Innovative rotary friction welding of heat exchanger tube nozzles on high pressure headers

IF 3 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping Pub Date : 2024-07-16 DOI:10.1016/j.ijpvp.2024.105263

D.G. Hattingh , M.N. James , F.K. Schwim , R. Opperman , D. Bernard , I. Wedderburn

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引用次数: 0

Abstract

This paper describes an innovative application, driven by an industrial requirement for an alternative welding process to submerged arc welding of header heat exchanger tube nozzles, of an automated friction hydro-pillar processing (FHPP) welding platform (WeldCore©). This was the first successful application of rotary friction welding of heat exchanger tube nozzles to high pressure-headers used in the high-pressure heaters of a boiler on a 609 MW steam turbo-generator unit. The FHPP WeldCore platform allows highly time- and cost-effective welding and repair of high temperature, high pressure power plant using a procedure that was approved in the 2015 ASME Boiler and Pressure Vessel Code, Supplement 3 as Code Case 2832 (WPS qualification for Friction Taper Hydro-Pillar (FTHP) welding). This certification opened the way to using FHPP welding for repair and refurbishment of power generation and high temperature process plant. After completing the welding of 448 nozzles onto each of two HP headers, all welds were found to be defect-free using ultrasonic testing, and test nozzle welds passed the weld qualification procedure required by industry.

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高压集管上热交换器管嘴的创新旋转摩擦焊

本文介绍了一项创新应用，该应用是在工业需求的驱动下，采用自动摩擦水柱加工（FHPP）焊接平台（WeldCore©），替代顶管热交换器管嘴埋弧焊的焊接工艺。这是首次在 609 兆瓦蒸汽涡轮发电机组锅炉高压加热器中成功应用热交换器管嘴旋转摩擦焊。FHPP WeldCore 平台可对高温高压发电厂进行高时效、高成本效益的焊接和维修，其程序已获 2015 ASME 锅炉和压力容器规范补充 3 批准，成为规范案例 2832（摩擦锥形水柱 (FTHP) 焊接的 WPS 资格认证）。该认证为使用 FHPP 焊接进行发电和高温工艺设备的维修和翻新开辟了道路。在完成两个高压顶管上 448 个喷嘴的焊接后，通过超声波检测发现所有焊缝均无缺陷，并且测试喷嘴焊缝通过了行业要求的焊接鉴定程序。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Pressure Vessels and Piping 工程技术-工程：机械

CiteScore

5.30

自引率

13.30%

发文量

208

审稿时长

17 months

期刊介绍： Pressure vessel engineering technology is of importance in many branches of industry. This journal publishes the latest research results and related information on all its associated aspects, with particular emphasis on the structural integrity assessment, maintenance and life extension of pressurised process engineering plants. The anticipated coverage of the International Journal of Pressure Vessels and Piping ranges from simple mass-produced pressure vessels to large custom-built vessels and tanks. Pressure vessels technology is a developing field, and contributions on the following topics will therefore be welcome: • Pressure vessel engineering • Structural integrity assessment • Design methods • Codes and standards • Fabrication and welding • Materials properties requirements • Inspection and quality management • Maintenance and life extension • Ageing and environmental effects • Life management Of particular importance are papers covering aspects of significant practical application which could lead to major improvements in economy, reliability and useful life. While most accepted papers represent the results of original applied research, critical reviews of topical interest by world-leading experts will also appear from time to time. International Journal of Pressure Vessels and Piping is indispensable reading for engineering professionals involved in the energy, petrochemicals, process plant, transport, aerospace and related industries; for manufacturers of pressure vessels and ancillary equipment; and for academics pursuing research in these areas.