Failure Analysis And Reliability Evaluation Of Shell-and-tube Heat Exchanger In Sulfuric Acid Industry

Shell-and-tube heat exchanger plays an important role in the chemical industrial systems.In the production process,the medium in contact with the heat exchanger tube bundle is more complex.It often has high pressure,high temperature,strong corrosion,high flow rate.Therefore,corrosion leakage and flushing leakage often occur.Failure of shell and tube heat exchangers will result in economic losses and various property losses.More importantly,it will result in major accidents such as fires and explosions,causing huge economic losses and casualties,and serious consequences of serious environmental pollution.These bring negative effect of society.Failure tree failure analysis of the shell-and-tube heat exchanger is performed to evaluate the main impact of failure of the shell-and-tube heat exchanger,and the weak links of the shell-and-tube heat exchanger operating system are identified.The protective measures are of great significance.This article mainly studies the following content:(1)We collect relevant data of shell-and-tube heat exchanger,and master the reason of its failure.It analyzes the factors that affect the failure risk of shell-and-tube heat exchanger,and draw the main risk factors and corresponding countermeasures.An accident tree model for the failure mode of shell-and-tube heat exchangers was established.The failure factors of shell-and-tube heat exchanger system are qualitatively evaluated,and the importance of risk factors was comprehensively determined.(2)Based on the analysis of the failure factors of the concentrated sulphuric acid cooler in a Chemical Industry,the failure fault tree analysis model of the concentrated sulphuric acid cooler was established.The fault tree analysis of the sulphuric acid cooler was analyzed and evaluated qualitatively,and the fault tree analysis was quantified with the method of fuzzy mathematics.Analyze the calculations,and finally use the accident tree simulation software to simulate the fault tree analysis and plot the chart,and discuss the improvement measures for the failure of the concentrated sulfuric acid cooler during operation.(3)Using the reliability theory to further analyze the failure mode of the concentrated sulphuric acid cooler.Through the actual production data of the concentrated sulphuric acid cooler,the corresponding weights and indexes are obtained,and a comprehensive evaluation system for reliability is successfully established,the feasibility of the theory is verified,and the safety factor has the greatest influence on the reliability of the concentrated sulphuric acid cooler system.