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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失效類型
波(bo)紋(wen)管(guan)(guan)(guan)(guan)的(de)(de)失(shi)(shi)(shi)效(xiao)(xiao)在管(guan)(guan)(guan)(guan)線試壓(ya)(ya)和(he)(he)(he)運行(xing)(xing)期間(jian)均有發生(sheng)。管(guan)(guan)(guan)(guan)線試壓(ya)(ya)時(shi)出現(xian)問題(ti)主要(yao)有三種(zhong)類(lei)型：由于管(guan)(guan)(guan)(guan)系(xi)臨時(shi)支撐不(bu)當，或管(guan)(guan)(guan)(guan)系(xi)固定支架(jia)設置不(bu)合理(li)，導致(zhi)支架(jia)破壞，波(bo)紋(wen)管(guan)(guan)(guan)(guan)過量變形而失(shi)(shi)(shi)效(xiao)(xiao)；由于波(bo)紋(wen)管(guan)(guan)(guan)(guan)設計所考慮的(de)(de)壓(ya)(ya)力或位移安全富裕度不(bu)夠，管(guan)(guan)(guan)(guan)線試壓(ya)(ya)時(shi)波(bo)紋(wen)管(guan)(guan)(guan)(guan)產生(sheng)失(shi)(shi)(shi)穩(wen)(wen)(wen)變形失(shi)(shi)(shi)效(xiao)(xiao)；補償器制(zhi)造質量問題(ti)，制(zhi)造廠偷工減料，5層不(bu)銹鋼私自(zi)改為(wei)(wei)3層或更少。波(bo)紋(wen)管(guan)(guan)(guan)(guan)在運行(xing)(xing)期間(jian)的(de)(de)失(shi)(shi)(shi)效(xiao)(xiao)主要(yao)表(biao)現(xian)為(wei)(wei)腐(fu)蝕(shi)泄漏和(he)(he)(he)失(shi)(shi)(shi)穩(wen)(wen)(wen)變形兩種(zhong)形式，其中以腐(fu)蝕(shi)失(shi)(shi)(shi)效(xiao)(xiao)居多。從(cong)腐(fu)蝕(shi)失(shi)(shi)(shi)效(xiao)(xiao)波(bo)紋(wen)管(guan)(guan)(guan)(guan)的(de)(de)餌(er)剖分析(xi)發現(xian)，腐(fu)蝕(shi)失(shi)(shi)(shi)效(xiao)(xiao)通常分點腐(fu)蝕(shi)穿孔和(he)(he)(he)應力腐(fu)蝕(shi)開裂，其中氯離子應力腐(fu)蝕(shi)開裂約占整個腐(fu)蝕(shi)失(shi)(shi)(shi)效(xiao)(xiao)的(de)(de)95％。波(bo)紋(wen)管(guan)(guan)(guan)(guan)失(shi)(shi)(shi)穩(wen)(wen)(wen)有強(qiang)度失(shi)(shi)(shi)穩(wen)(wen)(wen)和(he)(he)(he)結(jie)構失(shi)(shi)(shi)穩(wen)(wen)(wen)兩種(zhong)類(lei)型，強(qiang)度失(shi)(shi)(shi)穩(wen)(wen)(wen)包括內外壓(ya)(ya)波(bo)紋(wen)管(guan)(guan)(guan)(guan)平(ping)面(mian)失(shi)(shi)(shi)穩(wen)(wen)(wen)和(he)(he)(he)外壓(ya)(ya)波(bo)紋(wen)管(guan)(guan)(guan)(guan)周向(xiang)失(shi)(shi)(shi)穩(wen)(wen)(wen)；結(jie)構失(shi)(shi)(shi)穩(wen)(wen)(wen)是內壓(ya)(ya)波(bo)紋(wen)管(guan)(guan)(guan)(guan)補償器的(de)(de)柱失(shi)(shi)(shi)穩(wen)(wen)(wen)
1.2 設(she)計(ji)疲勞壽命(ming)與穩(wen)定性及(ji)應力腐(fu)蝕的關系
波紋(wen)(wen)管的(de)(de)(de)設(she)計(ji)主要考慮(lv)耐壓(ya)(ya)強度、穩(wen)定(ding)(ding)性(xing)和(he)疲(pi)勞性(xing)能等三個(ge)方(fang)(fang)面(mian)的(de)(de)(de)因素。雖(sui)然國家標(biao)準和(he)美國EJMA標(biao)準對(dui)這(zhe)幾方(fang)(fang)面(mian)的(de)(de)(de)計(ji)算和(he)評定(ding)(ding)都有(you)(you)明確(que)的(de)(de)(de)規定(ding)(ding)，但(dan)從多年的(de)(de)(de)應用(yong)(yong)實踐和(he)波紋(wen)(wen)管失(shi)效分析中發現，標(biao)準中給出(chu)的(de)(de)(de)關(guan)于穩(wen)定(ding)(ding)性(xing)的(de)(de)(de)計(ji)算和(he)評定(ding)(ding)方(fang)(fang)法不夠全面(mian)，且(qie)疲(pi)勞壽(shou)命(ming)也(ye)僅給出(chu)了比較粗的(de)(de)(de)界限范圍（平均疲(pi)勞壽(shou)命(ming)在(zai)(zai)10^3-10^3適用(yong)(yong)）。有(you)(you)時(shi)一個(ge)完全符合標(biao)準要求的(de)(de)(de)產品，在(zai)(zai)實際(ji)使用(yong)(yong)時(shi)也(ye)會出(chu)現一些問題。如(ru)內壓(ya)(ya)軸(zhou)向(xiang)型(xing)補(bu)(bu)償(chang)器預(yu)變(bian)位(wei)狀態(tai)在(zai)(zai)壓(ya)(ya)力(li)試驗時(shi)波紋(wen)(wen)管易產生平面(mian)失(shi)穩(wen)，大直(zhi)(zhi)徑(jing)外壓(ya)(ya)軸(zhou)向(xiang)型(xing)補(bu)(bu)償(chang)器全位(wei)移(yi)工作(zuo)狀態(tai)波紋(wen)(wen)管易產生周向(xiang)失(shi)穩(wen)，小直(zhi)(zhi)徑(jing)復式拉(la)桿型(xing)補(bu)(bu)償(chang)器、鉸鏈型(xing)補(bu)(bu)償(chang)器全位(wei)移(yi)工作(zuo)狀態(tai)易產生柱失(shi)穩(wen)。波紋(wen)(wen)管過大的(de)(de)(de)變(bian)形不僅對(dui)其(qi)穩(wen)定(ding)(ding)性(xing)造成(cheng)影響，還會為應力(li)腐蝕提供有(you)(you)利(li)的(de)(de)(de)環境條件(jian)。
1.2.1 波(bo)紋(wen)管(guan)(guan)疲勞(lao)壽(shou)(shou)命與(yu)其綜(zong)合應力波(bo)紋(wen)管(guan)(guan)的(de)補償量取決于其疲勞(lao)壽(shou)(shou)命，疲勞(lao)壽(shou)(shou)命越高(gao)，波(bo)紋(wen)管(guan)(guan)單波(bo)補償量越小。為了(le)降低成本，提高(gao)單波(bo)補償量，有些生產廠家將波(bo)紋(wen)管(guan)(guan)的(de)許用疲勞(lao)壽(shou)(shou)命降得很(hen)低，這樣會導(dao)致由位移引起的(de)波(bo)紋(wen)管(guan)(guan)子午向彎曲(qu)應力很(hen)大，綜(zong)合應力很(hen)高(gao)，大大降低了(le)波(bo)紋(wen)管(guan)(guan)的(de)穩(wen)定性。
1.2.2 波(bo)(bo)(bo)紋(wen)管(guan)(guan)的(de)(de)綜合(he)應力(li)與其耐壓(ya)強度 由標準中給出的(de)(de)波(bo)(bo)(bo)紋(wen)管(guan)(guan)平面穩定性和周向(xiang)穩定性的(de)(de)計算方(fang)法和評定標準可以看出，二(er)者反映的(de)(de)均(jun)為強度問題。當波(bo)(bo)(bo)紋(wen)管(guan)(guan)設計的(de)(de)許用壽命較(jiao)低(di)時，不僅其子(zi)午向(xiang)綜合(he)應力(li)較(jiao)高，環(huan)向(xiang)應力(li)也比較(jiao)高，使波(bo)(bo)(bo)紋(wen)管(guan)(guan)局部很快進入塑(su)性變形，導致波(bo)(bo)(bo)紋(wen)管(guan)(guan)失穩。
1.2.3 補(bu)(bu)償器(qi)位移與其(qi)柱穩(wen)定性(xing)對于(yu)復(fu)式拉桿型和鉸鏈型補(bu)(bu)償器(qi)，橫向(xiang)(xiang)位移是(shi)由(you)波(bo)紋(wen)管角變位引起中(zhong)間管段傾斜實現的。當波(bo)紋(wen)管產(chan)(chan)生角變位時，波(bo)紋(wen)管凸(tu)出側(ce)承壓(ya)面積(ji)大(da)于(yu)凹陷(xian)側(ce)承壓(ya)面積(ji)，導致補(bu)(bu)償器(qi)附(fu)加(jia)了一個橫向(xiang)(xiang)力(li)，較之(zhi)軸向(xiang)(xiang)型補(bu)(bu)償器(qi)更易產(chan)(chan)生柱失穩(wen)。顯然波(bo)紋(wen)管單(dan)波(bo)位移越大(da)，補(bu)(bu)償器(qi)橫向(xiang)(xiang)位移越大(da)，越易產(chan)(chan)生柱失穩(wen)。
2. 波紋管補償器的可靠性
波紋管補償(chang)器的可(ke)靠性(xing)是由設計、制(zhi)造、安裝及運行(xing)管理等多個(ge)環(huan)節構成的。可(ke)靠性(xing)也(ye)應該從這幾(ji)個(ge)方面進(jin)行(xing)考慮。
2．1 可靠性設計
2.1.1材(cai)(cai)(cai)(cai)料(liao)(liao)選(xuan)擇對用(yong)(yong)(yong)于(yu)(yu)供熱(re)(re)管(guan)(guan)(guan)(guan)(guan)網的(de)(de)波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)的(de)(de)選(xuan)材(cai)(cai)(cai)(cai)，除應考慮(lv)工(gong)(gong)作(zuo)介(jie)(jie)質、工(gong)(gong)作(zuo)溫度和(he)外(wai)部(bu)環境外(wai)，還(huan)應考慮(lv)應力腐蝕(shi)的(de)(de)可能(neng)性(xing)(xing)、水處理劑和(he)管(guan)(guan)(guan)(guan)(guan)道清洗(xi)劑對材(cai)(cai)(cai)(cai)料(liao)(liao)的(de)(de)影響(xiang)等，并在此基(ji)礎上(shang)結合(he)波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)材(cai)(cai)(cai)(cai)料(liao)(liao)的(de)(de)焊(han)接、成型以及材(cai)(cai)(cai)(cai)料(liao)(liao)的(de)(de)性(xing)(xing)能(neng)價(jia)(jia)格(ge)比，優選(xuan)出經(jing)濟實用(yong)(yong)(yong)的(de)(de)波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)制作(zuo)材(cai)(cai)(cai)(cai)料(liao)(liao)。一般情(qing)況下，選(xuan)用(yong)(yong)(yong)波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)的(de)(de)材(cai)(cai)(cai)(cai)料(liao)(liao)應滿(man)足(zu)下列條件(jian)：(1)良好(hao)(hao)的(de)(de)塑性(xing)(xing)，便于(yu)(yu)波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)的(de)(de)加(jia)工(gong)(gong)成形，且能(neng)通過隨(sui)后的(de)(de)處理工(gong)(gong)藝(yi)(冷作(zuo)硬化(hua)、熱(re)(re)處理等)獲得足(zu)夠的(de)(de)硬度和(he)強度。(2)高彈性(xing)(xing)極限、抗拉強度和(he)疲勞強度，保證波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)正常(chang)工(gong)(gong)作(zuo)。(3)良好(hao)(hao)的(de)(de)焊(han)接性(xing)(xing)能(neng)，滿(man)足(zu)波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)在制作(zuo)過程中的(de)(de)焊(han)接工(gong)(gong)藝(yi)要(yao)(yao)求。(4)較(jiao)好(hao)(hao)的(de)(de)耐(nai)腐蝕(shi)性(xing)(xing)能(neng)，滿(man)足(zu)波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)在不同環境下工(gong)(gong)作(zuo)要(yao)(yao)求。大多數生(sheng)產廠家都采用(yong)(yong)(yong)奧氏體(ti)不銹(xiu)鋼，為了提高波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)的(de)(de)耐(nai)蝕(shi)性(xing)(xing)，現供熱(re)(re)管(guan)(guan)(guan)(guan)(guan)網波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)的(de)(de)用(yong)(yong)(yong)材(cai)(cai)(cai)(cai)多選(xuan)用(yong)(yong)(yong)316或316L，這兩種材(cai)(cai)(cai)(cai)料(liao)(liao)用(yong)(yong)(yong)于(yu)(yu)熱(re)(re)力管(guan)(guan)(guan)(guan)(guan)網應該是性(xing)(xing)能(neng)價(jia)(jia)格(ge)比較(jiao)為優良的(de)(de)材(cai)(cai)(cai)(cai)料(liao)(liao)。對于(yu)(yu)地(di)溝敷設的(de)(de)熱(re)(re)力管(guan)(guan)(guan)(guan)(guan)網，當(dang)補償器所處管(guan)(guan)(guan)(guan)(guan)道地(di)勢較(jiao)低時，雨水或事(shi)故性(xing)(xing)污水會(hui)浸泡波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)，應考慮(lv)選(xuan)用(yong)(yong)(yong)耐(nai)蝕(shi)性(xing)(xing)更強的(de)(de)材(cai)(cai)(cai)(cai)料(liao)(liao)，如鐵(tie)鎳(nie)合(he)金、高鎳(nie)合(he)金等。由于(yu)(yu)此類材(cai)(cai)(cai)(cai)料(liao)(liao)價(jia)(jia)格(ge)較(jiao)高，在制造波(bo)(bo)紋(wen)(wen)管(guan)(guan)(guan)(guan)(guan)時，可以考慮(lv)僅在與腐蝕(shi)性(xing)(xing)介(jie)(jie)質接觸的(de)(de)表(biao)面(mian)增加(jia)一層耐(nai)蝕(shi)合(he)金
2.1.2 疲勞(lao)壽(shou)命設計(ji)由波紋(wen)管(guan)(guan)補(bu)償(chang)(chang)(chang)器的(de)失效類型及(ji)原因分析可(ke)(ke)以看(kan)出(chu)，波紋(wen)管(guan)(guan)的(de)平面穩定(ding)性(xing)(xing)、周向(xiang)穩定(ding)性(xing)(xing)及(ji)耐腐(fu)蝕(shi)(shi)性(xing)(xing)能均與(yu)(yu)其位(wei)移量即(ji)疲勞(lao)壽(shou)命相關(guan)。過低的(de)疲勞(lao)壽(shou)命將會導致(zhi)波紋(wen)管(guan)(guan)穩定(ding)性(xing)(xing)及(ji)耐蝕(shi)(shi)性(xing)(xing)能下降(jiang)。根(gen)據試驗和(he)使(shi)用(yong)經驗，用(yong)于供熱工程的(de)波紋(wen)管(guan)(guan)疲勞(lao)壽(shou)命應不(bu)小于1000次。大多數波紋(wen)管(guan)(guan)的(de)失效是由外部(bu)環境腐(fu)蝕(shi)(shi)造(zao)成的(de)，因此在(zai)進行(xing)補(bu)償(chang)(chang)(chang)器的(de)結(jie)構設計(ji)時(shi)，可(ke)(ke)考慮隔絕外部(bu)腐(fu)蝕(shi)(shi)介質與(yu)(yu)波紋(wen)管(guan)(guan)的(de)接觸。如對于外壓軸向(xiang)型補(bu)償(chang)(chang)(chang)器可(ke)(ke)在(zai)出(chu)口端環與(yu)(yu)出(chu)口管(guan)(guan)之(zhi)間增(zeng)加填料(liao)密(mi)封裝(zhuang)置(zhi)，其作(zuo)用(yong)相當于套(tao)筒(tong)補(bu)償(chang)(chang)(chang)器，既可(ke)(ke)抵擋(dang)外部(bu)腐(fu)蝕(shi)(shi)介質的(de)侵(qin)入(ru)，又給波紋(wen)管(guan)(guan)補(bu)償(chang)(chang)(chang)器增(zeng)加了一道安全(quan)屏障，即(ji)使(shi)波紋(wen)管(guan)(guan)破壞，補(bu)償(chang)(chang)(chang)器還可(ke)(ke)以起到補(bu)償(chang)(chang)(chang)作(zuo)用(yong)并(bing)避免(mian)波紋(wen)管(guan)(guan)失效。
2．2 保證(zheng)安裝質量
波紋(wen)管(guan)不(bu)能承重，應單獨(du)吊裝；除(chu)設計要求預拉伸或冷(leng)緊(jin)的(de)預變形量外，嚴禁用使(shi)波紋(wen)管(guan)變形的(de)方法(fa)來調整管(guan)道的(de)安裝偏差(cha)；安裝過程不(bu)允許(xu)焊渣(zha)飛(fei)濺(jian)到(dao)波紋(wen)管(guan)表(biao)面和受到(dao)其他機械性損傷；波紋(wen)管(guan)所有活動元件不(bu)得被外部構件卡(ka)死或限制其活動部位正常工作；水壓試驗用水須干凈、無(wu)腐蝕性，對奧氏體不(bu)銹鋼材質應嚴格(ge)控制水中(zhong)氯離子(zi)含量不(bu)超過25×10^-6，并應及時排(pai)盡波紋(wen)中(zhong)的(de)積水等。
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。