LNG低温管道法兰泄漏校核过程的探讨

Investigation of the Leakage Verification Process for Cryogenic LNG Pipeline Flanges

  • 摘要: 法兰泄漏校核是压力管道行业应力分析的重要环节,通过合理的方法评估法兰在各种复杂工况下的泄漏风险,并通过合理的手段将泄漏风险控制在合理范围内,对整个油气储运系统的安全稳定运行具有重要意义。然而,目前国内外标准中提到的法兰泄漏校核方法众多,各种方法在适用范围、校核重点、计算的难易程度、计算结果的保守性方面存在较大差异,采用哪种方法进行LNG低温管道的法兰泄漏校核尚无统一定论。本文在梳理国内外各种法兰泄漏校核方法的基础上,以某LNG接收站DN 300低压外输预留法兰为例,通过应力分析专业软件CAESAR II搭建管系分析模型,采用当量压力法、NC 3658.3法及ASME Section VIII Division 2法分别对其进行正常操作工况及热拱工况下的法兰泄漏校核,对比了三种方法校核结果的差异,并探究了降低法兰泄漏风险的有效措施。结果表明,正常操作工况下当量压力法计算结果最保守,NC 3658.3法计算结果较宽松,ASME Section VIII Division 2法计算结果居中且适用范围广、计算过程易于实现;热拱工况下法兰弯矩急剧增大,导致当量压力远超许用压力,法兰泄漏风险急剧增大。因此,推荐工程设计阶段采用ASME Section VIII Division 2法进行LNG管道的法兰泄漏校核,同时必须对热拱工况下法兰的泄漏风险进行评估。此外,优化管道布置方案、控制预冷速度及提高法兰磅级是降低法兰泄漏风险的三种有效措施,并建议LNG低温管道至少采用CL300法兰。

     

    Abstract: Flange leakage verification is a critical step in the stress analysis of the pressure piping industry. Assessing leakage risks under complex conditions through appropriate methods and effectively mitigating these risks are essential for ensuring the safe and stable operation of oil and gas storage and transportation systems. However, current domestic and international standards specify multiple verification methods for flange leakage, which exhibit significant differences in terms of application scope, key evaluation criteria, computational complexity and conservatism of results. And there is no unified consensus regarding the optimal methodology for conducting flange leakage verification in LNG cryogenic pipelines. Based on a comprehensive review of international flange leakage verification methodologies, this study focuses on a DN300 low-pressure discharge flange at a certain LNG terminal. A piping system model was established using the professional stress analysis software CAESAR II. The Equivalent Pressure Method, NC 3658.3 Method, and ASME Section VIII Division 2 Method were respectively applied to evaluate flange leakage under both normal operating conditions and thermal arching conditions. Then a comparative analysis of discrepancies in verification results obtained from these three methods was conducted, while effective mitigation measures to reduce flange leakage risks were explored. The results indicate that under normal operating conditions, the Equivalent Pressure Method yields the most conservative results, while the NC 3658.3 Method produces more lenient outcomes. The ASME Section VIII Division 2 Method demonstrates intermediate conservatism with broader applicability and enhanced computational efficiency. Under thermal arching conditions, flange bending moments experience dramatic increases, causing equivalent pressures to significantly exceed allowable limits and consequently elevating leakage risks substantially. Therefore, it is recommended to adopt the ASME Section VIII Division 2 Method for flange leakage verification in LNG pipeline design engineering, which concurrently requires rigorous assessment of leakage risks under thermal arching conditions. Furthermore, three effective mitigation measures have been identified: piping layout optimization, pre-cooling rate control during commissioning, and increasing flange class ratings. As a critical design specification, LNG cryogenic pipelines should implement Class 300 flanges as a minimum requirement to ensure operational integrity.

     

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