies application of main hazard's multiple contingency of plugging technology and possible method library, and uses the figures to show the application of emergency amplatzer device in disposal platform, summarizes the eight main emergency closure tools, and uses maps to show the practical application of plugging tool in occurance of hazard straight bending pipeline, pipeline connecting flange and tand leakage. The presented work depicts a hazard emergency plugging method library's core design framework, summarizes in detail about the five types of typical hazards' main database modules such as physicochemical characteristics, classification and characteristics, point of dealing with leakage, sealing method and sealing tools. It also analyzes sixteen types of plugging methods and corresponding emergency implanter device's disposal procedures. The proposed methods provide an important basis for leakage accident emergency's disposal. The presented research also provides important technical support for industrial safety in production and transportation during the system's normal operation.
本文对危险源管道、储罐及储运过程泄漏的成因及影响因素进行了分析,确定了管道、高压容器的主要泄漏部位,并对重大危险源的泄漏模式进行了研究,建立了危险源储罐及管道等泄漏模型以及三种介质流泄漏状态的数学模型；分析了七种影响泄漏扩散的主要因素,研究了15种泄漏模式的产生机理及条件,并建立了危险源管道的动力学模型。通过管道流体的CFD动力学仿真,对管道泄漏处流量和压力状态做出理论性评估,并得出在管道长度相同、主管道压力变化、泄漏小孔直径不同及入口压力变化的情况下泄漏平均总压力大小与泄漏孔尺寸变化的关系以及小孔泄漏平均压力跃变的情况,为封堵装置的设计提出了具体的性能指标。
本文设计的快速封堵装置是针对现有封堵装置效率低,难以适应复杂多变的工况和特定的泄漏状态而研发的快速有效的新型封堵装置。本文对适用于管道、储罐等压力容器泄漏时实施封堵的危险源管道内封堵导流气囊、管口应急封堵导流装置、管道泄漏外封堵气囊、自适应万向强磁封堵导流装置以及带压封堵装置的机械结构进行了详细剖析。当危险源管道及储罐发生断裂、裂纹或者孔洞泄漏时,确定以内封法、外封法及磁压法为主要封堵实施方法,详细设计了四种新型封堵装置,为危险源泄漏的应急处理处置增添了新手段。
本文针对封堵实验系统进行了研究,并研发了直管口泄漏与弯管小孔泄漏的综合封堵实验平台。利用自行研制的内封堵装置、外封堵装置及其改进装置在平台上进行实验。实验结果表明,在内封堵装置的密封橡胶气囊套长度增加20mm、气囊外圆的密封环数量增加5圈、充气和导流口侧的中空轴端盖直径增加24mm后的封堵效果非常明显,最大封堵压力几乎增加45%；在外封堵装置的充气橡胶气囊带的长度增加2m、气囊带外表面上复合细密的密封圈以及缠绕在管道上的气囊带匝数增加3匝时,封堵压力也有了较大的提升。同时对两种封堵装置与管道的面--面接触问题进行了有限元分析,验证了封堵装置的封堵性能。
另外,本文还对主要危险源发生泄漏的多种应急封堵技术和方法库的应用进行了研究,并以实物图的形式说明了应急封堵装置在处理处置平台上的运用；提出了八种主要应急封堵工具,并以导图形式说明危险源直弯管道、管线连接法兰及储罐发生泄漏时封堵工具的实际应用；提出了危险源应急封堵方法库的核心架构,对五种典型危险物的物化特性、泄漏分类及特性、泄漏处置要点、封堵方法及封堵工具等主要数据库模块进行了详细总结。分析了16种封堵方法及对应封堵装置的处置步骤,为危险源泄漏应急处理处置提供了重要依据。为企业安全生产提供了重要的技术保障。
With the rapidly development of our country's economy and the deepening of reform and opening up, the coal chemical industry has made a high-speed development in past decades. In the industrial processes, the pressure vessels and storage areas, which store a lot of dangerous chemicals such as poisonous, harmful, inflammable and explosive matters. As a result of careless management of such chemicals, together with the ageing equipment and man-made destruction can easily cause ruptures of pressure vessels or pipes, and lead to leakage accidents. Therefore, there is an emerging need to apply the Modern design theory and method to research the hazard's leakage, and select appropriate sealing devices to avoid such leakage accidents. When in the worse case hazard leakage occurs, we can take emergency treatment quickly and effectively to reduce or eliminate the resulting damage.
This thesis analyzes causes and affecting factors of possible leakages in hazard pipelines, tanks, as well as the leakages during the process of storage or transportation. The proposed method can locate the main leakage location in pipelines or pressure vessels. Furthermore, this thesis studies the mathematical models of significant hazard's leakages and establishes models of hazard's storage tanks and pipelines through three kinds of mathematical representations of medium flow leakage states. This thesis also analyzes seven main factors which affect the spreading of the leakages, researches fifteen types of mechanisms and conditions of leakage models, and establishes the dynamic model of the hazard pipeline. Through the CFD dynamics simulation of pipeline's fluid, the author makes theoretical evaluations of pipeline leakage's flow and pressure, and obtaines the variation of the inlet pressures in the case of main line pressure change with the same pipe length and different diameter of leakage's small hole. The author also presents the relationships between the average of total pressures and the change of leakage's size and variations of aperture leak's average pressure jump. Additionally the author puts forward specific performance indicators for sealing device' s working characteristic.
Rapidly sealing device is a fast and effective new-type device. It is developes for some plugging device with low efficiency but high difficulty to adapt to the complex conditions and certain leakage state. This thesis carries on the detailed analysis for risk source pipeline inner wall diversion airbag which applies to plugging in case of pressure vessel leakage, the emergency sealing mouth guiding device, the pipeline leak sealing air bages, adaptive universal strong magnetic closure guiding device and mechanical structure of take pressure sealing device. When hazards pipe and tank fractures, cracks or leaks, the proposed framework can determine the appropriate method among the sealing method, the outer method and the magnetic pressure method as the main sealing method. It designs four kinds of new type of rapid sealing device, and adds new content for method library of hazards leakage's emergency treatment and disposal technology.
This thesis studies the plugging experiment system, researches and develops the plugging experiment system in the situation of straight pipe leakage or hole leakage. Under the condition of straight pipe leakage and bent pipe leakage, with the experiment with sealed plugging device, outer sealing device and its improving device, we can see that, when sealing rubber sleeve's length in internal blocking increased20mm, the seal ring of air bag's outer circle increased5ring and the diameter of inflatable and diversion's hollow shaft cover increased24mm, the achieved plugging is quite effective. Maxinum sealing pressure increased almost45%; inflatable rubber bag band's length in external plugging device increased2m, airbag's appearance coated sealing convex circle, when winding circle number increased to3turns, the sealing pressure had more obvious improvement. The thesis then uses ANSYS to analyze the surface contact problems of two types of plugging devices and pipes, and validates the plugging device sealing performance in accordance with ecperimental results.
Based on the above research, this thesis studies application of main hazard's multiple contingency of plugging technology and possible method library, and uses the figures to show the application of emergency amplatzer device in disposal platform, summarizes the eight main emergency closure tools, and uses maps to show the practical application of plugging tool in occurance of hazard straight bending pipeline, pipeline connecting flange and tand leakage. The presented work depicts a hazard emergency plugging method library's core design framework, summarizes in detail about the five types of typical hazards' main database modules such as physicochemical characteristics, classification and characteristics, point of dealing with leakage, sealing method and sealing tools. It also analyzes sixteen types of plugging methods and corresponding emergency implanter device's disposal procedures. The proposed methods provide an important basis for leakage accident emergency's disposal. The presented research also provides important technical support for industrial safety in production and transportation during the system's normal operation.
引文
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