Forgings in the petrochemical industry may fail due to various factors during long-term use. Failure not only degrades device performance, but also may cause security accidents. Therefore, it is of great practical significance to analyze the failure of petrochemical forgings deeply and take effective preventive measures. This paper will focus on this topic.
Failure forms and causes of petrochemical forgings
Fracture failure: Forgings may fail when subjected to overload, shock or alternating loads. The main reasons include insufficient material strength, forging defects, improper heat treatment and so on.
Wear failure: forging in the long-term use of the process, due to friction, corrosion and other factors, may lead to surface wear. The main reasons include poor wear resistance of the material, poor lubrication, and harsh use environment.
Corrosion failure: there are a lot of corrosive media in the petrochemical environment, such as acid, alkali, salt, etc. Forgings are used in these media for a long time, and corrosion failure may occur. The main reasons include poor corrosion resistance of materials and improper protective measures.
Deformation failure: Forgings in high temperature, high pressure and other harsh environment for a long time use, deformation failure may occur. The main reasons include poor creep performance and improper heat treatment.
Preventive measures for failure of petrochemical forgings
Optimize material selection: Select the right material according to the working conditions and requirements of the equipment. Emphasis is placed on the strength, toughness, wear resistance and corrosion resistance of the material to ensure that the forgings can maintain good performance in a variety of environments.
Improve the forging process: strictly control the heating temperature, forging speed and cooling speed during the forging process to avoid forging defects. Adopt advanced forging technology and equipment to improve the internal quality and mechanical properties of forgings.
Optimize the heat treatment process: according to the composition and performance requirements of the material, develop a reasonable heat treatment process. By adjusting the heating temperature, holding time and cooling rate, the metallographic structure and mechanical properties of the material are optimized to improve the strength and toughness of the forging.
Enhanced surface treatment: The use of spraying, coating and other surface treatment technology to enhance the hardness and wear resistance of the forging surface. Clean and lubricate forgings regularly to keep their surfaces clean and well-lubricated.
Strengthen quality inspection and control: Establish a perfect quality inspection system, and carry out a comprehensive test on the chemical composition, mechanical properties and metallographic structure of forgings. Identify and deal with potential quality problems in a timely manner to ensure that the quality of forgings meets relevant standards and requirements.
Strengthen device maintenance and management: Check and maintain devices regularly to discover and handle potential security risks in a timely manner. The key parts of the forgings are replaced regularly to ensure that they are always in good working condition.
Failure analysis and preventive measures of petrochemical forgings are important links to ensure the safety and reliability of equipment. Through the in-depth analysis of the failure forms and causes, we can find out the root of the problem and take effective preventive measures. In the future, with the continuous emergence of new materials and new technologies, the manufacturing of petrochemical forgings will face more challenges and opportunities. Relevant enterprises should continue to learn and master new technologies and new methods to improve production efficiency and product quality to contribute to the sustainable development of the petrochemical industry.
