卷管接长技术要求要点.docx

1、卷管接长技术要求要点拉筋卷制接长（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，否则要进行技术调整（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.

2、直线度:在接管过程中及最终完成后，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部分按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D650，5; 对管径D650,0.25%理论直径对应的周长。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1000）1 技术要求1.1 管的椭圆度： Dmax-Dmin6mmDmax: 最大管径Dm

3、in: 最小管径1.2 管周长(外皮)公差：为0.25%的理论周长。1.3 管端部垂直度5mm。1.4 纵缝、环缝对接错皮要求：0.1倍壁厚或6 mm 取小值。单面焊接时不超过3mm。1.5 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下列给定值：3m以内（包括3m） 3mm；12m 以内（包括12m） 10mm;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，按照焊接程序进行。1. descriptio

4、n概述1.1 This structural pipes rolling procedure consists of the process of rolling plates to pipes and the process of pipe splicing.本结构钢管卷制程序包括板材卷管及管材接长程序。1.2 This procedure describes in detail the overall fabrication process, which starts from preparation of steel plates to rolling, welding, inspect

5、ion etc.本程序详细描述了整个建造过程，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.本程序按照API 2B, AWS D1.1 和 API RP2A等标准编制。2. DETAILS OF PROCESSESPROCESSDESCRIPTION1. Pipe Manufacture卷管 Prior to cutting, all materials shall be inspected and ac

6、cepted according to 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 plates 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. “Z” 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 directi

7、on of plates according to prescribed pipe size 按照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 a

8、nd after cutting.切割前后都必须检查尺寸。1.2 Edge crimping 卷边Plate edges are crimped by pressing to the prescribed radius before forming.卷制前按照规定的半径对板材压边。 Cutting again 再次切割Cut off edge bevel and perform beveling. 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 symmet

9、rically rolled to the prescribed pipe radius.从板材的边缘开始按照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 gradu

10、ally increased so that the required radius can be gradually achieved.逐渐增大上滚轮的压力，逐步达到要求的半径。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，利用卷管机的限位避免板材出现纵向的偏离。5. 60 degree inside arc template panels shall be made according to

11、required diameters for the inspection 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.卷管机在加载和卸载时，要避免板材和管材被吊索或卡具损伤。1.5 Tack welding of longitudinal

12、seam fit-up纵缝装配定位焊Root gap and high-low 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 l

13、ine with the requirements of welding procedure.纵缝的焊跟间隙和错皮要使用合适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

14、检测样板和直尺进行装配检验。1.7 Tab welding引弧焊Run-on and run-off tabs shall be welded at the both ends of longitudinal weld seam of pipes rolled from 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。1.8 Longitudi

15、nal root welding纵向封底焊See welding procedure for details.详见焊接程序。1.9 Internal welding of longitudinal seam纵缝内侧焊接See welding procedure for details.详见焊接程序。1.10 External gouging of longitudinal seam 纵缝外侧打磨Before external welding, root gouging on external side, including all the tack welds and root welds,

16、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，彻底清除掉碳化层和其它有害物质。1.11 External welding of longitudinal seam纵缝外侧焊接See welding procedure for details.详见焊接程序。1.12 Tabs removal弧板移除Tabs shall be removed with flame cutting and ground smooth.用火

17、焰切割去除弧板并打磨光滑。1.13 Pipe reforming管材修整If the welded pipe, after self-inspection, needs to be corrected, reforming shall be performed to the prescribed radius. If the pipe is found acceptable by self-inspection, it can be submitted to inspection department for further inspection. Before reforming howev

18、er, 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，则需要对卷管进行整改以达到规定的半径。如果卷管自检合格，则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 shall not press too much in case

19、 the weld and base metals are damaged mechanically.说明：整改过程中，上滚轮不要过度加压以免焊缝和母材受到机械损伤。1.14 Visual, dimensional and tolerance inspection 外观、尺寸和误差检验1. Visual inspection of welds as“Specification 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

20、shall not exceed t/10 or 6mm whichever is less, however, mismatch in excess of 3mm is not 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，否则错皮不能超过3mm。在没有特别说

21、明的情况下，相临两段纵缝至少错开90度。3. 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

22、 roundness, which is defined as the difference of maximum and minimum outer 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 is lesser. For pipes of external diameter greater than 2000 mm, shall not exceed

23、15 mm.对于外管径小于等于2000毫米的钢管，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 65

24、0 mm, or 5mm when 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

25、of 12m shall not 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 ax

26、is 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 (1/4 in), measured with right angle square across the pipe end. 管的端部坡口要达到特定的要求，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 NDT 无损检验NDT inspect

27、ion 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。1.16 Defect repair of base metal 母材缺陷修复Each defect found in base metal shall been further detected to determine its area. For pipes that have be completed, the defects whose depth does not exceed 5 percent of

28、 nominal wall thickness and mechanical damage the 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 concave shall be smooth. The removal thickness shall

29、 not exceed 7 percent of nominal wall thickness, with the maximum 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 welding shall not be allowed for defects with depth exceed

30、ing 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)，则缺陷可以忽略。超过上述限制的缺陷

31、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%，则不允许修复焊接。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。1.17 Repair of weld defects 焊接缺陷修复Weld defects that are not allowed by the specification shall be dealt with. For specific operations suc

32、h as removal and repair of defects in internal and external welds, please see the corresponding welding procedures.规范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For requirements of pipe end beveling, please see item 7 of Section 1.14， Bevel shape and sizes are as follows: