CN101811154A - Method for producing hot-bending elbow - Google Patents
Method for producing hot-bending elbow Download PDFInfo
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- CN101811154A CN101811154A CN200910078172A CN200910078172A CN101811154A CN 101811154 A CN101811154 A CN 101811154A CN 200910078172 A CN200910078172 A CN 200910078172A CN 200910078172 A CN200910078172 A CN 200910078172A CN 101811154 A CN101811154 A CN 101811154A
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Abstract
The invention discloses a method for producing a hot-bending elbow, and relates to the technical field of treatment of metal pipes and piping systems. The method comprises the following steps: purchasing raw materials, and storing; inspecting the raw materials; bending to obtain the elbow; carrying out first sample inspection and self-inspection; heat-treating; shaping before beveling; beveling; grinding welding seams; carrying out nondestructive inspection; carrying out product inspection; and packing, and sending the finished products out of the factory. From purchasing the raw materials to sending the finished products out of the factory, the invention specifies a complete and strict technological process. Thus, the invention has the advantages of safe production process, high speed, controllability and stable quality, and is a refined method for producing hot-bending elbows.
Description
Technical field
The present invention is a kind of method for producing hot-bending elbow.The processing and the pipe-line system technical field that relate to metal tube.
Background technology
Bend pipe is a large amount of tubing that use in the pipe-line construction, and is one of important critical product.It plays main effect in pipeline, the one, change duct orientation, the 2nd, the structural mechanics effect, can buffering pipe on-site stratum migration, earthquake and ambient temperature variation etc. be attached to drawing on the straight tube, compression and torsional interaction, pipeline delivery reliability, security and economy that the performance of bend pipe directly influences.Therefore, the process technology of bend pipe just seems especially important.At present, the process technology of bend pipe is mature on the whole, and the bend pipe of production can meet the demands substantially.But because rigorous not enough on production method, the control of bending quality is still strict inadequately, causes bending quality also not reach satisfied degree.
Summary of the invention
The objective of the invention is to invent a kind of safety, steady quality, fast controllable method for producing hot-bending elbow.
This method for producing hot-bending elbow is:
1) raw material enter factory, deposit;
2) inspection of raw and process materials;
3) bend pipe bends;
4) first item inspection, self check;
5) heat treatment;
6) shaping before the groove;
7) groove;
8) polishing welding seams;
9) nondestructive inspection;
10) product inspection;
11) pack the transmission of dispatching from the factory.
Wherein:
Raw material enter factory, deposit: pipe part should leave the well-ventilated in after entering factory, temperature is no more than 40 ℃ storehouse or simple and easy place; Do not allow to contact with flame and high temp objects; If then should there be overcover the resting period than long; Tubing answers horizontal stack to be placed on the smooth supporter or on the ground;
Stack and highly be not more than 1.5m; After taking safeguard measure, stack height and can suitably improve, but should be greater than 3m; Pipe fitting should successively stack neatly, guarantees not collapse, and is convenient to take and manage; When tubing is deposited, should be with the tubing classify and pile up of different-diameter and different wall;
Bend pipe should not have greasy dirt with steel tube surface; In steel pipe manufacturing, carrying, cargo handling process, do not allow to contact, otherwise should adopt suitable method (as sandblast) to remove with low-melting-point metal (Cu, Zn, Sn, Pb etc.);
The inspection of raw and process materials: the steel pipe raw material should have the steel pipe manufacturer quality certificate that conforms to quality requirements, and the steel pipe that unmarked, no lot number, no quality certificate or quality certificate are incomplete can not use; The steel pipe raw material enter factory, should be inspected for acceptance by lot number, specification, outward appearance and technical data by testing department;
Quality to the raw-material surface quality of steel pipe, weld seam, heat affected area is inspected check by random samples; After the acceptance of materials was qualified, the inspector filled in the check and accepting storing advice note, pressed the warehouse-in order, classification is different with stove lot number specification, according to our company's regulation establishment MAT'L mark, the verification mark is transplanted, and realizes the follow-up of quality to material, and material responsibility teacher is responsible for examining the warehouse-in advice note;
Bend pipe bends: technology department is responsible for the tissue and the enforcement of procedure qualification; Work out detailed manufacturing process according to the bend pipe basic parameter of contract for future delivery, bend pipe with steel pipe raw material and technical specification book, content comprises: bend heating-up temperature (℃), fltting speed (mm/ minute), heating tape width (m), cooling velocity (℃/s);
First item inspection, self check are:, and checked in the first batch by the relevant criterion in the pipe bending technique specifications according to the first batch of bend pipe of being worked out of manufacturing process manufacturing by production teams and groups;
First batch of check should be carried out under the supervisor that the side of purchasing represents or the side of purchasing entrusts situation on the scene, and the unit that mechanical property test should be delivered to the side's of purchasing appointment carries out;
After first batch of check all items finished and reaches correlation technique and require, procedure qualification finished, and can produce in batches;
Heat treatment is: the design of Technology for Heating Processing file should meet the regulation that correlation technique requires, and can satisfy the requirement that every performance indications of bend pipe after the heat treatment meet the pipe bending technique specifications;
Answer the individual layer discharging during bend pipe shove charge, at interval evenly, and should keep at a certain distance away between stove, bend pipe should be heated evenly;
The inaccurate contact of workpiece low-melting-point metal, as: Cu, Zn, Sn, Pb etc.;
Pack into the temperature measurement result of bend pipe of record charging situation, thermocouple;
The heat treatment report should comprise heat treatment cycle curve, heating-up temperature and temperature retention time and hardness examining report;
After heat treatment was intact, every bend pipe outer wall must be indicated corresponding heat treatment heat (batch) number, pipe number, bend pipe numbering;
The Technology for Heating Processing evaluation should be carried out under the supervisor that the side of purchasing represents or the side of purchasing entrusts situation on the scene; Merger can obtain evaluation result;
Shaping is before the groove: technology department is responsible to define the check job instruction, and the operator is responsible for the self check of bend pipe manufacture process, and the check group is responsible for the special project check to process quality, is responsible for carrying out the complete examination of finished product together with teams and groups;
According to measurement result, utilize hydraulic jack to carry out the pipe end ovality shaping of hot-bending bends, guarantee the pipe end ovality of bend pipe;
Utilize sonigauge that the bend pipe wall thickness is carried out thickness measure, and to defectively scab, defectives such as cut, pipe carry out reconditioning, till confirming that with painted or magnetic powder inspection method defective is eliminated fully;
Bend the back and should not heat once more or hot size, but bend pipe is surpassed except the bulk heat treatmet of tubing phase transition temperature bend pipe;
Groove is: the cross section of bend pipe should be vertical cross-section, when the pipe end groove has regulation, carries out groove by drawing;
When the drawing failed call, pipe end should meet the requirement of relevant criterion;
Polishing welding seams is: be not less than inner and outer welding reinforcement in the 100mm scope apart from the pipe end face and answer grinding to remove, and with adjacent tubes surface smooth transition;
Nondestructive inspection is: should submit used lossless detection method and technological procedure to the side of purchasing approval in written mode before producing;
In every bend pipe outer arc side, the inner arc side 1500mm scope and weld seam, should after tempering heat treatment, adopt manual ultrasonic examination inspection crack defect;
Manually ultrasonic examination equipment should be able to be checked the bend pipe whole outer surface uninterruptedly, and the equipment display defect should have enough sensitivity; Should use the contrast standard specimen sensitivity of checkout facility to be calibrated the beginning of per tour at least (8 hours) and should calibrating once midway; The contrast standard specimen should be taken from the bend pipe test specimen that has identical bending technique, same outer diameter as, radius of curvature, straight length wall thickness with tested bend pipe; Contrast standard specimen upper edge vertical wall thickness direction should be drilled with the perpendicular through hole (or in the circumferentially processing N5 cutting of contrast mark piece surfaces externally and internally edge, boring or cutting are selected by manufacturer) of 1.6mm diameter; 1.6mm the boring of diameter is used for calibrator (-ter) unit, the minimum dimension shortcoming that the equipment that can not be interpreted as can detect; If the signal that shortcoming produces produces 100% of echo height more than or equal to contrast standard specimen 1.6mm through hole, then think defective, this defective reconditioning should be carried out according to the specification requirement regulation;
The mend that bend pipe manufacturer is carried out adopts magnetic powder inspection or the inspection of liquid immersion method, and the lamination defect that does not allow virtually any size exists;
Should adopt suitable removing surface before the every bend pipe Non-Destructive Testing, remove the surface scale of bend pipe, and guarantee to have suitable surface;
Employed ultrasonic examination equipment should be intact, and manufacturer should submit to and detect and instrument verification standard and the method to finding that defective, position, size are confirmed; The ultrasonic wave scaling method should be submitted the detailed description that comprises contrast standard specimen and scaling method to, for the side's of purchasing approval;
Product inspection is: bend pipe mechanical property test and metal lographic examination exemplar can adopt bending length to be not less than the bend pipe of 1000mm, flow development length 300/500mm, its raw material, radius of curvature, straight length wall thickness, eddy-current heating bends with curved back tempering heat treatment process should be identical with a collection of bend pipe of representative;
By same batch tube material, same bending technique, no more than 50 of same radius of curvature, same straight length wall thickness bend pipe that same tempering process (shove charge or branch furnace treatment reason in batches) is produced are a collection of;
The tensile sample of body and weld seam is dimensioned to total wall thickness rectangular specimen sample by Fig. 4 regulation among the API 5L, and tension test is undertaken by the regulation of ASME A370;
The Charpy-type test of each assigned position should be got one group of 3 full size bar; Test block does not allow to cold pressing flat.The sample center line should be positioned at exemplar wall thickness center, and the breach orientation is answered the vertical wall thickness surface; Weld seam center and heat affected area Charpy bar gap position should adopt etching method to determine by the GB/T229 assigned position, and the breach orientation should be perpendicular to exemplar wall thickness surface; The vertical Charpy bar breach of transition region is opened in tube wall vertical section one side, the breach center line by crooked start line or end of a period line (can adopt etch to determine) perpendicular to sample wall thickness surface; Charpy bar should meet API 5L appendix F figure F-2 regulation, and test should be undertaken by the ASTME23 regulation under-20 ℃ set point of temperature;
The weld seam guided bend test should respectively be got the curved and curved sample of the back of the body of a face (sample do not have repair welding weld seam) from assigned position, and sample should meet API 5L Fig. 9 regulation;
Get the cross section sample from bend pipe exemplar assigned position, after polishing and/or etch, carry out Vickers 10kg load Hardness Surveillance by GB/T4340.1 or ISO6507-1 assigned position; All bend pipes of exemplar and production detect in the hardness of assigned position, and the reading that 3～5 equidistant hardness point are got in each position is a mean value;
The metallographic examination grain size of assigned position is according to GB/T4335, the regulation of GB/T6394 or ASME E112 is evaluated, the field trash grade is evaluated according to the regulation of GB/T10561 or ASME E45, the inspection position of weld seam macrostructure and microscopic structure and multiplication factor are according to shown in the specification requirement, and multiplication factor also can be selected suitable multiplying power by detecting unit; The grain size evaluation is undertaken by technical specification book regulation on the body sample of afore mentioned rules position;
If represent all tests of bend pipe exemplar of a collection of bend pipe all to meet the regulation of technical conditions, then this batch bend pipe is qualified, if represent arbitrary pilot project of exemplar of a collection of bend pipe defective, then allow this batch bend pipe is carried out tempering heat treatment again one time, and again exemplar is carried out above-mentioned inspection; Again tempering heat treatment only allows to carry out once; The steel pipe raw material that the tempering process system can adopt this batch bend pipe to use are simulated the heat treatment test evaluation;
The size of bend pipe, geometry and permissible variation are checked according to the SY5257 prescriptive procedure;
Packing dispatches from the factory to send: to the bend pipe that is up to the standards, manufacturer should do sign earlier by the requirement of technical specification book; The mark position is apart from pipe end 150mm place beginning, by manufacturer easily in proper order (when contract has regulation, as contracted) do sign at the bend pipe surfaces externally and internally; The sign press back does not allow to adopt hot and cold word punch die hammering sign;
Should adopt nylon sling or have the drop hanger of soft metal (do not allow with copper and alloy) thereof in the carrying of workshop and delivery; Manufacturer should submit to written method for carrying for the side's of purchasing approval to the side of purchasing;
Depositing of finished product bend pipe should be able to prevent distortion, destroy and corrosion; Manufacturer should submit to written deposit method for the side's of purchasing approval to the side of purchasing;
Manufacturer should before shipment, submit to complete handling technigue explanation confess can usefulness; Shipment should meet the requirement of railway transportation, highway transportation or sea-freight at least; The method that is proposed should comprise necessary computational methods and express and stack layout drawing, load-bearing band position, cushion block and tightening belt etc.;
Manufacturer should submit to the stacking of preparation employing and the method and the drawing thereof of fixed bending tube to supply the side's of purchasing approval; Bend pipe should be noted operation when depositing, loading and unloading and transporting, to avoid damage; The bend pipe groove is used the pipe cap protection, must not come off in transit;
The weld seam of bend pipe should not contact with any part of spacing block; Weld seam can not contact with any part of railcar and truck or trailer;
The contacting of metal and metal do not have between adjacent bend pipe; For all bend pipes, bend pipe with fasten between the chain or bend pipe and dividing plate between do not have and directly contact firmly;
Truck or trailer be should give cleaning before the shipment bend pipe.
Operation principle:
It is at first by designing requirement radius of curvature and angle of bend to be adjusted that induction heating syphon is simmered the system technology, utilize then load coil be enclosed within processed steel pipe around carry out eddy-current heating, make the heating part that is heated steel pipe in its plastic deformation scope, steel pipe in the tailstock clamping marches forward steel pipe with certain speed, and steel pipe just can be according to the predetermined radius and the bend pipe of angle.Owing to guarantee the overall performance of bend pipe, adopted omnidistance heating process, omnidistance heating is meant when bend pipe is made, and straight length is heated together, to guarantee the uniformity of bend pipe performance.Because the bend pipe manufacture process is actually quenching process, so the mechanical performance of bringing-up section and non-bringing-up section difference to some extent is more remarkable for its difference of some steel pipe.Also heating together of straight length seems extremely important to the raising of bend pipe quality when bend pipe is made.
As seen, the present invention until finished product dispatches from the factory and delivers in user's hand, has stipulated that a whole set of is complete, the strict process flow process from tubing advance factory, adopt a rigorous approach, and production process safety, fast controllable, steady quality is the refining of hot-bending bends processing method.
Description of drawings
Fig. 1 method for producing hot-bending elbow flow chart
The specific embodiment
Embodiment. also the present invention is further illustrated with this example the specific embodiment of the present invention to be described.
Transfering natural gas from the west to the east two wires engineering is one of maximum emphasis energy strategy engineering of country, engineering from Xinjiang Hall fruit this to the east of Shanghai and Guangdong, more than 7700 kilometer of total length, to satisfy the energy demand of Pearl River Delta and Yangtze River Delta Area, main line total length X80 grade of steel, caliber 1219mm, the west section discharge pressure is 12MPa, the eastern section discharge pressure is 10MPa, needs about 2,000,000 tons of X80 steel pipe altogether, and wherein bend pipe needs thousands of.
In order to adapt to domestic and international pipeline hot-bending bends, take up the development work of X80 hot-bending bends.Bend pipe is one of critical product important on the long distance pipeline of western two wires, in pipeline, play main effect, the one, change duct orientation, the 2nd, the structural mechanics effect, can buffering pipe on-site stratum migration, earthquake and ambient temperature variation etc. be attached to drawing on the straight tube, compression and torsional interaction, pipeline delivery reliability, security and economy that the performance of bend pipe directly influences.
This example is exactly the method for producing hot-bending elbow of developing for the required bend pipe of trial-production transfering natural gas from the west to the east two wires engineering.
This method for producing hot-bending elbow is:
1) raw material enter factory, deposit;
2) inspection of raw and process materials;
3) bend pipe bends;
4) first item inspection, self check;
5) heat treatment;
6) shaping before the groove;
7) groove;
8) polishing welding seams;
9) nondestructive inspection;
10) product inspection;
11) pack the transmission of dispatching from the factory.
Wherein:
Raw material enter factory, deposit: be leave the well-ventilated in after pipe part enters factory, temperature is no more than 40 ℃ storehouse; Do not contact with flame and high temp objects; The tubing horizontal stack is placed on the smooth supporter;
Stack and highly be not more than 1.5m; Pipe fitting successively stacks neatly, guarantees not collapse, and is convenient to take and manage; When tubing is deposited, should be with the tubing classify and pile up of different-diameter and different wall;
Bend pipe does not have greasy dirt with steel tube surface; In steel pipe manufacturing, carrying, cargo handling process, do not contact with low-melting-point metal (Cu, Zn, Sn, Pb etc.);
The inspection of raw and process materials: the steel pipe raw material have steel pipe manufacturer quality certificate, and unmarked, no lot number, no quality certificate or the infull steel pipe of quality certificate do not use; The steel pipe raw material enter factory, are inspected for acceptance by lot number, specification, outward appearance and technical data by testing department;
Quality to the raw-material surface quality of steel pipe, weld seam, heat affected area is inspected check by random samples; After the acceptance of materials was qualified, the inspector filled in the check and accepting storing advice note, pressed the warehouse-in order, classification is different with stove lot number specification, according to regulation establishment MAT'L mark, the verification mark is transplanted, and realizes the follow-up of quality to material, and material responsibility teacher is responsible for examining the warehouse-in advice note;
Bend pipe bends: technology department is responsible for the tissue and the enforcement of procedure qualification; Work out detailed manufacturing process according to the bend pipe basic parameter of contract for future delivery, bend pipe with steel pipe raw material and technical specification book, content comprises: bend heating-up temperature (℃), fltting speed (mm/ minute), heating tape width (mm), cooling velocity (℃/s);
First item inspection, self check are:, and checked in the first batch by the relevant criterion in the pipe bending technique specifications according to the first batch of bend pipe of being worked out of manufacturing process manufacturing by production teams and groups;
First batch of check is carried out under the supervisor that the side of purchasing represents or the side of purchasing entrusts situation on the scene, and the unit that mechanical property test is delivered to the side's of purchasing appointment carries out;
After first batch of check all items finished and reaches correlation technique and require, procedure qualification finished, and can produce in batches;
Heat treatment is: the design of Technology for Heating Processing file should meet the regulation that correlation technique requires, and can satisfy the requirement that every performance indications of bend pipe after the heat treatment meet the pipe bending technique specifications;
Individual layer discharging during the bend pipe shove charge at interval evenly, and leaves between stove at interval, and bend pipe should be heated evenly;
Workpiece does not contact low-melting-point metal, as: Cu, Zn, Sn, Pb etc.;
Pack into the temperature measurement result of bend pipe of record charging situation, thermocouple;
The heat treatment report should comprise heat treatment cycle curve, heating-up temperature and temperature retention time and hardness examining report;
After heat treatment was intact, every bend pipe outer wall was indicated corresponding heat treatment heat (batch) number, pipe number, bend pipe numbering;
The Technology for Heating Processing evaluation is carried out under the supervisor that the side of purchasing represents or the side of purchasing entrusts situation on the scene; Merger can obtain evaluation result;
Shaping is before the groove: technology department is responsible to define the check job instruction, and the operator is responsible for the self check of bend pipe manufacture process, and the check group is responsible for the special project check to process quality, is responsible for carrying out the complete examination of finished product together with teams and groups;
According to measurement result, utilize hydraulic jack to carry out the pipe end ovality shaping of hot-bending bends, guarantee the pipe end ovality of bend pipe;
Utilize sonigauge that the bend pipe wall thickness is carried out thickness measure, and to defectively scab, defectives such as cut, pipe carry out reconditioning, only till eliminate fully with painted or magnetic powder inspection method affirmation defective;
Bend the back to bend pipe not heating or hot size once more, but bend pipe is surpassed except the bulk heat treatmet of tubing phase transition temperature;
Groove is: the cross section of bend pipe is a vertical cross-section, when the pipe end groove has regulation, carries out groove by drawing;
When the drawing failed call, pipe end should meet the requirement of relevant criterion;
Polishing welding seams is: remove apart from the inner and outer welding reinforcement grinding that the pipe end face is not less than in the 100mm scope, and with adjacent tubes surface smooth transition;
Nondestructive inspection is: submitted used lossless detection method and technological procedure to the side of purchasing approval in written mode before producing;
In every bend pipe outer arc side, the inner arc side 1500mm scope and weld seam, after tempering heat treatment, adopt manual ultrasonograph to check crack defect;
Manually ultrasonic examination equipment can be checked the bend pipe whole outer surface uninterruptedly, and the equipment display defect has enough sensitivity; Use the contrast standard specimen that the sensitivity of checkout facility is calibrated, the beginning of per tour (8 hours) and should calibrating once midway; The contrast standard specimen is taken from the bend pipe test specimen that has identical bending technique, same outer diameter as, radius of curvature, straight length wall thickness with tested bend pipe; Contrast standard specimen upper edge vertical wall thickness direction is drilled with the perpendicular through hole of 1.6mm diameter; 1.6mm the boring of diameter is used for calibrator (-ter) unit, the minimum dimension shortcoming that the equipment that can not be interpreted as can detect; If the signal that shortcoming produces produces 100% of echo height more than or equal to contrast standard specimen 1.6mm through hole, then think defective, this defective reconditioning is carried out according to the specification requirement regulation;
The mend that bend pipe manufacturer is carried out adopts magnetic powder inspection or the inspection of liquid immersion method, and the lamination defect that does not allow virtually any size exists;
Adopt suitable removing surface before the every bend pipe Non-Destructive Testing, remove the surface scale of bend pipe, and guarantee to have suitable surface;
Employed ultrasonic examination Plant in good condition, manufacturer should submit to and detect and instrument verification standard and the method to finding that defective, position, size are confirmed; The ultrasonic wave scaling method is submitted the detailed description that comprises contrast standard specimen and scaling method to, for the side's of purchasing approval;
Product inspection is: bend pipe mechanical property test and metal lographic examination exemplar can adopt bending length to be not less than the bend pipe of 1000mm, flow development length 300/500mm, and its raw material, radius of curvature, straight length wall thickness, that eddy-current heating bends is identical with a collection of bend pipe of representative with curved back tempering heat treatment process;
By same batch tube material, same bending technique, no more than 50 of same radius of curvature, same straight length wall thickness bend pipe that same tempering process (shove charge or branch furnace treatment reason in batches) is produced are a collection of;
The tensile sample of body and weld seam is dimensioned to total wall thickness rectangular specimen sample by Fig. 4 regulation among the API 5L, and tension test is undertaken by the regulation of ASME A370;
One group of 3 full size bar is got in the Charpy-type test of each assigned position; Test block does not allow to cold pressing flat; The sample center line should be positioned at exemplar wall thickness center, breach orientation vertical wall thickness surface; Weld seam center and heat affected area Charpy bar gap position should adopt etching method to determine by Figure 10 assigned position, and the breach orientation should be perpendicular to exemplar wall thickness surface; The vertical Charpy bar breach of transition region is opened in tube wall vertical section one side, the breach center line by crooked start line or end of a period line (can adopt etch to determine) perpendicular to sample wall thickness surface; Charpy bar should meet API 5L appendix F figure F-2 regulation, and test should be undertaken by ASTM E23 regulation under-20 ℃ set point of temperature;
The weld seam guided bend test is respectively got the curved and curved sample of the back of the body of a face (sample do not have repair welding weld seam) from assigned position, and sample should meet API 5L Fig. 9 regulation;
Get the cross section sample from bend pipe exemplar assigned position, after polishing and/or etch, carry out Vickers 10kg load Hardness Surveillance by GB/T4340.1 or ISO6507-1 assigned position; All bend pipes of exemplar and production detect in the hardness of assigned position, and the reading that 3～5 equidistant hardness point are got in each position is a mean value;
The metallographic examination grain size of assigned position is according to GB/T4335, the regulation of GB/T6394 or ASME E112 is evaluated, the field trash grade is evaluated according to the regulation of GB/T10561 or ASME E45, the inspection position of weld seam macrostructure and microscopic structure and multiplication factor are according to shown in the specification requirement, and multiplication factor also can be selected suitable multiplying power by detecting unit; The grain size evaluation is undertaken by technical specification book regulation on the body sample of afore mentioned rules position;
If represent all tests of bend pipe exemplar of a collection of bend pipe all to meet the regulation of technical conditions, then this batch bend pipe is qualified, if represent arbitrary pilot project of exemplar of a collection of bend pipe defective, then allow this batch bend pipe is carried out tempering heat treatment again one time, and again exemplar is carried out above-mentioned inspection; Again tempering heat treatment only allows to carry out once; The steel pipe raw material that the tempering process system can adopt this batch bend pipe to use are simulated the heat treatment test evaluation;
The size of bend pipe, geometry and permissible variation are checked according to the SY5257 prescriptive procedure;
Packing dispatches from the factory to send: to the bend pipe that is up to the standards, do sign earlier by the requirement of technical specification book; The mark position is apart from pipe end 150mm place beginning, by manufacturer easily in proper order (when contract has regulation, as contracted) do sign at the bend pipe surfaces externally and internally; The sign press back does not adopt hot and cold word punch die hammering sign;
Carrying in workshop and delivery field should be adopted the nylon sling drop hanger; Manufacturer should submit to written method for carrying for the side's of purchasing approval to the side of purchasing;
Depositing of finished product bend pipe should be able to prevent distortion, destroy and corrosion; Submit to written deposit method for the side's of purchasing approval to the side of purchasing;
Before shipment, submit to complete handling technigue explanation confess can usefulness; Shipment should meet the requirement of railway transportation, highway transportation or sea-freight at least; The method that is proposed comprises necessary computational methods and expresses and stack layout drawing, load-bearing band position, cushion block and tightening belt etc.;
Manufacturer submits to the stacking of preparation employing and the method and the drawing thereof of fixed bending tube to supply the side's of purchasing approval;
Bend pipe is noted operation when depositing, loading and unloading and transporting, to avoid damage; The bend pipe groove is used the pipe cap protection, must not come off in transit;
The weld seam of bend pipe does not contact with any part of spacing block; Weld seam can not contact with any part of railcar and truck or trailer;
Contacting of metal and metal do not arranged between adjacent bend pipe; For all bend pipes, bend pipe with fasten between the chain or bend pipe and dividing plate between do not have and directly contact firmly;
Truck or trailer were cleared up before the shipment bend pipe.
The hot-bending bends of two wires, west first batch of bend pipe X80 Φ 1219 * 22 specifications formally transfers trial production in batches to by experiment, stewing system overall process by this method is in safety, stable, controllable state fast, the bottom line of the physical dimension control of bend pipe has been dissolved the contradiction of answering tempering to reduce straight length weld seam centric(al) impact toughness.The Functionality, quality and appealing design yield reaches more than 98% in the hot-bending bends of finishing, and no industrial accident takes place, and has obtained the favorable comment of each side.
Claims (12)
1. method for producing hot-bending elbow is characterized in that the flow process of this process is successively:
1) raw material enter factory, deposit;
2) inspection of raw and process materials;
3) bend pipe bends;
4) first item inspection, self check;
5) heat treatment;
6) shaping before the groove;
7) groove;
8) polishing welding seams;
9) nondestructive inspection;
10) product inspection;
11) pack the transmission of dispatching from the factory.
2. method for producing hot-bending elbow according to claim 1 is characterized in that described raw material enter factory, deposit and is: the steel pipe raw material advance after the factory storage condition be should leave the well-ventilated in, temperature is no more than 40 ℃ storehouse or simple and easy place; Away from flame and high temp objects; If then should there be overcover the resting period than long; Tubing answers horizontal stack to be placed on the smooth supporter or on the ground;
Stack and highly be not more than 1.5m; After taking safeguard measure, stack height and can suitably improve, but should be greater than 3m; Pipe fitting should successively stack neatly, guarantees not collapse, and is convenient to take and manage; When tubing is deposited, should be with the tubing classify and pile up of different-diameter and different wall;
Bend pipe should not have greasy dirt with steel tube surface; In steel pipe manufacturing, carrying, cargo handling process, isolate, otherwise should adopt suitable method to remove with low-melting-point metal.
3. method for producing hot-bending elbow according to claim 1 is characterized in that the described inspection of raw and process materials is: the steel pipe raw material should have the steel pipe manufacturer quality certificate that conforms to quality requirements; And after entering factory, the steel pipe raw material inspect for acceptance by lot number, specification, outward appearance and technical data; Quality to the raw-material surface quality of steel pipe, weld seam, heat affected area is inspected check by random samples; The verification mark is transplanted, and realizes the follow-up of quality to material.
4. method for producing hot-bending elbow according to claim 1, it is characterized in that described bend pipe bends is: bend pipe basic parameter as requested, bend pipe are worked out detailed manufacturing process with steel pipe raw material and technical specification book, and content comprises: bend heating-up temperature, fltting speed, heating tape width, cooling velocity.
5. method for producing hot-bending elbow according to claim 1 is characterized in that described first item inspection, self check are: according to the first batch of bend pipe of being worked out of manufacturing process manufacturing, and check in the first batch by the relevant criterion in the pipe bending technique specifications; After first batch of check all items finished and reaches correlation technique and require, procedure qualification finished, and can produce in batches.
6. method for producing hot-bending elbow according to claim 1 is characterized in that described heat treatment is: the design of Technology for Heating Processing should meet the regulation that correlation technique requires, and the every performance indications of the bend pipe after the heat treatment meet the requirements;
Answer the individual layer discharging during bend pipe shove charge, at interval evenly, and should keep at a certain distance away between stove, bend pipe should be heated evenly;
Workpiece should with low-melting-point metal at interval;
Pack into the temperature measurement result of bend pipe of record charging situation, thermocouple; And make the heat treatment that comprises heat treatment cycle curve, heating-up temperature and temperature retention time and hardness examining report and report;
After heat treatment was intact, every bend pipe outer wall must be indicated corresponding heat treatment heat (batch) number, pipe number, bend pipe numbering.
7. method for producing hot-bending elbow according to claim 1 is characterized in that the preceding shaping of described groove is: formulate the check job instruction, carry out the self check of bend pipe manufacture process, the special project check of process quality, the complete examination of finished product;
According to measurement result, utilize hydraulic jack to carry out the pipe end ovality shaping of hot-bending bends, guarantee the pipe end ovality of bend pipe;
Utilize sonigauge that the bend pipe wall thickness is carried out thickness measure, and to defectively scab, cut, skin lamination defect carry out reconditioning, till confirming that with painted or magnetic powder inspection method defective is eliminated fully;
Bend the back and should not heat once more or hot size, but bend pipe is surpassed except the bulk heat treatmet of tubing phase transition temperature bend pipe.
8. method for producing hot-bending elbow according to claim 1, it is characterized in that described groove is: the cross section of bend pipe should be vertical cross-section, when the pipe end groove has regulation, carries out groove by drawing; When the drawing failed call, pipe end should meet the requirement of relevant criterion.
9. method for producing hot-bending elbow according to claim 1 is characterized in that described polishing welding seams is: be not less than inner and outer welding reinforcement in the 100mm scope apart from the pipe end face and answer grinding to remove, and with adjacent tubes surface smooth transition.
10. method for producing hot-bending elbow according to claim 1 is characterized in that described nondestructive inspection is:
In every bend pipe outer arc side, the inner arc side 1500mm scope and weld seam, after tempering heat treatment, adopt manual ultrasonic examination to check crack defect;
Manually ultrasonic examination equipment should be able to be checked the bend pipe whole outer surface uninterruptedly, and the equipment display defect should have enough sensitivity; Should use the contrast standard specimen sensitivity of checkout facility to be calibrated per at least 8 hours beginning and should calibrating once midway; The contrast standard specimen should be taken from the bend pipe test specimen that has identical bending technique, same outer diameter as, radius of curvature, straight length wall thickness with tested bend pipe; Contrast standard specimen upper edge vertical wall thickness direction should be drilled with the perpendicular through hole of 1.6mm diameter or mark the piece surfaces externally and internally along circumferential processing N in contrast
5Cutting is used for calibrator (-ter) unit; If the signal that shortcoming produces produces 100% of echo height more than or equal to contrast standard specimen 1.6mm through hole, then think defective, this defective reconditioning should be carried out according to the specification requirement regulation;
The mend that bend pipe manufacturer is carried out adopts magnetic powder inspection or the inspection of liquid immersion method, and the lamination defect that does not allow virtually any size exists;
Should adopt suitable removing surface before the every bend pipe Non-Destructive Testing, remove the surface scale of bend pipe, and guarantee to have suitable surface.
11. method for producing hot-bending elbow according to claim 1, it is characterized in that described product inspection is: bend pipe mechanical property test and metal lographic examination exemplar adopt bending length to be not less than the bend pipe of 1000mm, flow development length 300/500mm, its raw material, radius of curvature, straight length wall thickness, eddy-current heating bends with curved back tempering heat treatment process should be identical with a collection of bend pipe of representative;
By same batch tube material, same bending technique, no more than 50 of same radius of curvature, same straight length wall thickness bend pipe that same tempering process is produced are a collection of;
The tensile sample of body and weld seam is dimensioned to total wall thickness rectangular specimen sample by Fig. 4 regulation among the API 5L, and tension test is undertaken by the regulation of ASME A370;
The Charpy-type test of each assigned position should be got one group of 3 full size bar; Test block does not allow to cold pressing flat; The sample center line is positioned at exemplar wall thickness center, breach orientation vertical wall thickness surface; Weld seam center and heat affected area Charpy bar gap position are pressed the GB/T229 assigned position and are adopted etching method to determine that breach is orientated perpendicular to exemplar wall thickness surface; The vertical Charpy bar breach of transition region is opened in tube wall vertical section one side, the breach center line by crooked start line or end of a period line perpendicular to sample wall thickness surface; Charpy bar should meet API 5L appendix F figure F-2 regulation, and test should be undertaken by ASTM E23 regulation under-20 ℃ set point of temperature;
The weld seam guided bend test is respectively got the curved and curved sample of the back of the body of a face from assigned position, and the repair welding weld seam that do not have on the sample, sample should meet API 5L Fig. 9 regulation;
Get the cross section sample from bend pipe exemplar assigned position, after polishing and/or etch, carry out Vickers 10kg load Hardness Surveillance by GB/T4340.1 or ISO6507-1 assigned position; All bend pipes of exemplar and production detect in the hardness of assigned position, and the reading that 3～5 equidistant hardness point are got in each position is a mean value;
The metallographic examination grain size of assigned position is according to GB/T4335, the regulation of GB/T6394 or ASME E112 is evaluated, the field trash grade is evaluated according to the regulation of GB/T10561 or ASME E45, the inspection position of weld seam macrostructure and microscopic structure and multiplication factor are according to shown in the specification requirement, and multiplication factor is selected suitable multiplying power by detecting unit; The grain size evaluation is undertaken by technical specification book regulation on the body sample of afore mentioned rules position;
If represent all tests of bend pipe exemplar of a collection of bend pipe all to meet the regulation of technical conditions, then this batch bend pipe is qualified, if represent arbitrary pilot project of exemplar of a collection of bend pipe defective, then allow this batch bend pipe is carried out tempering heat treatment again one time, and again exemplar is carried out above-mentioned inspection; Again tempering heat treatment only allows to carry out once; The steel pipe raw material that the tempering process system can adopt this batch bend pipe to use are simulated the heat treatment test evaluation;
The size of bend pipe, geometry and permissible variation are checked according to the SY5257 prescriptive procedure.
12. method for producing hot-bending elbow according to claim 1 is characterized in that described packing dispatches from the factory to send and is: to the bend pipe that is up to the standards, do sign on request earlier; The mark position is apart from pipe end 150mm place beginning, by order easily or in accordance with regulations, does non-hot and cold word punch die hammering sign at the bend pipe surfaces externally and internally;
Bend pipe is when depositing, loading and unloading and transporting, and the bend pipe groove is used the pipe cap protection;
Carrying should be adopted nylon sling or have copper removal and alloy soft metal drop hanger outward;
Depositing of finished product bend pipe should be able to prevent distortion, destroy and corrosion;
The weld seam of bend pipe should be isolated with any part of spacing block; Any part of weld seam and railcar and truck or trailer is isolated;
The isolation of metal and metal should be arranged between adjacent bend pipe; Bend pipe and fasten between the chain or bend pipe and dividing plate between soft isolation should be arranged.
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| CN200910078172A CN101811154A (en) | 2009-02-19 | 2009-02-19 | Method for producing hot-bending elbow |
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| CN200910078172A CN101811154A (en) | 2009-02-19 | 2009-02-19 | Method for producing hot-bending elbow |
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