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1、拉筋卷制接长直径在700以下1. 一次划线：一次划线目的是为接管用,接管的纵缝位置不是随意的,需按单件图指定位置 组对接管.2. 切割:接管前的管段切割应留出适当余量,以备接管焊接收缩用.3. 组对:接管组对时需考虑纵缝位置、组对接口处焊口间隙、错皮、以及接长后的弯曲 度.4. 二次划线是为了切割马鞍口所做的划线,应参照单件图和划线方案进行.5. 几何尺寸测量：A椭圆度：用板尺在被接管的管口处测量.B弯曲度：用水平仪和钢丝测量轴线方向,其测量结果应满足技术要求,否那么要进行技术调整可用千斤顶和火焰调整.接管技术要求：6. 椭圆度最大不超过理论内径的0.75%.7. 直线度:在接管过程中及最终完
2、成后,管子的直线度最大为在任意3M管段内管子的直线度不超过3mm,但任意12M内不超过10mm.8. 管子组对允许错皮为0.1倍的壁厚或6.0mm,取其小值.单面焊接时不超过 3mm.9. 不等壁厚的管段对接,将大壁厚的管段壁厚超出局部按1：2.5加工成过渡坡口.10. 管子的外周长误差不大于：对管径D0|650, 5;对管径D6650,0.25%!论直径 对应的周长.11. 制管及接管时用的临时吊点,临时支撑,定位块等用后必须切掉并打磨干净,不能 伤及母材.导管/立柱卷制接长直径大于10001技术要求1.1 管的椭圆度：Dmax-Dmin 6mmDmax:最大管径Dmin:最小管径1.2 管
3、周长外皮公差：为0.25%的理论周长.1.3 管端部垂直度0 5mm 01.4 纵缝、环缝对接错皮要求：0.1倍壁厚或6 mm取小值.单面次I接时不超过 3mm1.5 接长后,导管总长允许公差：020 mm.1.6 接长后的弯曲度不超过以下给定值：3m以内包括3m3mm；12m 以内包括 12m10mm;12m 以上12mm1.7 导管的环纵缝组对间隙及坡口按焊接程序进行.过度坡口1: 3.1.8 制管及接管时用的临时吊点、临时支撑、定位块等用后必须切掉并打磨干净,不能伤 及母材.需要及时防腐.1.9 如果焊接需要预热,根据焊接程序进行.1. DESCRIPTION 概述1.1 This st
4、ructural pipes rolling procedure consists of the process of rolling plates to pipes and the process of pipe splicing.本结构钢管卷制程序包括板材卷管及管材接长程序O1.2 This procedure describes in detail the overall fabrication process, which starts from preparation of steel plates to rolling, welding, inspection etc.本程序详细描
5、述了整个建造过程,包括板材准备到卷制、焊接、检验等.1.3 This procedure was established in accordance with such standards as API 2B, AWS D1.1 and API RP2A.本程序根据 API 2B, AWS D1.1和API RP2A等标准编制.2. DETAILS OF PROCESSESPROCESSDESCRIPTION1. PipeManufacturePrior to cutting, all materials shall be inspected and accepted accordin to
6、inspection procedure所有材料在切割之前,需根据检验程序验收.1.1 Plate cutting板材切割1. Decide plate s type, grade and brand.确认板材的型号、等级和炉批号.2. Note if there are special property requirements for the plates, e.g.direction property.材质有特殊要求的板材要特别注明,如“Z向性能板.3. Decide cutting lines and rolling direction of plates according to p
7、rescribed pipe size根据管的尺寸确定切割线和板的卷制方向.4. Cutting with flame cutting machineDouble bevel cutting before rolling(diameter more than 610mm ), single bevel cutting after rolling (to see 1.3 )用火焰切割机具切割双坡口在卷制前切割直径大于 610mm,单坡口在卷制完成后切 割参看1.3项.5. Dimensional inspection before and after cutting.切割前后都必须检查尺寸.1.
8、2 Edge crimping卷边Plate edges are crimped by pressing to the prescribed radius before forming.卷制前根据规定的半径对板材压边.Cutting again Cut off edge bevel and perform beveling.再次切割把板材边缘切成斜角形成坡口1.4 Plate rolling板材卷制Plates shall be rolled from the edge side first and then symmetrically rolled to the prescribed pip
9、e radius.从板材的边缘开始根据规定的半径对称均匀卷制.Notes说明：1. The edge is crimped by pressing.压边.2. If edge crimping is difficult due to the large thickness or high yield strength of the plates, use roll forming only.如果板材因过厚或者屈服强度过高压边困难,可直接卷制.3. Pressing of upper roll shall be gradually increased so that the required r
10、adius can be gradually achieved.逐渐增大上滚轮的压力,逐步到达要求的半径.4. During forming, limits of the rolling machine shall be used for avoiding pipe plate from longitudinal deviation.在卷制的过程中,利用卷管机的限位防止板材出现纵向的偏离.5. 60 degree inside arc template panels shall be made according to required diameters for the inspection
11、 of pipes according to the requirements described.根据直径制作60度内弧检测样板,按要求检测卷制钢管.6. When loaded on and off the rolling machine, plates and pipes shall be kept from damage caused by lifting slings and clamps.1.5 Tack welding of longitudinal seam fit-up纵缝装配定位焊卷管机在加载和卸载时,要防止板材和管材被吊索或卡具损伤.Root gap and high-l
12、ow of longitudinal seam shall be adjusted with suitable clamping apparatus and then fastened by tack welding, the total length of which shall be long enough to achieve the fastening strength required. Each section of tack weld shall be no less than 50mm, and in line with the requirements of welding
13、procedure.纵缝的焊跟间隙和错皮要使用适宜的夹具工具进行调整并用定位焊 固定,定位焊焊缝总长要足以保证强度要求,每段定位焊长度应不小 于50mm,并要满足焊接程序的要求.1.6 Fit-up inspection装配检验Fit-up inspection shall be performed with inside arc template panel and rulers according to API 2B and related welding procedure.根据API 2B和相关的焊接程序,利用内弧检测样板和直尺进行装配 检验.1.7 Tab welding引弧焊1.8
14、 Longitudinal root welding 纵向封底焊1.9 Internal welding of longitudinal seam 纵缝内侧焊接1.10 External gouging of longitudinal seam 纵缝外侧打磨1.11 External welding of longitudinal seam纵缝外侧焊接1.12 Tabs removal 弧板移除Run-on and run-off tabs shall be welded at the both ends of longitudinal weld seam of pipes rolled fr
15、om plates. The tabs, which are 100mm long, shall be consistent with the pipe in groove, thickness and curvature.在卷制管的纵缝两端要使用引弧和熄弧板,弧板长 100mm,坡口、 板厚和曲度与钢管一致.See welding procedure for details.详见焊接程序.See welding procedure for details.详见焊接程序.Before external welding, root gouging on external side, includ
16、ing all the tack welds and root welds, shall be performed. Finally the groove shall be ground to remove carbon layer and other defects.焊前必须清根,包括定位焊和封底焊,彻底去除掉碳化层和其它有 害物质.See welding procedure for details.详见焊接程序.Tabs shall be removed with flame cutting and ground smooth.用火焰切割去除弧板并打磨光滑.1.13 Pipe reform
17、ing管材修整1.14 Visual, dimensional and tolerance inspection外观、尺寸和误差 检验formingIf the welded pipe, after self-inspection, needs to be corrected, reshall be performed to the prescribed radius. If the pipe is foundacceptable by self-inspection, it can be submitted to inspection departmen for further inspec
18、tion. Before reforming however, overlaps of weld (if any) shall be ground off so that the weld may transits to the base metal smoothly to the visual requirements.如果焊接管在自检之后需要矫正,那么需要对卷管进行整改以到达规 定的半径.如果卷管自检合格,那么需报质检部门进一步检查.在整改 前,重叠的焊肉(如果有)要打磨掉,以使焊接光滑过度到母材,满 足外观要求.Note: During reforming, the upper roll
19、 shall not press too much in case the weld and base metals are damaged mechanically.说明：整改正程中,上滚轮不要过度加压以免焊缝和母材受到机械 损伤.1. Visual inspection of welds asSpecification for structural Weld and Inspection .外观检验依据?结构焊接检验规格书?.2. For tubule butt welded into lengths, the butt high-low shall not exceed t/10 or
20、6mm whichever is less, however, mismatch in excess of 3mm is no permitted unless the joint is welded from both sides. Longitudinal welds of two adjacent pipe sections shall be staggered by at least 90 except otherwise noted.环缝错皮不能超过t/10或6mm中的较小值,另外,除非是双面焊, 否那么错皮不能超过3mm.在没有特别说明的情况下,相临两段纵缝至 少错开90度.3.
21、Length tolerance 长度误差The Length tolerance shall meet requirements of API 2B & specification for structural fabrication of offshore platforms and structures .长度误差要满足API 2B和?海洋平台及结构物结构建造规格书?的 要求.4. Out roundness 椭圆度：For pipes of external diameter up to and including 2000 mm, the out roundness, which i
22、s defined as the difference of maximum and minimumouter diameters of pipes at any point along the pipe length, shall not exceed 0.75 percent of the nominal internal diameter or 6.4 mm (1/4 in) which islesser. For pipes of external diameter greater than 2000 mm, shall not exceed 15 mm.对于外管径小于等于2000毫米
23、的钢管,椭圆度不能超过0.75%倍的 内径或6.4毫米(1/4英寸)中的较小值.椭圆度是沿管长方向任意一 点最大与最小外径的差值.外径超过 2000毫米的钢管,椭圆度不超过 15毫米.5. Circumference 周长The tolerance of outer circumference of pipes at any point along the length of pipe shall be within 0.25% of the nominal circumference when external diameter greater than 650 mm, or 5mm whe
24、n external diameter up to and including 650 mm.当管径大于650毫米时,沿管长方向任意一点的外周长误差不能超 过0.25%倍的外径理论周长；当管径小于等于650毫米时,误差不能超过5毫米.6. Straightness 直线度The maximum allowable straightness deviation in any 3m increment of length shall be 3 mm. The maximum allowable straightness deviation in any length of 12m shall no
25、t exceed 10 mm, in any length greater than 12m shall be no more than 12 mm.在任意3米长管段上,直线度偏差不能超过3毫米；在任意12米长 管段上,直线度偏差不能超过10毫米；在12米长度以上的管段上, 直线度偏差不能超过12毫米.7. Pipe ends 管端Bevels of pipe ends shall be in line with specific requirements. Root face shall be perpendicular to the longitudinal axis of the pip
26、e. The deviation shall be within 1.6mm(1/16 in) in each 305mm(1ft) of diameter with the maximum of 6.4mm (1/4 in), measured with right angle square across the pipe end.管的端部坡口要到达特定的要求,坡口的钝边要垂直于管的纵轴.沿管径每305毫米(1英尺)垂直度偏差不超过1.6毫米(1/16英寸), 最大不超过6.4mm (1/4in),用直角尺在管端测量.1.15 NDTNDT inspection shall be accor
27、ding to Specification for Structural无损检验weld and Inspection 无损检验依照?结构焊接检验规格书?.1.16 Defect repair ofbase metal母材缺陷修复1.17 Repair of weld defects焊接缺陷修复to determineEach defect found in base metal shall been further detectedits area. For pipes that have be completed, the defects whose depth doesnot excee
28、d 5 percent of nominal wall thickness and mechanical damage th depth of which does not exceed 5 percent of nominal wall thickness 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 concaveshall be smooth. The removal thi
29、ckness shall not exceed 7 percent of nominal wall thickness, with the maximum of 3.2mm1/8 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 welding shall not be allowed for defects with de
30、pth exceeding 20 percent of nominal wall thickness or defect length/width exceeding 20 percent of nominal diameter. For pipes made of plates other than rolled, repair welding is prohibited without specific approval.母材上发现的每个缺陷都要进行进一步的检测以确定区域.对于已 卷制管材,如果缺陷深度不超过 5%倍壁厚,机械损伤不超过5%倍 壁厚或1.6毫米1/16英寸,那么缺陷可以忽略
31、.超过上述限制的缺陷要 消除,消除缺陷之后,凹面应平滑,去除厚度不能超过 7%倍壁厚, 最大不超过3.2毫米1/8英寸.用于卷管的板材,如果缺陷超过上述 限制,但在20%倍壁厚以内,可以进行焊接修复.如果缺陷深度超过 20%倍壁厚或缺陷长度/宽度超过管径的20%,那么不允许修复焊接.对 于板材制成的管而非卷制管,未经特别批准,不得进行修复焊接.Weld defects that are not allowed by the specification shall be dealt with. For specific operations such as removal and repair
32、of defects in internal and external welds, please see the corresponding welding procedures.标准不允许的焊接缺陷必须进行处理.对于类似消除和修复内外焊接缺陷的特别操作,参见相应的焊接程序.2. Pipe Splicing管的拼接2.1 Pipe end beveling 管端坡口6UFFor requirements of pipe end beveling, please see item 7 of Section1.14, Bevel shape and sizes are as follows:对管
33、端坡口的要求,参见1.14节的第7项,坡口形式及尺寸如下:TYPICAL PIPE END BEVELLINGFOR PIPES 610 AND LARGERrrPlCAL PIPE END BEVELLINGFOR PIPES WALLER THAN 061clTypical splicing details to be refer to Welding Procedure典型拼接细节参见?焊接程序?.2.2 Fit-up and tackwelding装配定位焊2.3 Inspection offit-up and straightness装配及直线度检验2.4 Root welding封
34、底焊1. Fit-up requirements:装酉己要求Root gap: 2.0-4.0mmhigh-low : please see item 2 of Section 1.14根部间隙：2.0 4.0毫米错皮：参见1.14节第2项.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 ma
35、ximum of 6 mm. If the high-low occurs along a length of 8t and a transition 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).如果错皮超过3mm,需要进行双面焊,这种情况下,环缝错皮不能 超过0.1t t代表管壁厚,最大不超过6毫米.如果在沿8倍壁厚 长度上产生错皮,并在这一区域使用焊材按
36、 4:1过渡,那么环缝错皮允 许到达0.3倍壁厚,但最大不超过9.5毫米3/8英寸.3. The preparation of inside and outside transition slopes made between unequal thickness shall be in line with AWS D1.1.不等壁厚内外过渡斜面要符合 AWS D1.1要求.4. Distance between the two adjacent girth welds shall not less than the pipe diameter or 1500 mm, whichever is
37、smaller. There shall not be more then two girth welds in any 3.0m long segments of pipes.两相邻环缝之间的距离不小于管径或1500毫米中的较小值,在任意3m长的管段上不能超过两道环缝.5. circumferential seams in cones and tubular transitions are not permitted.大小口和过渡段不允许环向焊缝.In accordance with the requirements described in Section 2.1 and 2.2 依据2.
38、1和2.2节要求.Tack welding shall be done with SMAWprocess. And inside root welding shall be done with SMAW process. For details, please see welding procedure.定位焊和内部封底焊采用SMAW程序,详见焊接程序.2.5 Inside girth weld welding内部环缝焊接2.6 Root gouging 清根2.7 Outside girth weld welding外部环缝焊接2.8 Visual inspection of welds焊缝
39、外观检查2.9 NDT 无损检验2.10 Visual and dimensional inspection 外观及尺寸检验2.11 Base metal and weld 母材与焊接2.12 Defect repair of base metal and weld母材和焊接缺陷 修复Use manual arc welding first and then use automatic submerged arc welding or shielded metal arc welding for f川er and caper. For details, see welding procedur
40、e.先使用手工电弧焊,然后采用埋弧自动焊或保护金属极电弧焊,详 见焊接程序.Same as longitudinal welds.同纵缝焊接.Use SAW, See welding procedure for details.使用电弧保护焊,详见焊接程序.Same as item 1 of Section 1.14同1.14节第1项.NDT inspection shall be according to Specification for Structural weld and Inspection 无损检验依照?结构焊接检验规格书?.Refer to Section 1.14参见1.14
41、节As per Section 1.16 and 1.17 参照1.16和1.17节.As per Section 1.16 and 1.17 参照1.16和1.17节.2.13 Identification On the inside and outside surfaces of both pipe ends the following items 标识shall be stenciled with letters not less than 25.4mm high (1 in):在管两端的内外外表,要用高度不小于25.4毫米(1英寸)的文字打印以下内容：a. Nominal diameter (O.D.) nominal wall thickness (plate thickness) length直径(外径)x壁厚(板材厚度)x长度b. Steel standard, brand and grade钢材规格、炉批号和等级c. Project name and member number.工程名称和杆件号