WO2016101298A1 - 一种带金属内衬的大口径螺旋焊接钢管及其制作方法 - Google Patents

一种带金属内衬的大口径螺旋焊接钢管及其制作方法 Download PDF

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Publication number
WO2016101298A1
WO2016101298A1 PCT/CN2014/095449 CN2014095449W WO2016101298A1 WO 2016101298 A1 WO2016101298 A1 WO 2016101298A1 CN 2014095449 W CN2014095449 W CN 2014095449W WO 2016101298 A1 WO2016101298 A1 WO 2016101298A1
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WO
WIPO (PCT)
Prior art keywords
wall
inner liner
pipe
steel pipe
liner
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PCT/CN2014/095449
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English (en)
French (fr)
Inventor
战福军
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南京联众建设工程技术有限公司
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Application filed by 南京联众建设工程技术有限公司 filed Critical 南京联众建设工程技术有限公司
Priority to US15/026,138 priority Critical patent/US10145502B2/en
Priority to AU2014405684A priority patent/AU2014405684B2/en
Publication of WO2016101298A1 publication Critical patent/WO2016101298A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/02—Rigid pipes of metal
    • F16L9/04—Reinforced pipes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/16—Rigid pipes wound from sheets or strips, with or without reinforcement
    • F16L9/165—Rigid pipes wound from sheets or strips, with or without reinforcement of metal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
    • F16L57/06—Protection of pipes or objects of similar shape against external or internal damage or wear against wear
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
    • F16L58/02—Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
    • F16L58/04—Coatings characterised by the materials used
    • F16L58/08—Coatings characterised by the materials used by metal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/02—Rigid pipes of metal
    • F16L9/04—Reinforced pipes
    • F16L9/047—Reinforced pipes comprising reinforcement rings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/14—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups
    • F16L9/153—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups comprising only layers of metal and concrete with or without reinforcement
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation

Definitions

  • the invention relates to a steel pipe and a manufacturing method thereof, in particular to a large diameter spiral welded steel pipe with a metal inner liner and a manufacturing method thereof.
  • fluids are generally transported by pipes.
  • Commonly used pipes are cement pipes, plastic pipes, ordinary carbon steel pipes, stainless steel pipes and galvanized steel pipes.
  • the cement pipe is a kind of prefabricated pipe which is made of cement and steel bar and is manufactured by the principle of centrifugal force.
  • the overall cost of the project is low, but it is easy to leak, and the internal pressure resistance is poor. It can not be used as a water supply pipe, and can only be used as a drain pipe.
  • the caliber can not be too large, generally 3 meters or less, each tube can not be too long, there are many joints, construction is difficult, the foundation is required during construction, and the construction cost is high.
  • the plastic tube is made of plastic resin as raw material, adding stabilizer and other additives, and is extruded in the tube making machine. It is light in weight and convenient in processing, but the caliber is not too large, the mechanical strength is low, the anti-destructive performance is poor, and it is intolerant. Wear, not resistant to high temperatures, easy to age.
  • the ordinary carbon steel pipe is a steel pipe made of carbon steel, the inner wall is not wear-resistant, the caliber cannot be made too large, and the pipe wall is thickened at a large diameter, and the cost is high. Stainless steel tubes are too costly.
  • the diameter of galvanized steel pipe can not be too large, and galvanizing is a polluting industry, which has great damage to the environment, and the galvanized layer is thin, generally less than 0.1mm in thickness and easily damaged. Therefore, in view of the above-mentioned shortage of pipelines, it is urgent to develop a new type of pipe body which can solve the above problems.
  • a first object of the present invention is to provide a metal-lined spiral welded steel pipe which has improved corrosion resistance and wear resistance, a large caliber, and a thin wall; a second object of the present invention is to provide a steel pipe manufacturing method .
  • the steel pipe according to the present invention comprises a pipe body spirally wound from a main steel strip; the inner wall of the pipe body is provided with a first inner liner and a second inner liner, and the first inner liner is spirally attached to the main body.
  • the second inner spiral is spirally fitted to the spiral joint formed between the adjacent tubular bodies, and the left and right sides of the second inner liner
  • the side is respectively welded to the adjacent first inner liner, the first inner liner and the second inner liner cover the inner wall of the whole tube;
  • a reinforcing ring having a semi-closed cross section is spirally arranged along the outer wall of the outer tube, the inner wall of the reinforcing ring and the tubular body
  • a spiral passage is formed between the outer walls.
  • first inner liner or the second inner liner is welded to the main steel strip.
  • the first inner liner or the second inner liner is provided with air holes for evacuating the gas between the main steel strip and the first inner liner or the second inner liner.
  • the passage between the inner wall of the reinforcing ring and the outer wall of the tube is filled with a preservative liquid.
  • the first lining or the second lining is a lining steel made of special alloy steel, stainless steel, wear-resistant steel, aluminum or copper.
  • the manufacturing method of the steel pipe of the present invention comprises the following steps:
  • a reinforcing ring steel strip having a semi-closed cross section is attached to the lower surface of the main steel strip, and the first inner lining steel strip is attached to the upper surface of the main steel strip, wherein the width of the first inner lining steel strip is smaller than that of the main steel strip Width to form a composite main steel strip;
  • the composite main steel strip is spirally wound to form a spiral welded steel pipe with a first inner liner and an outer wall with a reinforcing ring on the inner wall, and a spiral passage is formed between the inner wall of the reinforcing ring and the outer wall of the steel pipe;
  • a second inner liner is spirally fitted at a spiral joint formed between adjacent pipe bodies, and the first inner liner and the adjacent inner and outer sides of the second inner liner are respectively welded and welded, the first inner liner and the first inner liner
  • the second inner liner covers the inner wall of the entire spiral welded steel pipe.
  • the interlayer gap formed between the main steel strip at both ends and the first inner liner or the second inner liner is sealed to ensure sealing between the main steel strip and the inner liner. space.
  • the first inner liner or the second inner liner is provided with air holes for evacuating the gas between the main steel strip and the first inner liner or the second inner liner.
  • the pores may be evacuated or filled with an inert gas.
  • the passage between the inner wall of the reinforcing ring and the outer wall of the tube is filled with a preservative liquid.
  • the spiral welded steel pipe is completed, it is cut into segments, and the welding groove between the adjacent two steel pipes is Y-shaped.
  • the welding between the main steel strips is performed by submerged arc welding.
  • the welding between the second inner liner and the first inner liner, or the welding between the main steel strip and the first inner liner or the second inner liner is gas shielded welding.
  • the inner wall of the steel pipe of the invention is provided with a metal lining, which can improve the corrosion resistance and wear resistance of the steel pipe and avoid fluid pollution; at the same time, the thickness of the main steel strip steel is thinned, thereby reducing the material cost; the second inner lining covers the steel pipe itself.
  • the formed spiral weld reduces the impact of the internal fluid on the weld and protects the weld; the second liner has a narrow width, which ensures a high weld density between the inner liner and the main steel pipe wall.
  • the outer wall of the steel pipe of the invention has a semi-closed reinforcing ring, and the circumferential moment of the pipe wall has a much higher inertia moment than the general reinforcement mode, and the bearing capacity is improved, and the wall thickness of the main steel strip is greatly reduced compared with the wall thickness of the general steel pipe, and is reduced.
  • the present invention can seal the both ends of the steel pipe cut into segments, and eliminate the gap between the inner liner and the end of the main steel pipe.
  • the present invention can provide a gas hole or a gas nozzle on the inner liner of each end of each tube, and vacuum or fill an inert gas to prevent corrosion of the pipe wall.
  • the present invention can fill the reinforcing ring with a preservative liquid and improve the anticorrosive performance of the reinforcing ring.
  • a steel pipe having an extra large diameter can be produced by the method of the present invention.
  • the steel pipe of the present invention can be used for conveying a special medium such as a corrosive medium, a medium requiring high purity, a high temperature medium, and the like.
  • the reinforcing ring When the steel pipe of the present invention is used as a buried pipe, the force sharing effect of the pipe and the soil is utilized, and the reinforcing ring is mainly subjected to the pressure.
  • the diameter is too large (D>4m), it can be buried deep to a depth of more than 10 meters.
  • the reinforcing ring can be filled with high-performance concrete, and the section moment of inertia of the pipe wall can be increased, so that the reinforcing ring becomes a concrete steel pipe, which improves the pressure resistance and reduces the wall thickness.
  • Figure 1 is a schematic view showing the position of the main steel strip and the reinforcing ring steel strip and the inner lining steel strip;
  • FIG. 2 is a schematic structural view of a reinforcing ring steel strip which is formed by reinforcing a ring steel strip into a semi-closed shape;
  • FIG. 3 is a structural schematic view of the reinforcing ring steel strip and the inner lining steel strip respectively attached to the main steel strip;
  • Figure 4 is a schematic view showing the three-dimensional structure of the composite main steel strip
  • Figure 5 is a schematic view showing the structure of a composite main steel strip for forming a steel tube by three rolls;
  • Figure 6 is a schematic view showing the structure of the front and rear joints of adjacent tubular bodies
  • Figure 7 is a schematic view showing the laying of the second inner liner steel strip
  • Figure 8 is a schematic view showing the structure of the first inner liner steel strip and the second inner liner steel strip covering the inner wall of the steel pipe;
  • Figure 9 is a cross-sectional view of a steel pipe of the present invention.
  • Figure 10 is a longitudinal sectional view of a steel pipe of the present invention.
  • Figure 11 is a partial enlarged view of point A in Figure 10;
  • Figure 12 is a schematic view showing the welded structure of the end portion of the steel pipe section and the section of the present invention.
  • the metal-lined large-diameter spiral welded steel pipe (hereinafter referred to as "steel pipe") according to the present invention, the outer wall of the pipe body 101 of the steel pipe is provided with a reinforcing structure (in the present invention, the reinforcing ring 400), which is processed by a plurality of ordinary steel strips. It is uniformly wound and welded on the outer wall of the pipe in a spiral manner to increase the circumferential moment of the pipe wall and reduce the thickness of the pipe wall to facilitate subsequent rounding.
  • the inner wall of the steel pipe is provided with a metal inner lining, and the inner lining includes a first inner lining 200 and a second inner lining 300.
  • Both inner linings are covered on the inner wall of the steel pipe to form a lining pipe body welded to the inner wall of the steel pipe, which can improve the steel pipe. Corrosion resistance and wear resistance, avoiding contamination of the fluid passing through the steel pipe, and also reducing the wall thickness of the steel pipe.
  • the inner lining can be made of a special material, and the main body of the steel pipe is made of a general material, so that the overall performance of the steel pipe is improved. It can also reduce costs and increase the market competitiveness of steel pipes.
  • both ends of each steel pipe should be sealed and welded, and the gap between the inner lining of the welded steel pipe and the pipe body provides a closed space to isolate the outside air from the air in the gap.
  • air holes and/or air nozzles may be provided on the inner liners at both ends of the steel pipe for evacuating the gap between the inner liner and the pipe wall or filling the inert gas, and finally sealing the air holes. It is also possible to infuse the reinforcing ring with an anticorrosive material, such as an anticorrosive paint.
  • the forming angle of the screw forming machine is adjusted to an appropriate value according to the diameter of the produced steel pipe.
  • the main steel strip 100, the reinforcing ring steel strip 401, the first inner liner steel strip 201, and the second inner liner steel strip 301 are prepared.
  • the main steel strip 100 is subjected to rust removal and shot peening, and the reinforcing ring steel strip 401 and the first inner lining steel strip 201 (the number is set according to actual conditions) are subjected to unwinding, leveling, trimming, etc., according to FIG. Arranged in the position shown.
  • three reinforcing ring steel strips 401 are arranged under each main steel strip 100, two first inner lining steel strips 201 are arranged above, and the distance between the two first inner lining steel strips 201 is 1 -2mm.
  • the reinforcing ring steel strip 401 is bent into a semi-closed reinforcing ring 400 through a bending mechanism.
  • the reinforcing ring 400 is semi-circular in cross section, of course, according to actual needs. It is processed into other shapes such as trapezoidal, parabolic, and the like.
  • the reinforcing ring 400 is moved up and attached to the main steel strip 100, specifically, the two ports of the reinforcing ring 400 are welded to the contact portions of the lower surface of the main steel strip 100.
  • the first inner liner steel strip 201 is moved down, and is attached to the upper surface of the main steel strip 100.
  • the two first inner liner steel strips 201 are welded to the main steel strip 100 by gas shield welding, wherein A first weld bead 202 is formed between the two inner liner steel strips 201.
  • the composite main steel strip 103 is thus obtained as shown in FIG.
  • the composite main steel strip 103 is fed into a three-roll reel mechanism (see Fig. 7, including a 1# press roll, a 2# press roll, and a 3# press roll) for winding, as shown in Fig. 5. Since the outer wall is provided with a semi-closed reinforcing ring, the moment of inertia of the main steel strip is greatly improved, and the thin plate can be delivered when the round is rounded. In the case of rounding, the main steel strip forms a section of the pipe body, and the spiral joint 102 formed between the adjacent pipe bodies (the joint formed by the main steel strip itself) is welded, as shown in Figs. Wherein, the position of the 1# pressure roller is a solder joint.
  • the backing is about 200-300 mm (the roller position at the upper left of FIG. 7), and the second inner liner steel strip 301 is laid over the spiral joint 102 to reduce the inside of the pipe.
  • the impact of the fluid on the joint protects the seam.
  • the second inner liner steel strip 301 is welded to its adjacent first inner liner steel strip 201 to form a second weld seam 302, as shown in FIGS. 7 and 8, that is, the second inner liner steel strip 301 and the first The inner liner 201 and the main steel strip 100 are welded in a three-in-one manner.
  • the inner wall of the entire steel pipe is completely covered by a plurality of spiral linings (the first inner liner 200 and the second inner liner 300), and the inner liner is firmly welded to the inner wall of the pipe to obtain a lined steel pipe. .
  • the inner lining strip should have some properties different from ordinary carbon steel, such as anti-corrosion and wear resistance, high temperature resistance, etc.
  • the material types include but are not limited to the following: special alloy steel, stainless steel, wear-resistant steel, aluminum , copper, etc.
  • the width of the first inner liner and the second inner liner are generally different, and the wider first inner liner (the width of which is narrower than the main steel strip) is applied to the upper surface of the main steel strip, and the second inner liner is slightly narrower. At the spiral seam 102 on the inner wall, the second inner liner is narrower to ensure a higher weld density of the inner liner and the inner wall of the pipe.
  • the steel pipe when the steel pipe reaches the required length, it is cut, and the interlayer gap 106 formed between the main steel strip 100 at both ends of the steel pipe and the first inner liner 200 or the second inner liner 300 is sealed.
  • the interlayer gap 106 formed between the main steel strip 100 at both ends of the steel pipe and the first inner liner 200 or the second inner liner 300 is sealed.
  • the depth of the air hole 500 should only penetrate the inner liner without touching the main steel strip, and the air nozzle 501 can be welded to the air hole 500 (if needed) to facilitate connection of the gas device.
  • At least one air hole may be provided for each lining at the pipe end, and if there are four linings, at least four air holes may be provided at each end.
  • the gas is used to discharge the gas between the main steel strip and the inner liner to prevent corrosion of the tube body, and the process is used to detect the quality of the weld seam, and then the air hole 500 and the gas nozzle 501 are sealed.
  • the reinforcing ring slit 402 is filled with the antiseptic liquid, and when the formed liquid injection (which can be larger than the circumference of the 1/3 reinforcing ring) is flush with the filling opening
  • the pipe body 101 is started to rotate, and finally the remaining anti-corrosion liquid flows out from the other end of the steel pipe, so that the inner wall of the reinforcing ring of the whole steel pipe and the outer wall of the steel pipe are covered by the anti-corrosion liquid, which can improve the anti-corrosion performance of the inner wall of the reinforcing ring.
  • the high-strength concrete 600 can be filled into the reinforcing ring, so that the reinforcing ring becomes a concrete steel pipe, the pressure resistance is improved, and the wall thickness of the main steel pipe is reduced.
  • the welding method of different parts of the steel pipe of the invention is different.
  • the welded part should be processed into a Y-shaped groove, and the welding between the main steel strips is performed by submerged arc welding 104, the inner lining and the inner lining and The welding between the main steel strips is performed by gas shielded welding 105.
  • a semi-closed hollow reinforcing ring is arranged on the outer wall of the spiral welded steel pipe.
  • the circumferential moment of inertia of the pipe wall can be increased.
  • the wall thickness of the main steel strip is greatly reduced compared with the wall thickness of the general steel pipe, which not only reduces the material cost. And can produce large diameter and large diameter steel pipe;
  • the reinforcement ring is set, the steel strip is cross-sectioned. The area and moment of inertia are greatly increased, and the delivery is easy to achieve when winding, which is easy to process.
  • the inner wall of the steel pipe is provided with an inner lining to avoid or reduce the corrosion of the steel pipe to the corrosion and wear of the steel pipe and the pollution of the pipe body.
  • the thickness of the main steel strip steel can be reduced, the material cost is further reduced, and the steel pipe anticorrosion is improved. Wear resistance.
  • the end of the steel pipe is sealed to provide a closed space for evacuating or filling the inert gas. By arranging the air holes on the first or second inner lining, the air in the closed space can be effectively discharged, the internal clearance of the steel pipe can be prevented from being rusted, and the welding quality can also be detected.
  • the corrosion resistance of the inner wall of the reinforcing ring can be improved by injecting the anticorrosive material into the reinforcing ring.
  • the steel pipe of the invention has the following uses: water supply pipe or drainage pipe; conveying sand and dust; urban sewage and industrial sewage; chemical fluid; underground water collecting pipe; high temperature medium; sea water pipeline.

Abstract

一种带金属内衬的大口径螺旋焊接钢管，包括由主钢带（100）螺旋卷制而成的管体（101）；管体内壁设有第一内衬（200）和第二内衬（300），第一内衬螺旋贴合于主钢带的表面，并且第一内衬的宽度小于主钢带的宽度，第二内衬螺旋贴合于相邻管体间形成的螺旋形接缝（102）处，并且第二内衬的左右两侧分别与其相邻的第一内衬焊接，第一内衬和第二内衬覆盖整个管体内壁；沿管体外壁螺旋设有截面为半闭合状的加强环（400），该加强环内壁与管体外壁之间形成螺旋状的通道。还公开了一种带金属内衬的大口径螺旋焊接钢管的制作方法。钢管内壁设置的金属内衬可提高钢管的防腐性和耐磨性，避免流体污染；钢管外壁设置的加强环可提高管壁周向断面惯性矩，主钢带的壁厚比一般钢管壁厚减薄，降低成本。

Description

一种带金属内衬的大口径螺旋焊接钢管及其制作方法 技术领域
本发明涉及一种钢管及其制作方法，尤其涉及一种带金属内衬的大口径螺旋焊接钢管及其制作方法。
背景技术
目前，一般用管道输送流体，常用的管道有水泥管、塑料管、普通碳钢钢管、不锈钢管和镀锌钢管等。其中，水泥管是用水泥与钢筋为材料，运用离心力原理制造的一种预制管道，其工程总体造价低，但易泄漏，耐内压能力差，不能用做供水管，只能用做排水管，同时口径不能太大，一般3米或3米以下，每节管不能太长，接头多，施工困难，施工时要做基础，施工成本高。塑料管是以塑料树脂为原料，加入稳定剂及其它添加剂，在制管机内经挤压加工而成，质量轻，加工方便，但是口径不能太大，机械强度低，抗破坏性能差，不耐磨损，不耐高温，易老化。普通碳钢钢管是用碳素钢制成的钢管，内壁不耐磨蚀，口径不能做的太大，大口径时管壁增厚，成本高。不锈钢管则成本太高。镀锌钢管口径不能太大，且镀锌是污染行业，对环境破坏大，而且镀锌层较薄，一般厚度小于0.1mm，易损坏。因此，针对上述管道的不足，亟待研制出一种能解决以上问题的新型管体。
发明内容
发明目的：本发明的第一目的是提供一种提高防腐性和耐磨性、口径大、管壁薄的带金属内衬的螺旋焊接钢管；本发明的第二目的是提供该钢管的制作方法。
技术方案：本发明所述的钢管，包括由主钢带螺旋卷制而成的管体；管体内壁设有第一内衬和第二内衬，所述第一内衬螺旋贴合于主钢带的表面，并且第一内衬的宽度小于主钢带的宽度，所述第二内衬螺旋贴合于相邻管体间形成的螺旋形接缝处，并且第二内衬的左右两侧分别与其相邻的第一内衬焊接，第一内衬和第二内衬覆盖整个管体内壁；沿管体外壁螺旋设有截面为半闭合状的加强环，该加强环内壁与管体外壁之间形成螺旋状的通道。
其中，所述第一内衬或第二内衬与主钢带焊接。
所述第一内衬或第二内衬上设有用于排空所述主钢带与第一内衬或第二内衬之间气体的气孔。
所述加强环内壁与管体外壁之间的通道内填充防腐液体。
所述第一内衬或第二内衬为特种合金钢、不锈钢、耐磨钢、铝或铜制成的内衬钢材。
本发明所述钢管的制作方法，包括如下步骤：
在主钢带下表面贴合截面为半闭合状的加强环钢带，在主钢带上表面贴合第一内衬钢带，其中，该第一内衬钢带的宽度小于主钢带的宽度，从而形成复合型主钢带；
将复合型主钢带螺旋卷绕形成内壁带第一内衬、外壁带加强环的螺旋焊接钢管，同时，加强环内壁与钢管的管体外壁之间形成螺旋状的通道；
在相邻管体之间形成的螺旋形接缝处螺旋贴合第二内衬，并且该第二内衬的左右两侧分别与其相邻的第一内衬及焊接，第一内衬和第二内衬覆盖整个螺旋焊接钢管的内壁。
其中，所述螺旋焊接钢管制作完成后，对其两端的主钢带与第一内衬或第二内衬之间形成的层间缝隙进行封焊，保证主钢带与内衬之间形成密闭空间。
所述第一内衬或第二内衬上设有用于排空所述主钢带与第一内衬或第二内衬之间气体的气孔。可以向该气孔向内抽真空或填充惰性气体。
向所述加强环内壁与管体外壁之间的通道内填充防腐液体。
进一步地，螺旋焊接钢管制作完成后切割成段，相邻两段钢管之间的焊接坡口为Y型。复合型主钢带螺旋卷绕形成钢管时，主钢带间的焊接采用埋弧焊。第二内衬与第一内衬之间的焊接方式，或主钢带与第一内衬或第二内衬之间的焊接方式为气体保护焊。
有益效果：本发明与现有技术相比，其显著优点为：
(1)本发明钢管内壁设金属内衬，可以提高钢管的防腐性和耐磨性，避免流体污染；同时，主钢带钢材的厚度减薄，降低了材料成本；第二内衬覆盖钢管自身形成的螺旋形焊缝，减少了内部流体对焊缝的冲击力，保护焊缝；第二内衬宽度较窄，可以保证内衬与主钢管管壁的焊缝密度较大。
(2)本发明钢管外壁带半闭合状的加强环，管壁周向断面惯性矩比一般的加强方式提高很多，承载能力提高，主钢带的壁厚比一般钢管壁厚大大减薄，降低了材料成本；同时，主钢带截面惯性矩大大提高，卷圆时可实现薄板递送。
(3)本发明可以对切割成段的钢管两端部进行封焊，消除内衬管与主钢管端部之间的间隙。
(4)本发明可以在每段管两端的内衬上设置气孔或气嘴，抽真空或填充惰性气体，以防止管壁锈蚀。
(5)本发明可以向加强环内填充防腐液体，提高加强环的防腐性能。
(6)利用本发明方法可以制作出超大口径的钢管。
(7)本发明的钢管可用于输送特殊介质，例如腐蚀性介质、对纯净度要求较高的介质、高温介质等。
(8)本发明钢管用作埋地管时，利用管土共用受力效应，由加强环为主承受压力， 超大直径时(D>4m)，可以埋土很深达到10米以上深度。同时，可向加强环内充填高性能混凝土，增加管壁的断面惯性矩，使加强环成为混凝土钢管，提高抗压能力，减少管壁厚度。
附图说明
图1为主钢带与加强环钢带及内衬钢带的摆放位置示意图；
图2为加强环钢带压制成截面为半闭合形的加强环钢带的结构示意图；
图3为加强环钢带、内衬钢带分别与主钢带贴合后的结构示意图；
图4为复合型主钢带的三维结构示意图；
图5为复合型主钢带进行三辊卷圆形成钢管的结构示意图；
图6为相邻管体前后节对接的结构示意图；
图7为第二内衬钢带铺贴示意图；
图8为第一内衬钢带和第二内衬钢带全部覆盖钢管内壁的结构示意图；
图9为本发明钢管的横截面图；
图10为本发明钢管的纵向剖视图；
图11为图10中A点的局部放大图；
图12为本发明钢管段与段间端部焊接结构示意图。
具体实施方式：
下面结合附图对本发明的技术方案作进一步说明。
本发明所述的带金属内衬的大口径螺旋焊接钢管(以下简称“钢管”)，钢管的管体101外壁设加强结构(本发明中为加强环400)，其由多条普通钢带加工而成，以螺旋方式均匀缠绕并焊接在管体外壁上，用以提高管壁周向断面惯性矩，减薄管壁厚度，利于后续卷圆。钢管内壁设金属材质的内衬，内衬包括第一内衬200和第二内衬300，两种内衬全部覆盖在钢管内壁上，形成了与钢管内壁焊接的内衬管体，可提高钢管的耐腐蚀性和耐磨性，避免通过钢管的流体受到污染，同时还能减薄钢管壁厚，另外，内衬可采用特殊材质，而钢管主体采用一般性材质，如此不仅提高钢管整体性能，还能降低成本，提高钢管的市场竞争力。为了进一步提高钢管的使用寿命，每一段钢管的两端都应该进行封焊，封焊钢管两端内衬与管体之间的间隙，提供一个封闭的空间，隔离外部空气与间隙内空气。另外，可以在钢管两端的内衬上设置气孔和/或气嘴，用于将内衬与管壁之间的间隙抽真空或填充惰性气体，最后封焊气孔。还可以向加强环内灌注防腐材料，如防腐漆。
下面介绍钢管的制作过程：
首先，根据所制作钢管的直径，将螺旋整型机的成型角调节为合适值。
接着，准备主钢带100、加强环钢带401、第一内衬钢带201和第二内衬钢带301。对主钢带100进行除锈、喷丸处理，加强环钢带401和第一内衬钢带201(数量按实际情况设定)经过放卷、矫平、修边等工序后，按图1所示位置排列。本次制管过程中，每一条主钢带100下方均布三条加强环钢带401，上方排列两条第一内衬钢带201，两条第一内衬钢带201之间的距离为1-2mm。
如图2所示，加强环钢带401经过弯曲机构，弯曲成断面为半闭合状的加强环400，本次制管过程中，加强环400截面压制为半圆形，当然，可根据实际需要将其加工成其它形状，例如梯形，抛物线形等。
如图3所示，将加强环400上移，与主钢带100贴合，具体是将加强环400的两端口与主钢带100下表面的接触部位焊接。同时，将第一内衬钢带201下移，与主钢带100的上表面贴合，具体是利用气体保护焊将两条第一内衬钢带201与主钢带100进行三位一体焊接，其中，两条内衬钢带201之间形成第一焊缝202。如此得到了复合型主钢带103，如图4所示。
将复合型主钢带103送入三辊卷圆机构(参见图7，包括1#压辊、2#压辊和3#压辊)进行卷圆，如图5所示。由于外壁设有半闭合状的加强环，主钢带截面惯性矩大大提高，卷圆时可实现薄板递送。在卷圆时，主钢带形成一节一节的管体，对相邻管体之间形成的螺旋形接缝102(主钢带自身形成的接缝)进行焊接，如图6、7所示，其中，1#压辊的位置为焊点。紧接着，以1#压辊为起点，后退约200-300mm(图7左上方的辊子位置)，将第二内衬钢带301铺贴覆盖在该螺旋形接缝102处，可减少管道内部流体对该接缝的冲击力，保护接缝。同时第二内衬钢带301与其相邻的第一内衬钢带201焊接以形成第二焊缝302，如图7、8所示，也就是说，第二内衬钢带301与第一内衬201以及主钢带100进行三位一体焊接。如此使整个钢管管体内壁被多条螺旋状的内衬(第一内衬200和第二内衬300)完全覆盖，并且内衬牢牢焊接在管体内壁上，得到了带内衬的钢管。
内衬带材应具有某种有异于普通碳钢钢材的性能，如防腐耐磨、耐高温等等性能，材料品种包括但不限于如下几种：特种合金钢、不锈钢、耐磨钢、铝、铜等。第一内衬与第二内衬的宽度一般不同，较宽的第一内衬(其宽度窄于主钢带)用于铺贴在主钢带上表面，略窄的第二内衬铺贴于内壁上的螺旋形接缝102处，第二内衬较窄，可以保证内衬与管体内壁的焊缝密度较大。
如图9、10所示，当钢管达到要求长度后，将其切断，对钢管两端主钢带100与第一内衬200或第二内衬300之间形成的层间缝隙106进行封焊，保证主钢带与内衬带材之间形成密闭的空间，便于后续处理，例如充、排气体。在管体101内壁内衬的侧面或 顶部开气孔500，该气孔500的深度应只穿透内衬，而不触及主钢带，在气孔500上可以焊上气嘴501(如果需要)，便于连接气体装置。在管端的每条内衬可至少设一个气孔，如果有4条内衬，每端可以设至少4个气孔。利用气孔可以排出主钢带与内衬之间的气体，防止管体锈蚀，同时利用这一过程检测焊缝质量，然后将气孔500和气嘴501封焊。
在切割成段的钢管端部所形成的加强环切口402处，向该加强环切口402内灌注防腐液体，当形成的液注(可以大于1/3加强环的周长)与灌注口齐平时，开始旋转管体101，最终剩余的防腐液体从钢管另一端切口流出，如此整个钢管的加强环内壁与钢管外壁之间被防腐液体所覆盖，可以提高加强环内壁的防腐性能。当管道埋地时，可向加强环内充填高性能混凝土600，使加强环成为混凝土钢管，提高抗压能力，减少主钢管管壁厚度。
本发明钢管不同部位的焊接方法不同，例如当钢管段与段之间连接时，焊接部分应加工成Y型坡口，主钢带间的焊接采用埋弧焊104，内衬间以及内衬与主钢带之间的焊接采用气体保护焊105。
发明原理：首先，螺旋焊接钢管外壁设置半闭合状空心的加强环，第一、可以增加管壁周向惯性矩，主钢带的壁厚比一般钢管壁厚大大减薄，不仅降低了材料成本，而且能制造出大口径及超大口径的钢管；第二、当主钢带钢材较薄时，卷圆过程中，递送力会使钢带曲饶，无法递送，设置加强环后，钢带横截面积及惯性矩大增，卷圆时递送很容易实现，便于加工。其次，钢管内壁设有内衬，是为了避免或减少流体对钢管的锈蚀、磨损及管体对流体的污染，同时还可以减薄主钢带钢材的厚度，进一步降低材料成本，提高了钢管防腐耐磨性能。此外，对钢管端部进行封焊，是为抽真空或填充惰性气体提供封闭的空间。通过在第一或第二内衬上安设气孔，可以有效排出封闭空间内的空气，防止钢管内部间隙锈蚀，也可检测焊接质量。通过向加强环内灌注防腐材料，可以提高加强环内壁的防腐性能。
本发明的钢管具有以下用途：供水管或排水管；输送砂石、粉尘；城市污水和工业污水；化工流体；地下集水管；高温介质；海水管道等。

Claims (10)

  1. 一种带金属内衬的大口径螺旋焊接钢管，其特征在于：包括由主钢带(100)螺旋卷制而成的管体(101)；管体内壁设有第一内衬(200)和第二内衬(300)，所述第一内衬(200)螺旋贴合于主钢带(100)的表面，并且第一内衬(200)的宽度小于主钢带(100)的宽度，所述第二内衬(300)螺旋贴合于相邻管体(101)间形成的螺旋形接缝(102)处，并且第二内衬(300)的左右两侧分别与其相邻的第一内衬(200)焊接，第一内衬(200)和第二内衬(300)覆盖整个管体内壁；沿管体外壁螺旋绕设截面为半闭合状的加强环(400)，该加强环内壁与管体外壁之间形成螺旋状的通道。
  2. 根据权利要求1所述带金属内衬的大口径螺旋焊接钢管，其特征在于：所述第一内衬(200)或第二内衬(300)上设有用于排空所述主钢带(100)与第一内衬(200)或第二内衬(300)之间气体的气孔(500)。
  3. 根据权利要求1或2所述带金属内衬的大口径螺旋焊接钢管，其特征在于：所述加强环内壁与管体外壁之间的通道内填充防腐液体。
  4. 根据权利要求1或2所述带金属内衬的大口径螺旋焊接钢管，其特征在于：所述第一内衬(200)或第二内衬(300)为特种合金钢、不锈钢、耐磨钢、铝或铜制成的内衬钢材。
  5. 根据权利要求1所述带金属内衬的大口径螺旋焊接钢管的制作方法，其特征在于包括如下步骤：
    在主钢带(100)下表面贴合截面为半闭合状的加强环钢带(401)，在主钢带(100)上表面贴合第一内衬钢带(201)，其中，该第一内衬钢带(201)的宽度小于主钢带的宽度，从而形成复合型主钢带(103)；
    将复合型主钢带(103)螺旋卷绕形成内壁带第一内衬(200)、外壁带加强环(400)的螺旋焊接钢管，加强环内壁与钢管的管体(101)外壁之间形成螺旋状的通道；
    在管体(101)内壁上，相邻管体(101)之间形成的螺旋形接缝(102)处螺旋贴合第二内衬(300)，并且该第二内衬(300)的左右两侧分别与其相邻的第一内衬(200)焊接，第一内衬(200)和第二内衬(300)覆盖整个螺旋焊接钢管的内壁。
  6. 根据权利要求5所述带金属内衬的大口径螺旋焊接钢管的制作方法，其特征在于：所述螺旋焊接钢管制作完成后，对其两端的主钢带与第一内衬或第二内衬之间形成的层间缝隙(106)进行封焊。
  7. 根据权利要求6所述带金属内衬的大口径螺旋焊接钢管的制作方法，其特征在于：所述第一内衬(200)或第二内衬(300)上设有用于排空所述主钢带(100)与第一内衬(200)或第二内衬(300)之间气体的气孔(500)。
  8. 根据权利要求7所述所述带金属内衬的大口径螺旋焊接钢管的制作方法，其特 征在于：向所述气孔(500)向内抽真空或填充惰性气体。
  9. 根据权利要求5-8任一所述带金属内衬的大口径螺旋焊接钢管的制作方法，其特征在于：向所述加强环内壁与管体外壁之间的通道内填充防腐液体。
  10. 根据权利要求5-8任一所述带金属内衬的大口径螺旋焊接钢管的制作方法，其特征在于：所述螺旋焊接钢管制作完成后切割成段，相邻两段钢管之间的焊接坡口为Y型。
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