本文選題：工業(yè)爐管　切入點：離心鑄造　出處：《北京化工大學(xué)》2013年碩士論文　論文類型：學(xué)位論文

【摘要】：工業(yè)爐管是乙烯裂解裝置等石化生產(chǎn)裝置中反應(yīng)爐的核心組成部分,可以分為輻射段爐管和對流段爐管。其中裂解反應(yīng)主要在輻射段爐管內(nèi)進(jìn)行,輻射段爐管需要長期在高溫低壓的條件下工作,容易產(chǎn)生滲碳、腐蝕、斷裂等問題。因此,其質(zhì)量的優(yōu)劣對石化產(chǎn)品質(zhì)量和石化生產(chǎn)安全起著重要的作用。輻射段爐管的生產(chǎn)大多數(shù)采用離心鑄造的方式,因為采用這種方式所得的產(chǎn)品具有組織致密、晶型完整、金屬夾渣物少和機(jī)械性能良好等優(yōu)點,能夠很好地適用于各種石化生產(chǎn)。 在一些鑄造企業(yè)中,工人大多根據(jù)生產(chǎn)經(jīng)驗來進(jìn)行生產(chǎn),并通過對單一參數(shù)的控制來保證爐管的質(zhì)量。但爐管生產(chǎn)過程復(fù)雜,影響因素眾多,且各影響因素之間存在一定的相關(guān)性,各因素協(xié)同影響爐管最終的質(zhì)量。因此,依據(jù)經(jīng)驗或?qū)我粎?shù)控制的方法無法實現(xiàn)對產(chǎn)品質(zhì)量嚴(yán)格控制和廢品產(chǎn)生原因的有效查找。 本文以某企業(yè)輻射段爐管鑄造生產(chǎn)過程為對象,按照批次對每根爐管的離心鑄造生產(chǎn)過程信息進(jìn)行全流程的采集,具體包括物料信息,離心鑄造過程信息和質(zhì)檢信息等。以這些過程采集的數(shù)據(jù)信息為基礎(chǔ),采用多元統(tǒng)計模型對爐管生產(chǎn)過程進(jìn)行監(jiān)測。操作工人可對模型預(yù)測有質(zhì)量問題的爐管進(jìn)行全面的檢測,避免不合格產(chǎn)品混入合格產(chǎn)品中。本文以主元分析方法為基礎(chǔ),通過分析各參數(shù)對故障貢獻(xiàn)的大小,從而找出引起產(chǎn)品質(zhì)量不合格的主要參數(shù),為實際生產(chǎn)過程提供參考,在下一根爐管的生產(chǎn)中及時調(diào)整生產(chǎn)條件,以保證生產(chǎn)的正常進(jìn)行,達(dá)到提高爐管產(chǎn)品質(zhì)量,降低生產(chǎn)成本的目的。因此爐管質(zhì)量監(jiān)測模型的建立具有重要的工業(yè)實際應(yīng)用價值和研究意義。本文的主要研究內(nèi)容包括： (1)對原料熔煉和離心鑄造這兩個影響爐管質(zhì)量的關(guān)鍵環(huán)節(jié)進(jìn)行了詳細(xì)的分析。討論了主要操作變量對爐管質(zhì)量的影響。結(jié)合文獻(xiàn)資料、生產(chǎn)經(jīng)驗和變量收集的可行性等因素確定了建立爐管質(zhì)量監(jiān)測模型所需的變量種類、變量采集方式和采集頻率等重要內(nèi)容。 (2)對建立爐管質(zhì)量監(jiān)測模型所需的訓(xùn)練數(shù)據(jù)進(jìn)行預(yù)處理,以消除建模數(shù)據(jù)的異常點,保證模型的準(zhǔn)確性。用交叉驗證法確定模型最優(yōu)主元個數(shù),采用該模型對實際生產(chǎn)數(shù)據(jù)進(jìn)行監(jiān)測。 (3)為提高爐管質(zhì)量監(jiān)測模型的效果,討論了建模變量的數(shù)量和種類以及建模數(shù)據(jù)的數(shù)量等因素的影響,并通過貢獻(xiàn)圖的方法對質(zhì)量不合格爐管的生產(chǎn)數(shù)據(jù)進(jìn)行分析,確定引起爐管質(zhì)量問題的主要參數(shù)。將模型對爐管質(zhì)量預(yù)測的結(jié)果同工廠實際檢測結(jié)果相對比,可得模型正確預(yù)報質(zhì)量不合格爐管的比率為86.67%,錯誤預(yù)報質(zhì)量不合格爐管的比率為2.86%,對實際生產(chǎn)過程具有一定的指導(dǎo)意義。
[Abstract]:Industrial furnace tube is the core part of reaction furnace in petrochemical production plant such as ethylene pyrolysis unit, which can be divided into radiation section furnace tube and convection section furnace tube, in which the cracking reaction mainly takes place in the radiation section furnace tube. The radiation section furnace tube needs to work under the condition of high temperature and low pressure for a long time. It is easy to cause carburization, corrosion, fracture and so on. Its quality plays an important role in the quality of petrochemical products and the safety of petrochemical production. Most of the tubes in the radiation section are produced by centrifugal casting, because the products obtained by this way are compact in structure and complete in crystal form. The advantages of less metal slag and good mechanical properties can be well applied to various petrochemical production. In some foundry enterprises, most of the workers produce according to their production experience, and ensure the quality of the furnace tube by controlling the single parameter, but the production process of the furnace tube is complicated and the influence factors are many. There is a certain correlation among the influencing factors, and all factors influence the final quality of furnace tube. Therefore, the strict control of product quality and the cause of waste can not be effectively found according to experience or the method of single parameter control. In this paper, the whole process information of centrifugal casting of each furnace tube is collected according to the batch, which includes the material information, taking the casting process of the furnace tube in a certain enterprise as the object. Based on the data collected from these processes, the multivariate statistical model is used to monitor the tube production process. Based on principal component analysis (PCA), this paper analyzes the contribution of each parameter to the failure, and finds out the main parameters that cause the unqualified quality of the product, and provides a reference for the actual production process. Adjust the production conditions in time in the production of the next furnace tube in order to ensure the normal production and improve the product quality of the furnace tube. Therefore, the establishment of furnace tube quality monitoring model has important practical application value and research significance in industry. The main research contents of this paper are as follows:. 1) two key links which affect the quality of furnace tube are analyzed in detail, that is, raw material melting and centrifugal casting. The influence of main operating variables on tube quality is discussed. Factors such as production experience and the feasibility of variable collection determine the types of variables needed to establish the quality monitoring model of furnace tubes, variable collection methods and acquisition frequency and other important contents. In order to eliminate the abnormal points of the modeling data and ensure the accuracy of the model, the training data needed to establish the furnace tube quality monitoring model are preprocessed, and the optimal number of principal components of the model is determined by cross-validation method. The model is used to monitor the actual production data. In order to improve the effect of the quality monitoring model of furnace tube, the influence of the quantity and type of modeling variables and the quantity of modeling data are discussed, and the production data of unqualified furnace tube are analyzed by the method of contribution diagram. The main parameters causing tube quality problems are determined. The prediction results of furnace tube quality by the model are compared with the actual test results in the factory. The ratio of the unqualified furnace tube predicted correctly by the available model is 86.67, and the ratio of the unqualified furnace tube predicted by the error prediction is 2.86, which is of certain guiding significance to the actual production process.
【學(xué)位授予單位】：北京化工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2013
【分類號】：TQ086.3

【參考文獻(xiàn)】

相關(guān)期刊論文 前10條

1 胡軼,劉西濤,李健玲,王宇;淺談乙烯裂解反應(yīng)爐管的技術(shù)進(jìn)展[J];甘肅科技;2005年11期

2 石永剛;黃中輝;;淺析石化企業(yè)事故原因分析及事故預(yù)防[J];化學(xué)工程與裝備;2011年06期

3 尤兆宏;;乙烯裂解爐爐管失效分析[J];化工機(jī)械;2007年06期

4 馮晉芬;王勝;;鑄造過程質(zhì)量的控制研究[J];機(jī)電產(chǎn)品開發(fā)與創(chuàng)新;2008年04期

5 劉靖;韓靜濤;周芬燕;;離心鑄造Q235鋼/高鉻鑄鐵復(fù)合管的熱處理工藝[J];金屬熱處理;2012年07期

6 陳梅榮;;我國石油化工產(chǎn)業(yè)的發(fā)展現(xiàn)狀及發(fā)展前景[J];科技致富向?qū)?2012年14期

7 孫德海;世界石化工業(yè)發(fā)展趨勢的幾點啟示[J];遼寧化工;2005年02期

8 任章;李清東;董磊;潘宇雄;孫艷兵;;基于案例推理和等價空間的定性/定量混合故障診斷方法[J];南京航空航天大學(xué)學(xué)報;2011年S1期

9 王榮杰;胡清;;基于知識的故障診斷方法的發(fā)展現(xiàn)狀與展望[J];微計算機(jī)信息;2006年07期

10 胡金海;謝壽生;駱廣琦;楊帆;彭靖波;;一種基于貢獻(xiàn)率圖的KPCA故障識別方法[J];系統(tǒng)工程與電子技術(shù);2008年03期

，

本文編號：1648787