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波紋管補償器之所以能夠在許多行業中得到廣泛應用，除具有良好的補償能力之外，高可靠性是主要原因。其可靠性是通過設計、制造、安裝、運行管理等多個環節來保證的，任何一個環節的失控都會導致補償器壽命的降低甚至失效。經過多年統計發現，造成波紋管補償器失效的原因：設計占10％，制造廠家偷工減料占50％，安裝不符合設備說明要求占20％，其余由運行管理不當引起的。
1. 波紋管補償器的失效類型及原因分析
1.1失效(xiao)類型
波(bo)(bo)紋(wen)(wen)管(guan)(guan)的(de)(de)失(shi)(shi)(shi)(shi)(shi)(shi)效(xiao)(xiao)(xiao)(xiao)在管(guan)(guan)線試壓(ya)和運行(xing)期間均有(you)發(fa)生(sheng)。管(guan)(guan)線試壓(ya)時出現(xian)(xian)問(wen)題主要有(you)三種類型(xing)：由于(yu)管(guan)(guan)系臨時支(zhi)撐不當(dang)，或(huo)管(guan)(guan)系固定支(zhi)架設置不合理(li)，導致支(zhi)架破壞，波(bo)(bo)紋(wen)(wen)管(guan)(guan)過(guo)量變(bian)形(xing)而(er)失(shi)(shi)(shi)(shi)(shi)(shi)效(xiao)(xiao)(xiao)(xiao)；由于(yu)波(bo)(bo)紋(wen)(wen)管(guan)(guan)設計所考慮(lv)的(de)(de)壓(ya)力或(huo)位(wei)移安全富裕度不夠，管(guan)(guan)線試壓(ya)時波(bo)(bo)紋(wen)(wen)管(guan)(guan)產生(sheng)失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)變(bian)形(xing)失(shi)(shi)(shi)(shi)(shi)(shi)效(xiao)(xiao)(xiao)(xiao)；補償(chang)器(qi)制(zhi)造質量問(wen)題，制(zhi)造廠偷工減料，5層(ceng)不銹鋼私(si)自改為3層(ceng)或(huo)更少。波(bo)(bo)紋(wen)(wen)管(guan)(guan)在運行(xing)期間的(de)(de)失(shi)(shi)(shi)(shi)(shi)(shi)效(xiao)(xiao)(xiao)(xiao)主要表(biao)現(xian)(xian)為腐蝕泄漏和失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)變(bian)形(xing)兩(liang)種形(xing)式，其(qi)中(zhong)以(yi)腐蝕失(shi)(shi)(shi)(shi)(shi)(shi)效(xiao)(xiao)(xiao)(xiao)居多。從(cong)腐蝕失(shi)(shi)(shi)(shi)(shi)(shi)效(xiao)(xiao)(xiao)(xiao)波(bo)(bo)紋(wen)(wen)管(guan)(guan)的(de)(de)餌剖分析發(fa)現(xian)(xian)，腐蝕失(shi)(shi)(shi)(shi)(shi)(shi)效(xiao)(xiao)(xiao)(xiao)通常分點腐蝕穿孔和應(ying)力腐蝕開裂(lie)，其(qi)中(zhong)氯離子應(ying)力腐蝕開裂(lie)約占整個腐蝕失(shi)(shi)(shi)(shi)(shi)(shi)效(xiao)(xiao)(xiao)(xiao)的(de)(de)95％。波(bo)(bo)紋(wen)(wen)管(guan)(guan)失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)有(you)強度失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)和結(jie)構(gou)失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)兩(liang)種類型(xing)，強度失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)包括內(nei)外壓(ya)波(bo)(bo)紋(wen)(wen)管(guan)(guan)平面失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)和外壓(ya)波(bo)(bo)紋(wen)(wen)管(guan)(guan)周向失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)；結(jie)構(gou)失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)是內(nei)壓(ya)波(bo)(bo)紋(wen)(wen)管(guan)(guan)補償(chang)器(qi)的(de)(de)柱失(shi)(shi)(shi)(shi)(shi)(shi)穩(wen)
1.2 設計疲勞壽命與穩定性及應力腐(fu)蝕的關系
波(bo)紋(wen)管(guan)的設計(ji)主要(yao)(yao)考慮耐壓(ya)強度(du)、穩(wen)定(ding)(ding)性(xing)和疲勞性(xing)能等三個方(fang)面的因素。雖然國家標準(zhun)(zhun)和美國EJMA標準(zhun)(zhun)對這幾(ji)方(fang)面的計(ji)算(suan)和評定(ding)(ding)都有(you)明確的規定(ding)(ding)，但從多年的應用(yong)(yong)實踐和波(bo)紋(wen)管(guan)失(shi)(shi)效(xiao)分析中發現，標準(zhun)(zhun)中給(gei)(gei)出的關于穩(wen)定(ding)(ding)性(xing)的計(ji)算(suan)和評定(ding)(ding)方(fang)法(fa)不(bu)夠(gou)全(quan)面，且疲勞壽命(ming)也(ye)僅給(gei)(gei)出了(le)比較粗的界限范圍（平(ping)均疲勞壽命(ming)在10^3-10^3適用(yong)(yong)）。有(you)時一個完(wan)全(quan)符合(he)標準(zhun)(zhun)要(yao)(yao)求的產品，在實際使用(yong)(yong)時也(ye)會出現一些(xie)問題。如內壓(ya)軸向型補償(chang)器(qi)預變(bian)(bian)位狀(zhuang)態在壓(ya)力試驗時波(bo)紋(wen)管(guan)易(yi)產生平(ping)面失(shi)(shi)穩(wen)，大(da)直徑(jing)外壓(ya)軸向型補償(chang)器(qi)全(quan)位移工作(zuo)狀(zhuang)態波(bo)紋(wen)管(guan)易(yi)產生周向失(shi)(shi)穩(wen)，小直徑(jing)復式(shi)拉桿型補償(chang)器(qi)、鉸(jiao)鏈型補償(chang)器(qi)全(quan)位移工作(zuo)狀(zhuang)態易(yi)產生柱失(shi)(shi)穩(wen)。波(bo)紋(wen)管(guan)過(guo)大(da)的變(bian)(bian)形不(bu)僅對其穩(wen)定(ding)(ding)性(xing)造成影響，還會為應力腐(fu)蝕提(ti)供有(you)利的環境條件。
1.2.1 波(bo)紋(wen)管疲(pi)勞(lao)(lao)壽(shou)命(ming)(ming)與其(qi)綜合應(ying)力(li)波(bo)紋(wen)管的(de)(de)補償(chang)(chang)量取決于其(qi)疲(pi)勞(lao)(lao)壽(shou)命(ming)(ming)，疲(pi)勞(lao)(lao)壽(shou)命(ming)(ming)越(yue)高，波(bo)紋(wen)管單波(bo)補償(chang)(chang)量越(yue)小(xiao)。為了降低(di)成本，提高單波(bo)補償(chang)(chang)量，有些(xie)生產廠家將波(bo)紋(wen)管的(de)(de)許用(yong)疲(pi)勞(lao)(lao)壽(shou)命(ming)(ming)降得很(hen)低(di)，這樣會(hui)導致由位(wei)移引起的(de)(de)波(bo)紋(wen)管子午向彎曲應(ying)力(li)很(hen)大(da)，綜合應(ying)力(li)很(hen)高，大(da)大(da)降低(di)了波(bo)紋(wen)管的(de)(de)穩定性。
1.2.2 波紋管(guan)的綜合(he)應力(li)與其耐(nai)壓(ya)強度 由標(biao)準(zhun)中(zhong)給(gei)出的波紋管(guan)平面穩(wen)定性和周向(xiang)穩(wen)定性的計算(suan)方法和評定標(biao)準(zhun)可以看出，二者反映的均為強度問題。當(dang)波紋管(guan)設計的許用壽命(ming)較(jiao)低時，不(bu)僅其子(zi)午向(xiang)綜合(he)應力(li)較(jiao)高，環向(xiang)應力(li)也比(bi)較(jiao)高，使波紋管(guan)局部很快進入塑性變形，導致波紋管(guan)失穩(wen)。
1.2.3 補償(chang)(chang)器(qi)位(wei)移與其柱穩定性對(dui)于(yu)復式拉桿(gan)型(xing)和鉸鏈型(xing)補償(chang)(chang)器(qi)，橫(heng)向位(wei)移是由波(bo)(bo)紋(wen)管角變位(wei)引起中(zhong)間管段傾斜實(shi)現的。當波(bo)(bo)紋(wen)管產生(sheng)角變位(wei)時，波(bo)(bo)紋(wen)管凸出側承壓面(mian)積大(da)于(yu)凹陷側承壓面(mian)積，導致(zhi)補償(chang)(chang)器(qi)附加(jia)了一個橫(heng)向力(li)，較之軸向型(xing)補償(chang)(chang)器(qi)更易產生(sheng)柱失(shi)穩。顯然波(bo)(bo)紋(wen)管單波(bo)(bo)位(wei)移越(yue)大(da)，補償(chang)(chang)器(qi)橫(heng)向位(wei)移越(yue)大(da)，越(yue)易產生(sheng)柱失(shi)穩。
2. 波紋管補償器的可靠性
波(bo)紋(wen)管(guan)補償器的(de)可(ke)靠(kao)(kao)性(xing)是(shi)由設計、制造、安裝及運(yun)行管(guan)理等多個(ge)環節(jie)構成的(de)。可(ke)靠(kao)(kao)性(xing)也應該從這幾個(ge)方面進行考慮。
2．1 可靠性設計
2.1.1材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)選擇對用(yong)(yong)(yong)于(yu)(yu)(yu)供熱管(guan)(guan)(guan)(guan)網(wang)(wang)的(de)(de)(de)波(bo)紋管(guan)(guan)(guan)(guan)的(de)(de)(de)選材(cai)，除應考慮工(gong)(gong)作(zuo)(zuo)介質、工(gong)(gong)作(zuo)(zuo)溫度(du)和外(wai)部環境外(wai)，還(huan)應考慮應力(li)腐(fu)蝕(shi)的(de)(de)(de)可(ke)能(neng)性(xing)(xing)(xing)、水(shui)處理劑(ji)和管(guan)(guan)(guan)(guan)道(dao)清洗劑(ji)對材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)的(de)(de)(de)影響等(deng)，并在此(ci)基礎上結合(he)波(bo)紋管(guan)(guan)(guan)(guan)材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)的(de)(de)(de)焊(han)接、成型以(yi)及材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)的(de)(de)(de)性(xing)(xing)(xing)能(neng)價格(ge)(ge)比(bi)，優選出經濟實用(yong)(yong)(yong)的(de)(de)(de)波(bo)紋管(guan)(guan)(guan)(guan)制作(zuo)(zuo)材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)。一(yi)般情(qing)況下，選用(yong)(yong)(yong)波(bo)紋管(guan)(guan)(guan)(guan)的(de)(de)(de)材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)應滿足(zu)下列(lie)條件：(1)良(liang)好的(de)(de)(de)塑性(xing)(xing)(xing)，便于(yu)(yu)(yu)波(bo)紋管(guan)(guan)(guan)(guan)的(de)(de)(de)加工(gong)(gong)成形，且能(neng)通過(guo)隨(sui)后的(de)(de)(de)處理工(gong)(gong)藝(冷作(zuo)(zuo)硬(ying)化、熱處理等(deng))獲(huo)得足(zu)夠的(de)(de)(de)硬(ying)度(du)和強(qiang)度(du)。(2)高(gao)彈性(xing)(xing)(xing)極限(xian)、抗拉強(qiang)度(du)和疲勞強(qiang)度(du)，保(bao)證波(bo)紋管(guan)(guan)(guan)(guan)正常工(gong)(gong)作(zuo)(zuo)。(3)良(liang)好的(de)(de)(de)焊(han)接性(xing)(xing)(xing)能(neng)，滿足(zu)波(bo)紋管(guan)(guan)(guan)(guan)在制作(zuo)(zuo)過(guo)程中的(de)(de)(de)焊(han)接工(gong)(gong)藝要(yao)(yao)求。(4)較好的(de)(de)(de)耐(nai)腐(fu)蝕(shi)性(xing)(xing)(xing)能(neng)，滿足(zu)波(bo)紋管(guan)(guan)(guan)(guan)在不同環境下工(gong)(gong)作(zuo)(zuo)要(yao)(yao)求。大(da)多數(shu)生(sheng)產廠家都(dou)采用(yong)(yong)(yong)奧氏體不銹鋼，為了(le)提高(gao)波(bo)紋管(guan)(guan)(guan)(guan)的(de)(de)(de)耐(nai)蝕(shi)性(xing)(xing)(xing)，現供熱管(guan)(guan)(guan)(guan)網(wang)(wang)波(bo)紋管(guan)(guan)(guan)(guan)的(de)(de)(de)用(yong)(yong)(yong)材(cai)多選用(yong)(yong)(yong)316或(huo)(huo)316L，這兩種材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)用(yong)(yong)(yong)于(yu)(yu)(yu)熱力(li)管(guan)(guan)(guan)(guan)網(wang)(wang)應該是性(xing)(xing)(xing)能(neng)價格(ge)(ge)比(bi)較為優良(liang)的(de)(de)(de)材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)。對于(yu)(yu)(yu)地(di)溝敷設的(de)(de)(de)熱力(li)管(guan)(guan)(guan)(guan)網(wang)(wang)，當補償器所處管(guan)(guan)(guan)(guan)道(dao)地(di)勢較低(di)時，雨(yu)水(shui)或(huo)(huo)事故(gu)性(xing)(xing)(xing)污水(shui)會浸泡(pao)波(bo)紋管(guan)(guan)(guan)(guan)，應考慮選用(yong)(yong)(yong)耐(nai)蝕(shi)性(xing)(xing)(xing)更(geng)強(qiang)的(de)(de)(de)材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)，如鐵(tie)鎳合(he)金(jin)、高(gao)鎳合(he)金(jin)等(deng)。由(you)于(yu)(yu)(yu)此(ci)類材(cai)料(liao)(liao)(liao)(liao)(liao)(liao)價格(ge)(ge)較高(gao)，在制造(zao)波(bo)紋管(guan)(guan)(guan)(guan)時，可(ke)以(yi)考慮僅在與腐(fu)蝕(shi)性(xing)(xing)(xing)介質接觸(chu)的(de)(de)(de)表面增(zeng)加一(yi)層耐(nai)蝕(shi)合(he)金(jin)
2.1.2 疲(pi)勞壽命(ming)設計(ji)由(you)波(bo)(bo)紋(wen)(wen)(wen)(wen)管(guan)(guan)補(bu)償(chang)(chang)器(qi)的(de)(de)失(shi)效(xiao)類型(xing)及(ji)原因(yin)分析可(ke)以看出(chu)(chu)，波(bo)(bo)紋(wen)(wen)(wen)(wen)管(guan)(guan)的(de)(de)平面(mian)穩(wen)定性、周向穩(wen)定性及(ji)耐(nai)腐(fu)蝕性能均與(yu)其位移(yi)量即(ji)疲(pi)勞壽命(ming)相關(guan)。過低的(de)(de)疲(pi)勞壽命(ming)將會導致(zhi)波(bo)(bo)紋(wen)(wen)(wen)(wen)管(guan)(guan)穩(wen)定性及(ji)耐(nai)蝕性能下降。根(gen)據試驗和使用經驗，用于(yu)供熱工程的(de)(de)波(bo)(bo)紋(wen)(wen)(wen)(wen)管(guan)(guan)疲(pi)勞壽命(ming)應(ying)不小于(yu)1000次(ci)。大多數波(bo)(bo)紋(wen)(wen)(wen)(wen)管(guan)(guan)的(de)(de)失(shi)效(xiao)是(shi)由(you)外(wai)部(bu)環境腐(fu)蝕造成的(de)(de)，因(yin)此在進行補(bu)償(chang)(chang)器(qi)的(de)(de)結構設計(ji)時，可(ke)考慮隔絕外(wai)部(bu)腐(fu)蝕介(jie)質與(yu)波(bo)(bo)紋(wen)(wen)(wen)(wen)管(guan)(guan)的(de)(de)接觸(chu)。如對于(yu)外(wai)壓軸(zhou)向型(xing)補(bu)償(chang)(chang)器(qi)可(ke)在出(chu)(chu)口端(duan)環與(yu)出(chu)(chu)口管(guan)(guan)之間增加填料(liao)密封裝置，其作用相當于(yu)套筒補(bu)償(chang)(chang)器(qi)，既可(ke)抵擋(dang)外(wai)部(bu)腐(fu)蝕介(jie)質的(de)(de)侵入(ru)，又(you)給波(bo)(bo)紋(wen)(wen)(wen)(wen)管(guan)(guan)補(bu)償(chang)(chang)器(qi)增加了一道安全屏障，即(ji)使波(bo)(bo)紋(wen)(wen)(wen)(wen)管(guan)(guan)破壞，補(bu)償(chang)(chang)器(qi)還可(ke)以起到補(bu)償(chang)(chang)作用并避免(mian)波(bo)(bo)紋(wen)(wen)(wen)(wen)管(guan)(guan)失(shi)效(xiao)。
2．2 保證安裝(zhuang)質(zhi)量
波紋管(guan)(guan)不能承重，應單獨(du)吊裝；除設(she)計要求(qiu)預(yu)拉伸或(huo)(huo)冷(leng)緊(jin)的(de)預(yu)變形(xing)(xing)量外，嚴禁(jin)用使波紋管(guan)(guan)變形(xing)(xing)的(de)方法來調整管(guan)(guan)道(dao)的(de)安(an)(an)裝偏差(cha)；安(an)(an)裝過(guo)程不允許(xu)焊渣飛濺到波紋管(guan)(guan)表(biao)面(mian)和受到其他(ta)機械(xie)性損傷；波紋管(guan)(guan)所有(you)活動(dong)元件(jian)不得被外部(bu)(bu)構件(jian)卡(ka)死或(huo)(huo)限制其活動(dong)部(bu)(bu)位正(zheng)常工作；水(shui)(shui)壓試(shi)驗用水(shui)(shui)須干(gan)凈(jing)、無腐蝕性，對奧氏體不銹鋼材質(zhi)應嚴格(ge)控(kong)制水(shui)(shui)中(zhong)氯離子含量不超(chao)過(guo)25×10^-6，并應及時(shi)排(pai)盡波紋中(zhong)的(de)積水(shui)(shui)等。
3. 結束語
補償器存在的問題主要有波紋管的穩定性及腐蝕。通過合理的設計波紋管波形參數和疲勞壽命、安裝正確及管系應力分析完善等措施，可以解決波紋管的穩定性問題。對于腐蝕問題，可以通過兩種方式解決：(1)合理的波紋管選材和補償器結構設計，阻斷腐蝕源。(2)加強小室積水管理，從根本上解決腐蝕問題。