钢管设备工艺中英文对照 - 图文

直缝钢管生产装备与工艺介绍

中英文对照

1.直缝管生产主要装备技术简介

ERW生产线全线采用PLC自动控制。

开卷机：双锥自动开卷，采用光电对中控制系统，可开卷重20吨；

接板机：自动剪切对焊，前后钢卷头尾对接埋弧自动焊； 储料坑：采用光电检测系统；

成型机：采用目前比较先进的排辊成型方式，接近自然成型，这种成型原理是：当带钢初成型后进入排辊成型，通过大量小直径被动排辊使钢带逐渐形成圆形，这种“自然成型方法”有以下优点：

⑴实际成型过程中，带钢边部纵向平整、无波浪、无皱 折；

⑵在圆周上得到精确的几何形状；

⑶三架精成型采用四辊万能机架，便于调整，可得到理想的几何形状；

高频发生器：600KW高频发生器由一个PLC控制，具有焊接温度显示自动控制系统，防止火花短路系统，报警系统，即适用于感应焊，也适用于接触焊。震荡电路有自己的柜体，该柜体积小，便于靠近焊管生产线，使高频发生器输出和感应圈之间的功率损失最小，整机输出功率高；

挤压焊接装置：由四辊挤压和焊接顶辊完成，可方便调整挤压力和V型开口角，既能保证适当的挤压力，又能得到一个稳定的烧化和熔解的过程；

内毛刺去除装置:由液压控制，稳定可靠，内毛刺剩余高度控制在合同规定的范围；

热处理装置：焊缝中频常化热处理机三台（1500KW、美国），加热宽度30mm，加热效率高，保证加热深度渗透全壁

1

厚；同时具有消除焊接残余应力作用；

定径矫直机：采用四辊万能机架，经减径整圆，达到理想的外径公差、圆度及直度，兼有降低焊缝残余应力作用；

飞切定尺机：采用微机控制的液压加力旋切式（四把园盘切刀）切断方式，无噪音、无铁屑消耗，对焊缝无损伤，定尺精度±3mm；

平头倒坡口机：采用先进的液压仿型装置，微机自动控制升降台架、传输、平头、倒坡口。管端可加工为用户要求的形状，便于用户管端对口接焊。

2.直缝管生产工艺 2.1工艺简述

准备段：主要包括备卷、开卷、直头整平、剪切对焊、 递料、储料、拉出整平、对中、板材电磁超声波探伤等工序。 制管段：予成型、排辊成型、精成型、五辊挤压高频焊接、去除内外毛刺、在线超声波探伤、焊缝热处理、定径、矫直飞切定尺。

精整段：平头倒坡口、水压试验、手动超声波复检、最终检验、标识、包装。

2.2 工艺流程图

Steel Pipe Manufacturing Equipments

and Technology Process

1. Line Pipe Main Manufacturing Equipment Technology

(ERW) production line adopt PLC automatic control completely.

Uncoiler: Double-cone uncoiler, adopting light and electricity center control system, can uncoil 20MT

2

weight.

Coil butting-welding machine: welding of coil in automatic shears, the former end and the later head is butting- welding by submerged arc welding.

Store material spot: adopting light and electrical inspection system.

Forming machine: adopting the relatively advanced standing forming way of roller at present. It’s close to natural forming. This kind of forming principle is: After skelp pre-formed and enter standing-roller form, arrange roller make skelp form in the round gradually passively through little diameters. There are following merits in this kind of “natural forming method”

⑴ In actual forming process ,the transverse edges of coil are smooth without wave ,wrinkly .

⑵ In circumference to get the accurate geometry. ⑶There fine-forming adopt four rollers of omnipotence stand. easy to adjust, can get the ideal geometry form .

600KW high frequency generator is controlled by one PLC .There is temperature of welding that shows the

3

automatic control system .It prevents flash short circuit system ,warning system suitable for reaction weld and keeping in touch welding too .Oscillating circuit have own cupboard body with little volume .It’s easy close to welding production line .Making the high frequency generator export the power while enclosing with reaction to lose the minimum .The out put power of the complete machine is high .

Extruded welding equipments:

It’s finished by four rollers and extruded welding, very convenient to adjust extrusion strength and V type opening’s corner ,can guarantee proper extrusion strength ,also get the course of a steady burning and fusion .

The removal equipments of internal flash: The equipment is controlled by the hydraulic pressure , It’s reliable to be steady .Interior burr reinforcement shall be controlled within the range stipulated in the contract .

Heat treatment equipments:

Three welding seam mid-frequency normalized heat treatment (1500KW, USA). Heating width is 30mm with

4

high efficiency and can penetrate the whole wall thickness .Dispel welding remaining stress function at the same time

Sizing and Straightening Machine:

Adopting four rollers of omnipotence stand, through reducing diameter and rounded, reach the ideal OD tolerance, roundness and straightness . Reduce the remaining stress function of welding seam too.

Flying cut-off disc cutter:

Adopt hydraulic pressure thrust augmentation who computer control (four disc cutter) cut off the way without noise and scrapes abrasion and no imperfection in welding seam . sizing precision : ± 3mm End beveled machine:

Adopting advanced hydrostatic pressure imitative device , computer automatically control go up and down table , transmit crew cut , chamfer .In charge of accurate from chamfering angle : 30±(0-5)°C . The root face leave :1.6mm ±0.8mm . It’s convenient to user connect and weld.

2.Line Pipe Manufacturing Process 2.1Brief

5

Item Acceptance Criteria 项目 验收标准 12100mm±50mm,no pipe against each iten is less than 5 meter.For finished helical seam pipe,junctions of coil end welds and Length helical-seam welds shall be at least 长度 300mm from the pipe ends. 12100mm±50mm，每个项目中钢管长度都不应小于5米。成品螺旋钢管上，钢带对头焊缝和螺旋焊缝的交点距管端至少300mm。 The deviation from a straightness for all pipelines shall Straightnless than 0.2％ of the pipe length, ess pipe end 1m local straightness shall 直线度 be less than 4mm. 每支管直线度小于管长的0.2％，管端1m局部直线度小于4mm。 Any hard spot having a minimum dimension greater than 50 mm in any Hard Spots direction and hardness greater than 硬块 345 HV10 shall be rejected. 在任意方向的长度大于50mm，且硬度大于345 HV10的硬块不允许存在。 Item Acceptance Criteria 项目 验收标准 Individual undercut of any length having a maximum depth of 0.4 mm are acceptable. Individual undercut of a maximum length of 0.5t having a maximum depth shall not exceeding 10% of the Undercut specified wall thickness are 咬边 acceptable provided that there are not more than two such undercuts in any 300 mm of the weld length, and all such undercuts should be dressed out. Any undercut exceeding the above limits shall be repaired or the suspect area shall be cut off or the 16

pipe shall be rejected. 允许深度≤0.4mm而长度不限的咬边存在。 最大长度为0.5t，深度不超过规定壁厚的10％的单个咬边允许存在，在任意300mm长度焊缝上这样的咬边不多于两处，且有这样的咬边应修磨。 超过上述规定的任何咬边应予以修补，或将可疑区域切除或拒收。 Extended to pipe surface or on the bevel, the delamination or inclusion which circumferential length is larger than 6.4mm are Laminatiojudged as defect and shall be cut ns until there is no such defect. 分层 扩展到钢管表面或坡口面上，且外观检查周向长度大于6.4mm的任何分层或夹杂应判为缺陷，有上述缺陷的段需切除，直到管端上没有这种分层和夹杂存在为止。 The length of the dent in any direction shall not exceed one-half the diameter of the pipe. The pipe shall contain no dents depth greater than 6.4 mm. All cold-formed dents deeper than 3.2mm with a sharp bottom gouge Dent shall be considered a defect. 摔坑 The gouge shall be removed by grinding. 摔坑在任何方向上的长度不应超过钢管直径的一半。 钢管不得有深度超过6.4mm的摔坑。 所有冷态形成的深度超过3.2mm并带有尖底划伤的摔坑，均应视为缺陷。 划伤部分可用修磨去除。 The depth≤0.125t and without influence of the min. thickness, Other shall be accepted. Defects The depth>0.125t, and without 其他缺陷 influence of the min. thickness, shall be judged as defects. 深度≤0.125t，且不影响最小允许17

壁厚的缺陷，为可接受缺陷。 深度>0.125t，且不影响最小允许壁厚的缺陷，应判定为缺陷。

17.称重测长

Length and Weight Measurement Device

使用称重测长设备自动测量每支钢管重量、长度。 The weight and length of each pipe should be automatically measured with the length and weight measurement device.

18.标记Marking

标记的项目和数字的单位按客户规定，并用白色油漆印在钢管内外表面两端。

Marked item and numeral unit shall meet the requirement of customer and use white paint to mark on both the inside and outside surfaces at the ends of each pipe.

19.色环color band

色环为50mm(宽)，距管端228.6mm在钢管两端外表面涂

18

刷。

第一环为黑色，第二环为红色，两个色环彼此相距101.6mm。

The dimension is 50mm (width),the color band shall be painted on both ends on the outside surface of the pipe.

The first band shall be black,the second band shall be red.and placed 101.6mm from each other.

20.加坡口保护器

Attaching Bevel Protector

钢管两端应加上如下所示的坡口保护器。

The following bevel protector should be attached to both ends of each pipe.

注释：坡口保护器可能在堆放场地安装。

Note: the beveled pipe-end protector may be

19

installed on the storage field.

21.转运、存储和装卸

Handling, Storage and Loading

在钢管转运、存储和装卸过程中，不得对钢管产生伤害和破损。

铁路运输时符合API RP 5L1《管线管铁路运输推荐作法》，内陆及船运时应符合API RP 5LW《管线管内陆及海上船舶运输推荐作法》。

During handling, storage and loading, the pipe should be free from injured and damaged.

Railway transport shall conform to API RP 5L1 Recommended Practice of Railway Transport of Steel Pipes for Pipeline, and inland and marine transport shall conform to API RP 5LW Recommended Practice of Inland and Marine Transport of Steel Pipes for Pipeline.

22.焊接修补Welding Repair

允许对管体进行补焊。

20

验，以证明手动焊的可焊性，取自这些焊缝的试样应进行机械性能试验，试验项目如下：

In order to proof the weldability of manually welding, the manufacturer should implement welding procedure qualification test for strip, plate and pipe. These welding seam specimens should be taken mechanical properties tests which are listed as below:

No. 序号 1 2 3 4 Test 试验项目 Welding Seam Tensile 焊缝拉伸试验 Test Welding Seam Guided-Bend 焊缝导向弯曲试验 Test Macro Metallographic 宏观金相和硬度检Test and Hardness Test 验 Manually Ultrasonic Test 手动超声波检验

4.产品试验Product Test

生产期间，取自钢管的试样，应进行试验，试验项目见以下内容：

试验频次：每炉选一支钢管试验，如果一炉多于200支，则选2支进行试验。

During production, the specimens taken from pipe should be tested as below:

Test frequency: 1 pipe per heat, 2 pipes are chose for testing in case of the pipe quantity of one heat

26

is more than 200 pipes.

No. Test 序号 试验项目 1 Product Analysis(sampling 产品分析（取样location: plate or pipe) 位置：钢板或钢管） 2 Tensile Test 拉伸试验 3 Guided-Bend Test 导向弯曲试验 4 Macro Metallographic Test 宏观金相和硬度and Hardness Test 检验 5 X-Ray Test X射线检验 6 Hydrostatic Test 水压试验 7 Ultrasonic Test 超声波检验 8 Visual Inspection 外观尺寸检验

27

本文来源：https://www.bwwdw.com/article/ixwx.html