网络化控制在宝钢UOE的应用实践

介绍了宝钢UOE项目的基本情况,并结合UOE工艺路径的特点,对UOE焊管机组全工序网络化控制的必要性及可行性进行了初步的研究。针对UOE工厂检查区域全面质量控制的难点,结合为UOE焊管机组配套设置的水压、无损探伤类过程质量检验工序,开发了计算机自动判定与人工辅助判定相结合的UOE工厂检查综合判定系统。该系统于2008年4月投入使用,运行稳定可靠。     

宝钢UOE大口径直缝埋弧焊管机组的技术特点与优势

宝钢UOE机组是我国第一套现代化大口径直缝埋弧焊管机组,也是世界上装备最先进的大口径直缝埋弧焊生产线.介绍了宝钢UOE机组的概况和特色,并论述了该机组的一贯制体系优势、原料优势和设备优势,对关键的成型和焊接设备的技术特点进行了重点阐述,同时也介绍了宝钢在自主技术方面的研发情况.     

我国管道业发展对板带业的拉动

本文叙述了我国管道业面临的市场机遇和受到天然气价格等因素的制约以及进口钢管的挑战。建议中国管道业应适当发展ERW610机组和UOE机组的高质量产品；在钢板上宜以X70级为主，设备潜力可向X80级为目标而努力。     

宝钢UOE机组的装备水平与工艺技术

为满足中国石油、天然气能源输送管道建设需要大量高等级钢管的需求,宝钢分公司钢管厂兴建了一套现代化的大口径直缝埋弧焊管机组(UOE).该机组广泛采用了当今先进的UOE制造技术:大步幅的预弯边机、UO成型大压缩率控制、O成型的钢管中心恒定控制、O成型机的两段式变径液压缸、快速工具更换装置、数值分析模型等.同时概括介绍了该机组的产品方案,生产工艺、装备的技术参数和特点,并对采用的最新的C,U,O成型技术进行了论述.     

UOE成型三维有限元仿真研究

研究UOE成型三维有限元模拟方法。基于弹塑性有限元方法,通过建立UOE焊管成型的三维有限元模型,全方位模拟具有大变形和复杂接触的弹塑性成型过程,分析板料在弯边、U成型、O成型、预焊及扩径等各个成型阶段的变形构型、等效塑性应力和应变分布的变化,并与实际工艺质量进行比较,验证了模型的准确性。并且通过有限元仿真的手段研究了板料尺寸在UOE成型过程中的变化规律。研究结果可为UOE工艺设计以及UOE焊管可制造性评估提供借鉴。     

珠江钢管公司在发展中崛起

叙述了珠江钢管公司发展UOE焊管的市场背景，以UOE工艺流程和X70级为代表的“西气东输”钢管的冶金工业水平，从而折射出这家公司在发展中崛起。     

φ1219×12．7mm X52MS耐蚀焊管的开发

主要介绍抗HIC及抗SSC耐蚀用X52MS管线管在宝钢UOE生产线的开发。通过化学成分合理设计与冶炼工艺要点控制,并采用TMCP（控制轧制＋ACC）厚板轧制工艺,设置合理的UOE焊管成型、焊接、扩径等工艺参数,成功开发出了X52MS φ1219×12．7mm耐蚀焊管,其力学性能及抗HIC、SSC性能优良,较好地满足了用户的使用条件。     

宝钢X65MS耐蚀焊管的生产

研究了X65MS耐蚀管线管在宝钢UOE生产线的生产。通过合理进行成分设计,并采用TMCP（控制轧制＋ACC）厚板轧制工艺,并通过设置合理的UOE焊管成型、焊接、扩径等工艺参数,成功生产出了X65MSφ813×20．61mm耐蚀焊管,其力学性能及抗HIC、SSC性能优良,满足了用户的使用条件。     

JFE钢铁获得面向欧洲气体输送用管线的钢材订单

正近日,JFE钢铁宣布和希腊钢管厂家CORINTH公司及伊藤忠丸红钢铁共同获得了面向欧洲气体输送用管线项目Trans Adriatic Pipeline的钢材订单,包括热轧板、厚板和UOE钢管合计7.8万t。此次订单中热轧板5.2万t、厚板2.3万t、UOE钢管3000 t,UOE钢管为X70等级,口径48英寸。所有钢材由JFE钢铁西日本制铁所福山厂和东日本制铁所京滨厂生产,预计在2016年内分3次全部出厂。     

海洋管线铺设环焊技术现状及宝钢研究进展

综述了当前深水海洋管线钢管铺设方法以及对应的施工环缝焊接技术,海管高效自动环缝焊接技术成为今后的发展趋势.介绍了双车双炬熔化极气体保护自动焊接技术、闪光对焊技术、激光—电弧复合焊接技术、非真空电子束焊接技术等在海管施工焊接领域具有很大应用潜力的技术.当前,宝钢UOE钢管产品致力于高等级海管的生产与经营,在UOE海管自动环缝焊接方面开展了研究,旨在为用户提供相应技术服务与支撑.     

Engineering critical assessment on welding flaws of the X65 UOE girth weld based on CRACKWISE

Focused on the girth weld of a Φ762 × 28. 6 mm( X65) offshore UOE pipe,the fracture toughness properties at different weld joint positions were tested. Meanwhile,the largest size of different cracks under service condition was calculated by using CRACKWISE. The service life of the UOE pipe with postulated crack-like flaws was calculated by considering various fatigue factors,such as vibrations caused by ocean current and fluctuations of inner pressure. The assessment process and results can be used to direct the repair of weld flaws laid in pipes or to assess the reliability of in-serving pipes.     

大口径油气管道环焊技术的进展及在宝钢的应用

介绍了当前管道工业的发展及管道焊接技术的进展情况,并阐明了管道全位置下向焊接技术的特性.管道环焊缝是由根焊、热焊、填充焊、盖面焊等不同焊道组成.对常用的手工焊、半自动焊和自动焊接方法在管道环焊缝不同焊道焊接时的应用以及各自特点做了介绍,还对焊接材料的选用、焊接设备的选型作了描述.宝钢铜管厂大口径直缝埋弧焊管(UOE)项目即将投产,投产后大口径焊管产品使用技术的研究势在必行,宝钢应尽快开展大口径UOE焊管的环缝焊接技术的研究,为将来的推广应用提供必要的技术支撑.     

Practice and reflection of Baosteel longitudinal UOE submerged arc welding technologies self-reliance integrated innovation

The capability of self-reliance integrated innovation is one of the key factors that influence steel enterprise’ s core competitiveness.The main equipments of Baoteel UOE unit are from abroad,but the key consistent pipe manufacturing technologies including iron making,steel making,heavy plates are self-reliance integrated.The self-reliance integrated innovation of Baosteel UOE unit has the features of high challenge, high efficiency,high starting point,consistent technologies etc.The independent innovation capacity achieved by adjusting measures to local conditions and periods in introducing projects is the key to the development of continuing robust.Baosteel longitudinal UOE submerged arc welding tube project practice also offer beneficial reference for independent of integration innovation.     

Product development of Baosteel HFW 610 Mill

Baosteel’s high-frequency electric resistance welded(HFW) 610 longitudinal seam mill(8 5/8″-24″, the yearly output 300000 t) and UOE 1422 longitudinal submerged arc welding(SAW) mill(20" -56",the yearly output 500000 t) are established in 2005 and 2008,respectively.Product specification covers whole of API 5CT standard and most of API 5L standard,terminating the history of manufacturing the medium and large size pipes at Baosteel.The yearly output increased from 1,200000 t to nearly 2000000 t.HFW 610 mill is oriented at mid size pipes,which are mainly linepipe and welded casing.The designed yearly output of HFW mill is 300000 t,including casing of 90000 t,linepipe of 180000 t,round structural pipe of 15000 t and rectangle structural pipe of 15000 t. The yearly output of oil casing line supporting the welding line is 120000 t,among which including welded casing and seamless casing of 30000 t.Baosteel’s HFW 610 longitudinal seam mill was established on October 27,2005. After the equipment trial run In October,2005 - March,2006 and equipment function examination In April,2006 - June,2006,mass production started in July 2006.And in December 2006,monthly designed capacity was achieved,reaching to 30496.644 t in welding pipe and 28 349.939 t in finished pipe.The output of 2006,2007, 2008 and 2009 was 117 067 t,223 554 t,255 791 t,and 204 424 t,with the comprehensive yield ratio 79.4%, 87.8%,90.80%and 91.92%respectively.This study introduces Baosteel HFW 610 Mill which is the world class,energy conservation and environmental protection enterprise,including product orientation,process and new product development.     

Numerical simulation of the UOE forming process based on MSC. Marc secondary development technology

U-ing-O-ing-Expanding (UOE),the main process for making longitudinal submerged arc welded pipe(LSAW) with steel plate,is famous for its superior quality and reliability.Based on the famous non-linear finite element analysis (FEA) software MSC.Marc,a finite element model (FEM) has been established to simulate the whole UOE forming process by using the secondary development technology with the Python language.Research has also been conducted systematically on the crimping,U-ing,O-ing and mechanical expanding processes.The practice has shown that the simulation calculation is in close conformity with the actual site production data.The FEM has been successfully applied in the UOE production at Baosteel.     

短流程重轨生产工艺在鞍钢大型厂的应用

经过多次扩建和改造,鞍钢大型厂的装备及技术均已达到了世界一流水平.回顾了该厂的生产历史及其改造背景,介绍了改造后的工艺流程、生产规模、产品结构以及万能轧机、平立复合矫直机等主要生产设备的性能参数,全面阐述了短流程重轨生产工艺在鞍钢大型厂的成功应用.