卷管接長技術(shù)要求

1、拉筋卷制接長（直徑在 700 以下）1.一次劃線 : 一次劃線目的是為接管用，接管的縱縫位置不是隨意的，需按單件圖指定位置 組對接管。2.切割 : 接管前的管段切割應(yīng)留出適當(dāng)余量，以備接管焊接收縮用。3.組對 : 接管組對時需考慮縱縫位置、組對接口處焊口間隙、錯皮、以及接長后的彎曲度。4.二次劃線是為了切割馬鞍口所做的劃線，應(yīng)參照單件圖和劃線方案進行。5.幾何尺寸測量 :A） 橢圓度: 用板尺在被接管的管口處測量。B） 彎曲度: 用水平儀和鋼絲測量軸線方向，其測量結(jié)果應(yīng)滿足技術(shù)要求，否則要進行 技術(shù)調(diào)整（可用千斤頂和火焰調(diào)整）。接管技術(shù)要求 :6.橢圓度最大不超過理論內(nèi)徑的 0.75 。7.直

2、線度:在接管過程中及最終完成后，管子的直線度最大為在任意3M 管段內(nèi)管子的直線度不超過3mm,但任意12M內(nèi)不超過10mm。8.管子組對允許錯皮為0.1倍的壁厚或6.0mm,取其小值。單面焊接時不超過 3mm。9.不等壁厚的管段對接,將大壁厚的管段壁厚超出部分按 1:2.5加工成過渡坡口。10.管子的外周長誤差不大于：對管徑D W 650, 5;對管徑D 650,0.25%理論直徑 對應(yīng)的周長。11.制管及接管時用的臨時吊點,臨時支撐,定位塊等用后必須切掉并打磨干凈,不能 傷及母材。導(dǎo)管 / 立柱卷制接長（直徑大于 1000）1 技術(shù)要求1.1管的橢圓度：Dmax-Dmin 6mmDmax:

3、最大管徑Dmin: 最小管徑1.2管周長 （外皮）公差：為 0.25%的理論周長。1.3管端部垂直度w 5mm。1.4縱縫、環(huán)縫對接錯皮要求： 0.1 倍壁厚或 6 mm 取小值。單面焊接時不超過 3mm1.5接長后，導(dǎo)管總長允許公差： 020 mm 。1.6接長后的彎曲度不超過下列給定值：3m 以內(nèi)（包括 3m）3mm；12m 以內(nèi)（包括 12m）10mm;12m 以上12mm1.7導(dǎo)管的環(huán)縱縫組對間隙及坡口按焊接程序進行。過度坡口1 ：3。1.8制管及接管時用的臨時吊點、臨時支撐、定位塊等用后必須切掉并打磨干凈，不能傷 及母材。需要及時防腐。1.9如果焊接需要預(yù)熱，按照焊接程序進行。1.D

4、ESCRIPTION 概述1.1 This structural pipes rolling procedure consists of the process of rolling plates to pipes and the process of pipe splicing.本結(jié)構(gòu)鋼管卷制程序包括板材卷管及管材接長程序。1.2 This procedure describes in detail the overall fabrication process, which starts from preparation of steel plates to rolling, weldin

5、g, inspection etc.本程序詳細描述了整個建造過程，包括板材準(zhǔn)備到卷制、焊接、檢驗等。1.3 This procedure was established in accordance with such standards as API 2B, AWS D1.1 and API RP2A.本程序按照 API 2B, AWS D1.1 和 API RP2A 等標(biāo)準(zhǔn)編制。PROCESS1. PipeManu facture卷管1.1 Plate cutt ing板材切割1.2 Edge crimp ing卷邊Cutt ing aga in再次切割2.DETAILS OF PROCES

6、SESDESCRIPTIONPrior to cutt ing, all materials shall be in spected and accepted accord in to in specti on procedure所有材料在切割之前，需根據(jù)檢驗程序驗收。1. Decide plate s type, grade and brand.確認板材的型號、等級和爐批號。2. Note if there are special property requireme nts for the plates, e.g. direct ion property.材質(zhì)有特殊要求的板材要特別注明，如

7、“Z”向性能板。3. Decide cutt ing lines and rolli ng directi on of plates accord ing to prescribed pipe size按照管的尺寸確定切割線和板的卷制方向。4. Cutting with flame cutting machineDouble bevel cutt ing before rolli ng(diametermore tha n 610mm ),single bevel cutting after rolling (to see 1.3 )用火焰切割機具切割雙坡口在卷制前切割(直徑大于610m m)

8、，單坡口在卷制完成后切割(參看1.3項)。5. Dimensional inspection before and after cutting.切割前后都必須檢查尺寸。Plate edges are crimped by press ing to the prescribed radius before formi ng.卷制前按照規(guī)定的半徑對板材壓邊。Cut off edge bevel and perform beveli ng. 把板材邊緣切成斜角形成坡口。1.4 Plate rolli ng板材卷制1.5 Tack weld ing of Ion gitud inal seam fit

9、-up縱縫裝配定位焊1.6 Fit-up in specti on裝配檢驗Plates shall be rolled from the edge side first and the n symmetrically rolled to the prescribed pipe radius.從板材的邊緣開始按照規(guī)定的半徑對稱均勻卷制。Notes說明：1. The edge is crimped by press ing.壓邊。2.If edge crimping is difficult due to the large thickness or high yield stre ngth of

10、 the plates, use roll formi ng on ly.如果板材因過厚或者屈服強度過高壓邊困難，可直接卷制。3.Press ing of upper roll shall be gradually in creased so that the required radius can be gradually achieved.逐漸增大上滾輪的壓力，逐步達到要求的半徑。4.During formi ng, limits of the rolli ng mach ine shall be used for avoidi ng pipe plate from Ion gitud i

11、nal deviati on.在卷制的過程中，利用卷管機的限位避免板材出現(xiàn)縱向的偏離。5.60 degree in side arc template pan els shall be made accordi ng to required diameters for the inspection of pipes according to the requireme nts described.根據(jù)直徑制作60度內(nèi)弧檢測樣板，按要求檢測卷制鋼管。6.Whe n loaded on and off the rolli ng mach ine, plates and pipes shall be

12、 kept from damage caused by lift ing sli ngs and clamps.卷管機在加載和卸載時，要避免板材和管材被吊索或卡具損傷。Root gap and high-low of Ion gitud inal seam shall be adjusted with suitable clamp ing apparatus and the n faste ned by tack weld ing, the total len gth of which shall be long eno ugh to achieve the faste ning stre n

13、gth required. Each secti on of tack weld shall be no less tha n 50mm, and in line with the requireme nts of weld ing procedure.縱縫的焊跟間隙和錯皮要使用合適的夾具工具進行調(diào)整并用定位焊 固定，定位焊焊縫總長要足以保證強度要求，每段定位焊長度應(yīng)不小 于50mm，并要滿足焊接程序的要求。Fit-up in spect ion shall be performed with in side arc template panel and rulers accord ing t

14、o API 2B and related weldi ng procedure.根據(jù)API 2B和相關(guān)的焊接程序，利用內(nèi)弧檢測樣板和直尺進行裝配 檢驗。1.7 Tab weldi ngRun-on and run-off tabs shall be welded at the both ends of Ion gitud inal引弧焊weld seam of pipes rolled from plates. The tabs, which are 100mm long, shall be con siste nt with the pipe in groove, thick ness an

15、d curvature.在卷制管的縱縫兩端要使用引弧和熄弧板，弧板長100mm,坡口、板厚和曲度與鋼管一致。1.8 Lon gitud inal rootSee weldi ng procedure for details.weld ing縱向封底焊詳見焊接程序。1.9 In ternal weldi ngSee weldi ng procedure for details.of Ion gitud inal詳見焊接程序。seam縱縫內(nèi)側(cè)焊接1.10 Exter nal gougi ngBefore exter nal weld ing, root goug ing on exter nal

16、side, in clud ing all theof Ion gitudi naltack welds and root welds, shall be performed. Fin ally the groove shall beseamground to remove carb on layer and other defects.縱縫外側(cè)打磨焊前必須清根，包括定位焊和封底焊，徹底清除掉碳化層和其它有 害物質(zhì)。1.11 External weld ingSee weldi ng procedure for details.of Ion gitud inal詳見焊接程序。seam縱縫外側(cè)焊

17、接1.12 Tabs removalTabs shall be removed with flame cutt ing and ground smooth.弧板移除用火焰切割去除弧板并打磨光滑。1.13 Pipe reform ing管材修整1.14 Visual,dime nsional and tolera nee in speeti on外觀、尺寸和誤差 檢驗If the welded pipe, after self- in speeti on, n eeds to be corrected, reformi n shall be performed to the prescribed

18、 radius. If the pipe is found acceptable by self- in speeti on, it can be submitted to in speeti on departme n for further in spect ion. Before reformi ng however, overlaps of weld (if any) shall be ground off so that the weld may tran sits to the base metal smoothly to the visual requireme nts.如果焊接

19、管在自檢之后需要矯正，則需要對卷管進行整改以達到規(guī) 定的半徑。如果卷管自檢合格，貝U需報質(zhì)檢部門進一步檢查。在整改 前，重疊的焊肉(如果有)要打磨掉，以使焊接光滑過度到母材，滿 足外觀要求。Note: During reform ing, the upper roll shall not press too much in case the weld and base metals are damaged mecha ni cally.說明：整改過程中，上滾輪不要過度加壓以免焊縫和母材受到機械 損傷。1. Visual in speeti on of welds asSpecification

20、 for structural Weld andInspeetion ”.外觀檢驗依據(jù)結(jié)構(gòu)焊接檢驗規(guī)格書。2. For tubule butt welded into len gths, the butt high-low shall not exceed t/10 or 6mm whichever is less, however, mismatch in excess of 3mm is no permitted uni ess the joint is welded from both sides. Lon gitudi nal welds of two adjace nt pipe s

21、ecti ons shall be staggered by at least 90 except otherwise no ted.環(huán)縫錯皮不能超過t/10或6mm中的較小值，另外，除非是雙面焊， 否則錯皮不能超過3mm。在沒有特別說明的情況下，相臨兩段縱縫至 少錯開90度。3. Len gth tolera nee 長度誤差The Len gth tolera nee shall meet requireme nts of API 2B &specificati on for structural fabricati on of offshore platforms and structu

22、res ”.長度誤差要滿足API 2B和海洋平臺及結(jié)構(gòu)物結(jié)構(gòu)建造規(guī)格書的 要求。4.Out rou ndn ess 橢圓度：For pipes of exter nal diameter up to and in clud ing 2000 mm, the out roundn ess, which is defi ned as the differe nee of maximum and minimum outer diameters of pipes at any point along the pipe len gth, shall not exceed0.75 percent of t

23、he nominal internal diameter or 6.4 mm (1/4 in) which is lesser. For pipes of exter nal diameter greater tha n 2000 mm, shall not exceed 15 mm.1.15 NDT無損檢驗對于外管徑小于等于2000毫米的鋼管，橢圓度不能超過0.75%倍的 內(nèi)徑或6.4毫米(1/4英寸)中的較小值。橢圓度是沿管長方向任意一 點最大與最小外徑的差值。外徑超過 2000毫米的鋼管，橢圓度不超過 15毫米。5.Circumfere nee 周長The tolera nee of o

24、uter circumfere nee of pipes at any point along the len gth of pipe shall be with in 0.25% of the nominal circumfere nee whe n exter nal diameter greater tha n 650 mm, or 5mm whe n exter nal diameter up to and in clud ing 650 mm.當(dāng)管徑大于650毫米時，沿管長方向任意一點的外周長誤差不能超 過0.25%倍的外徑理論周長；當(dāng)管徑小于等于650毫米時，誤差不能超過5毫米。6

25、.Straight ness 直線度The maximum allowable straight ness deviati on in any 3m in creme nt of len gth shall be 3 mm. The maximum allowable straight ness deviatio n in any len gth of 12m shall not exceed 10 mm, in any len gth greater tha n 12m shall be no more tha n 12 mm.在任意3米長管段上，直線度偏差不能超過3毫米；在任意12米長 管

26、段上，直線度偏差不能超過10毫米；在12米長度以上的管段上， 直線度偏差不能超過12毫米。7.Pipe en ds管端Bevels of pipe ends shall be in line with specific requirements. Root face shall be perpe ndicular to the Ion gitud inal axis of the pipe. The deviation shall be within 1.6mm(1/16 in) in each 305mm(1ft) of diameter with the maximum of 6.4mm

27、(1/4 in), measured with right an gle square across the pipe end.管的端部坡口要達到特定的要求，坡口的鈍邊要垂直于管的縱軸。 沿管徑每305毫米(1英尺)垂直度偏差不超過1.6毫米(1/16英寸)， 最大不超過6.4mm (1/4in)，用直角尺在管端測量。NDT in specti on shall be accordi ng to Specificati on for Structuralweld and In specti on ”無損檢驗依照結(jié)構(gòu)焊接檢驗規(guī)格書。1.16 Defect repair ofbase metal母

28、材缺陷修復(fù)1.17 Repair of welddefects焊接缺陷修復(fù)2. Pipe Splici ng管的拼接Each defect found in base metal shall bee n further detected to determ ine its area. For pipes that have be completed, the defects whose depth does not exceed 5 perce nt of nominal wall thick ness and mecha ni cal damage the depth of which do

29、es not exceed 5 perce nt of nominal wall thick ness or 1.6mm(1/16 in) may be neglected. The defects exceeding the above limits shall be removed to the sound metal. After removal, the con cave shall be smooth. The removal thickness shall not exceed 7 percent of nominal wall thickness, with the maximu

30、m of 3.2mm(1/8 in). For rolled steel plates, repair welding is permitted if the defect depth exceeds the above limits but within 20 percent of the nominal wall thickness. Repair weldi ng shall not be allowed for defects with depth exceedi ng 20 perce nt of nominal wall thick ness or defect le ngth/w

31、idth exceed ing 20 perce nt of nominal diameter. For pipes made of plates other than rolled, repair weldi ng is prohibited without specific approval.母材上發(fā)現(xiàn)的每個缺陷都要進行進一步的檢測以確定區(qū)域。對于已 卷制管材，如果缺陷深度不超過 5%倍壁厚，機械損傷不超過5%倍 壁厚或1.6毫米（1/16英寸），貝U缺陷可以忽略。超過上述限制的缺陷要 消除，消除缺陷之后，凹面應(yīng)平滑，去除厚度不能超過7%倍壁厚，最大不超過3.2毫米（1/8英寸）。用于卷管

32、的板材，如果缺陷超過上述 限制，但在20%倍壁厚以內(nèi)，可以進行焊接修復(fù)。如果缺陷深度超過 20%倍壁厚或缺陷長度/寬度超過管徑的20%,則不允許修復(fù)焊接。對 于板材制成的管而非卷制管，未經(jīng)特別批準(zhǔn)，不得進行修復(fù)焊接。Weld defects that are not allowed by the specificati on shall be dealt with. For specific operatio ns such as removal and repair of defects in in ternal and exter nal welds, please see the cor

33、resp onding weldi ng procedures.規(guī)范不允許的焊接缺陷必須進行處理。對于類似消除和修復(fù)內(nèi)外焊接缺陷的特別操作，參見相應(yīng)的焊接程序。2.1 Pipe end beveli ng管端坡口For requireme nts of pipe end beveli ng, please see item 7 of Section1.14, Bevel shape and sizes are as follows:對管端坡口的要求，參見1.14節(jié)的第7項，坡口形式及尺寸如下:FOR PIPES SALLE THAN(5610Typical splici ng details

34、to be refer to Weldi ng Procedure 典型拼接細節(jié)參見焊接程序。F+5TYPICAL PIPE END BEVELLINGFOR PIPES 0610 AND LARGERPfPlCAL PIPE END BEVELLING2.2 Fit-up and tackweld ing裝配定位焊2.3 In spect ion of fit-up and straight ness 裝配及直線度檢驗2.4 Root weld ing封底焊1. Fit-up requireme nts:裝配要求Root gap: 2.0-4.0mmhigh-low : please see

35、 item 2 of Secti on 1.14 根部間隙：2.0-4.0毫米錯皮：參見1.14節(jié)第2項。2. If the high-low exceeds3mm, welding shall be performed on both sides, in this case, the high-low of girth welds shall not exceed 0.1t ( “ t representswall thickness) with the maximum of 6 mm. If the high-low occurs along a len gth of 8t and a t

36、ran siti on slope of 4:1 is made with weld metal along the area, the high-low of the girth welds is allowed up to 0.3t with the maximum of 9.5mm (3/8 in).如果錯皮超過3mm,需要進行雙面焊，這種情況下，環(huán)縫錯皮不能 超過0.1t （” t代表管壁厚），最大不超過6毫米。如果在沿8倍壁厚 長度上產(chǎn)生錯皮，并在這一區(qū)域使用焊材按 4: 1過渡，則環(huán)縫錯皮允 許達到0.3倍壁厚，但最大不超過9.5毫米（3/8英寸）.3.The preparati

37、on of in side and outside tran siti on slopes made betwee n un equal thick ness shall be in line with AWS D1.1.不等壁厚內(nèi)外過渡斜面要符合 AWS D1.1要求。4. Dista nee betwee n the two adjace nt girth welds shall no t less tha n the pipe diameter or 1500 mm, whichever is smaller. There shall not be more then two girth

38、 welds in any 3.0m long segme nts of pipes.兩相鄰環(huán)縫之間的距離不小于管徑或 1500毫米中的較小值，在任意 3m長的管段上不能超過兩道環(huán)縫。5. circumferential seams in cones and tubular transitions are not permitted.大小口和過渡段不允許環(huán)向焊縫。In accorda nee with the requireme nts described in Secti on 2.1 and 22 依據(jù)2.1和2.2節(jié)要求。Tack weld ing shall be done with SMAWprocess. And in side root welding shall be done with SMAW process. For