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Cracking failure mechanism and design optimization of the desuperheating water spray nozzle weld of a high‑pressure bypass valve in a 1 000 MW ultra‑supercritical unit
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Zhaoguang YIN1, Qin DONG1, Yiwei XU1, Weiwei ZHAO2, 3, Yunqing WANG1, Yuan GU1, Bingyi CHEN2, 3, Yimin CUI2, 3, Ningning ZHAO2, 3, Chuanyang LÜ4
Pressure Vessel Technology | 2026, 43(3) : 70 - 77
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Pressure Vessel Technology | 2026, 43(3): 70-77
• Safety Analysis •
Cracking failure mechanism and design optimization of the desuperheating water spray nozzle weld of a high‑pressure bypass valve in a 1 000 MW ultra‑supercritical unit
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Zhaoguang YIN1, Qin DONG1, Yiwei XU1, Weiwei ZHAO2, 3, Yunqing WANG1, Yuan GU1, Bingyi CHEN2, 3, Yimin CUI2, 3, Ningning ZHAO2, 3, Chuanyang LÜ4
Affiliations
  • 1Zhejiang Zheneng Zhongmei Zhoushan Coal & Electricity Co.，Ltd.，Zhoushan 316135，China
  • 2Zhejiang Energy Technology Research Institute Co.，Ltd.，Hangzhou 311121，China
  • 3Zhejiang Key Laboratory of Thermal Power Generation Energy Efficiency and Pollutant Control Technology，Hangzhou 311121，China
  • 4Institute of Process Equipment and Control Engineering，Zhejiang University of Technology，Hangzhou 310023，China
Published: 2026-03-30 doi: 10.3969/j.issn.1001-4837.2026.03.007
Outline
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To address the issue of frequent cracking in the weld of the desuperheating water spray nozzle of a high‑pressure bypass valve in a 1 000 MW ultra‑supercritical unit，the failure mechanism of the weld was revealed and a structural optimization scheme was proposed by means of metallographic structure analysis，microhardness testing，and other physical and chemical inspection methods combined with finite element numerical simulation technology.The results show that the high hardness of the weld between the desuperheating water inlet pipe and the nozzle，together with the low‑cycle strain fatigue induced by structural constraints，mutually superimposed to promote the rapid initiation and propagation of cracks in the fillet weld，thereby leading to leakage of the desuperheating water pipe.For the optimization scheme of lengthening the vertical desuperheating water pipe to enhance pipeline flexibility，finite element analysis shows that when the vertical pipe length is increased to 380 mm，the stress at the fillet weld significantly decreases to 65 MPa，effectively avoiding stress concentration.The research results can provide reference for the structural design and safe operation of similar high‑pressure bypass valves.

ultra‑supercritical unit  /  high‑pressure bypass valves  /  failure anasysis  /  finite element analysis  /  stress calculation
殷兆广, 董勤, 徐以伟, 赵炜炜, 王云庆, 顾渊, 陈秉怡, 崔益民, 赵宁宁, 闾川阳. 1 000 MW超超临界机组高压旁路阀减温水喷嘴焊缝开裂失效机理与设计优化. 压力容器, 2026 , 43 (3) : 70 -77 . DOI: 10.3969/j.issn.1001-4837.2026.03.007
Zhaoguang YIN, Qin DONG, Yiwei XU, Weiwei ZHAO, Yunqing WANG, Yuan GU, Bingyi CHEN, Yimin CUI, Ningning ZHAO, Chuanyang LÜ. Cracking failure mechanism and design optimization of the desuperheating water spray nozzle weld of a high‑pressure bypass valve in a 1 000 MW ultra‑supercritical unit[J]. Pressure Vessel Technology, 2026 , 43 (3) : 70 -77 . DOI: 10.3969/j.issn.1001-4837.2026.03.007
Appendix
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Year 2026 volume 43 Issue 3
103
42
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Article Info
doi: 10.3969/j.issn.1001-4837.2026.03.007
  • Receive Date：2025-05-14
  • Online Date：2026-10-23
  • Published：2026-03-30
Article Data
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History
  • Received：2025-05-14
  • Revised：2026-02-26
Affiliations
    1Zhejiang Zheneng Zhongmei Zhoushan Coal & Electricity Co.，Ltd.，Zhoushan 316135，China
    2Zhejiang Energy Technology Research Institute Co.，Ltd.，Hangzhou 311121，China
    3Zhejiang Key Laboratory of Thermal Power Generation Energy Efficiency and Pollutant Control Technology，Hangzhou 311121，China
    4Institute of Process Equipment and Control Engineering，Zhejiang University of Technology，Hangzhou 310023，China
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https://castjournals.cast.org.cn/joweb/ylrq/EN/10.3969/j.issn.1001-4837.2026.03.007
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表12种不同金属材料的力学参数
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小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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