CN112059374B - Tee joint product preparation method and prefabricated tee joint product - Google Patents
Tee joint product preparation method and prefabricated tee joint product Download PDFInfo
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- CN112059374B CN112059374B CN202010962466.5A CN202010962466A CN112059374B CN 112059374 B CN112059374 B CN 112059374B CN 202010962466 A CN202010962466 A CN 202010962466A CN 112059374 B CN112059374 B CN 112059374B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/18—Submerged-arc welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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Abstract
The invention belongs to the technical field of pipeline welding, and particularly relates to a tee joint product preparation method and a prefabricated tee joint product, aiming at solving the problem of difficult butt joint caused by unequal wall thicknesses in the prior art, wherein the tee joint product preparation method provided by the invention comprises the following steps: the method comprises the steps of preparing a tee product and sleeves, splicing the two sleeves with two ends of the tee product respectively, sequentially carrying out root welding, outer welding filling, capping, inner welding cleaning, polishing and capping on circumferential welding seams to obtain a prefabricated sleeve tee product, carrying out ultrasonic detection, X-ray detection, magnetic powder detection and tempering heat treatment on the circumferential welding seams of the prefabricated sleeve tee product, and carrying out pipe end groove machining, size detection, ultrasonic detection, integral magnetic powder detection, surface rust removal, anticorrosion identification and packaging on the prefabricated sleeve tee product for warehousing. The invention realizes factory prefabrication of circumferential weld joint welding between the three-way product and the sleeve, reduces the operation difficulty of a construction site, improves the construction safety of the pipeline and prolongs the service life of the pipeline.
Description
Technical Field
The invention belongs to the technical field of pipeline manufacturing, and particularly relates to a preparation method of a tee joint product and a prefabricated tee joint product.
Background
In recent years, high-pressure and large-output oil and gas pipelines are the development trend of long-distance pipelines in China, and with the start-up construction of important oil and gas transmission pipeline engineering at home and abroad, the market demand of large-diameter and thick-wall tee pipes is continuously increased. In the practical application process, the wall thickness of the tee product is much larger than that of the connecting pipeline, and the wall thickness problem of unequal wall thicknesses exists when the tee product and the connecting pipeline are in butt joint, so that the great difficulty is brought to the operation on the construction site, the on-site operation progress is seriously influenced, and meanwhile, the safety of the pipeline is also influenced to a great extent.
Disclosure of Invention
In order to solve the above problems in the prior art, that is, to solve the problem of difficult butt joint caused by unequal wall thickness between the tee product and the connecting pipeline in the prior art, the invention provides a method for preparing the tee product on one hand, which comprises the following steps:
step S100, preparing a three-way product and sleeves with preset sizes, wherein the wall thickness of each sleeve is the same as that of a connecting pipeline, and welding the two ends of the three-way product with splicing gaps of the two sleeves for the first time to obtain a first prefabricated sleeve three-way product;
step S200, performing second welding on the circumferential welding seam of the first prefabricated sleeve tee product to obtain a second prefabricated sleeve tee product, wherein the second welding comprises external welding filling and capping;
step S300, performing third welding on the circumferential welding seam to obtain a third prefabricated sleeve tee product, wherein the third welding is inner welding;
step S400, detecting circumferential welding seams of the third prefabricated sleeve tee product;
and S500, carrying out tempering heat treatment on the third prefabricated sleeve tee product to obtain a fourth prefabricated sleeve tee product.
In some preferred embodiments, the "first welding" in the step S100, the "second welding" in the step S200, and the "third welding" in the step S300 are performed by using a preformed welding wire, and the preformed welding wire includes, in mass%, in the total mass of the preformed welding wire:
C：0.03％-0.06％、Si：0.05％-0.256％、Mn：0.80％-1.40％、P：0％-0.015％、S：0％-0.010％、Ni：2.8％-3.8％、Cr：0.05％-0.10％、V：0.003％-0.008％、Mo：0.10％-0.50％、Ti：0.002％-0.006％、B：0％-0.0006％。
in some preferred embodiments, the method further comprises:
step S600, groove machining is carried out on the fourth prefabricated sleeve tee product, and the fourth prefabricated sleeve tee product is detected;
and S700, adding an anticorrosive mark after the surface of the fourth prefabricated sleeve tee product is subjected to rust removal treatment.
In some preferred embodiments, the detection in step S400 includes ultrasonic detection, X-ray detection, and magnetic particle detection.
In some preferred embodiments, the detection in step S600 includes size detection, ultrasonic detection, and magnetic particle detection.
In some preferred embodiments, the welding process of the first welding includes: and controlling the welding current, the arc voltage and the diameter of the filling material in the process parameters of the Nth welding layer to be larger than the process parameters of the (N-1) th welding layer, wherein N is a positive integer.
In some preferred embodiments, the welding process of the second welding includes: controlling welding current in process parameters of a first filled weld layerIs A1Arc voltage of U1A welding speed of V1(ii) a Controlling the welding current in the process parameters of the Mth filling welding layer to be A2Arc voltage of U2A welding speed of V2Wherein M is more than or equal to 2;
A1∈(480-30A，480+30A)、U1∈(30-2V，30+2V)、V1∈(550-30mm/min，550+30A mm/min)；
A2∈(520-30A，520+30A)、U2∈(32-2V，32+2V)、V2∈(500-30mm/min，500+30A mm/min)。
in some preferred technical solutions, the welding process of the second welding further includes controlling a process parameter of an outer welding cover surface, the process parameter of the outer welding cover surface is the same as the welding process parameter of the third welding, and the welding process of the third welding includes controlling a welding current to be a3Arc voltage of U3A welding speed of V3；
A3∈(520-30A，520+30A)、U3∈(32-2V，32+2V)、V3∈(450-30mm/min，450+30A mm/min)。
In some preferred embodiments, the length of the sleeve is L, L e (500mm, 2000 mm).
The invention provides a prefabricated tee product, which is the fourth prefabricated sleeve tee product prepared by the tee product preparation method based on any one of the above technical schemes.
The invention has the beneficial effects that:
the method for preparing the tee joint product realizes factory prefabrication of circumferential weld joint welding between the tee joint product and the sleeve (connecting pipe section), can effectively solve the problem of unequal wall thickness between the tee joint product and the connecting pipeline, is convenient for construction site operation, and improves the safety and the service life of the pipeline.
The lengths of the sleeves at two ends of the prefabricated sleeve tee product are respectively 500-2000 mm (straight pipe sections), and the wall thickness of the sleeves is the same as that of the connecting pipeline. The structural design can realize equal wall thickness butt joint of the sleeve and the connecting pipeline on one hand, and on the other hand can freely select the length dimension in the length direction of the sleeve according to the construction and installation requirements on the premise of ensuring the safety of a three-way product, thereby facilitating flexible installation of a construction site.
The special submerged arc welding wire, namely the prefabricated welding wire, designed by the invention can adapt to the service environment condition of the pipeline, ensure that the physical and chemical performance indexes of the product, such as the strength, toughness and hardness of the welding line meet the requirements of technical specifications, and realize the welding of the circumferential welding line between the three-way product and the sleeve.
The special welding equipment for the prefabricated sleeve tee joint can solve the problems that a pipe branch side of a prefabricated sleeve tee joint product has a large-degree unbalance loading due to irregular structural shape, and workpieces are uneven in rotation speed and jump up and down in the welding rotation process caused by the fact that sleeves at two ends of the tee joint are not parallel and concentric. Meanwhile, the roller of the carrier roller can increase the friction force between the workpiece and the rotating roller, so that the workpiece and the rotating roller are prevented from generating instant rapid displacement, and the influence of eccentric loading of the workpiece is eliminated.
Drawings
Other features, objects and advantages of the present application will become more apparent upon reading of the following detailed description of non-limiting embodiments thereof, made with reference to the accompanying drawings in which:
FIG. 1 is a flow chart of a method for making a three-way product according to an embodiment of the present invention;
FIG. 2 is a partial cross-sectional structural view of a prefabricated sleeve tee product and connecting lines in accordance with an embodiment of the present invention;
FIG. 3 is a schematic view of an overall structure of a welding apparatus for a prefabricated sleeve tee according to an embodiment of the present invention;
FIG. 4 is a schematic view of an overall structure of a welding apparatus for prefabricating a sleeve tee according to an embodiment of the present invention;
FIG. 5 is a first schematic structural diagram of a lift-type slewing mechanism according to an embodiment of the present invention;
FIG. 6 is a schematic structural diagram of a second embodiment of the swing-over-and-tilt mechanism of the present invention;
fig. 7 is a schematic view of an angle between a carrier roller wheel and a workpiece according to an embodiment of the present invention.
List of reference numerals:
100-a base; 200-lifting type swing mechanism, 210-cross universal coupling, 220-swing disc, 230-lifting slide plate and 240-bed head box body; 300-roller, 310-driving rotating roller and 320-driven rotating roller; 400-welding device, 410-welding head; 500-three-way products; 600-sleeve; 700-connecting the lines.
Detailed Description
In order to make the embodiments, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it is apparent that the described embodiments are some, but not all embodiments of the present invention. It should be understood by those skilled in the art that these embodiments are only for explaining the technical principle of the present invention, and are not intended to limit the scope of the present invention.
The invention provides a preparation method of a three-way product, which comprises the following steps:
step S100, preparing a three-way product and sleeves (connecting pipelines and straight pipe sections) with preset sizes, wherein the wall thickness of each sleeve is the same as that of each connecting pipeline, and welding the two ends of the three-way product with splicing gaps of the two sleeves for the first time respectively to obtain a first prefabricated sleeve three-way product;
step S200, performing second welding on the circumferential welding seam of the first prefabricated sleeve tee product to obtain a second prefabricated sleeve tee product, wherein the second welding comprises external welding filling and capping;
step S300, performing third welding on the circumferential welding seam to obtain a third prefabricated sleeve tee product, wherein the third welding is inner welding;
step S400, detecting circumferential welding seams of the third prefabricated sleeve tee product;
and S500, carrying out tempering heat treatment on the third prefabricated sleeve tee product to obtain a fourth prefabricated sleeve tee product.
On the other hand, the prefabricated tee product is a fourth prefabricated sleeve tee product prepared based on the tee product preparation method.
In order to more clearly explain the preparation method of the three-way product of the invention, a preferred embodiment of the invention is detailed below with reference to the accompanying drawings.
In order to effectively solve the problem of unequal wall thickness of a tee joint and a connecting pipeline and realize factory prefabrication of circumferential weld welding between the tee joint and a sleeve (connecting pipeline), as a preferred embodiment of the invention, a preparation method of a tee joint product disclosed by the invention is shown in figure 1 and comprises the following steps:
step S100, preparing a three-way product and sleeves with preset sizes, wherein the wall thickness of each sleeve is the same as that of a connecting pipeline, and welding the two ends of the three-way product and the splicing gaps of the two sleeves for the first time to obtain a first prefabricated sleeve three-way product. Specifically, the first weld is a root weld (SMAW). The tee product is the most concentrated part of stress in the pipeline, so the wall thickness of the tee product with the same bearing capacity is much larger than that of the connecting pipeline, the inner diameter of the tee product is consistent with that of the sleeve to be spliced, the axis of the tee product, the axis of the sleeve and the axis of the connecting pipeline are consistent, and the quality and the performance of circumferential welding seams among the tee product, the sleeve and the connecting pipeline are guaranteed through a subsequent welding process to ensure the safety and the service life of a finished product.
The three-way product and the sleeve with preset sizes are preferably X80 steel grade steel, namely the steel with the minimum yield value of 552 Mpa; nominal internal diameter is DN1500 and below, wall thickness is not more than 70mm, and lowest service temperature is not lower than-45 ℃. Specifically, it can be understood by those skilled in the art that preset product values of dimension parameters such as length, width, thickness, etc. need to be set according to the size of the tee-joint product to be processed and the finished product size of the sleeve, and the tee-joint product and the sleeve of different dimensions need to use steel plates of different dimensions, and the length L of the sleeve in this embodiment is equal to or greater than 500mm, and L ∈ (500mm, 2000mm), it should be noted that if the length L of the sleeve is less than 500mm, the quality of the circumferential weld joint is limited, and the safety cannot be ensured, if the length L of the sleeve is greater than 2000mm, the transportation difficulty is increased, and the factory production and manufacturing capability is limited, therefore, in this embodiment, the length of the sleeve is preferably in the range of 500mm to 2000mm, and the wall thickness of the sleeve is the same as that of the connecting pipeline, the structural design can realize effective butt joint of the sleeve with the wall thickness of the connecting pipeline on the one hand, and on the other hand, on the premise of ensuring the safety of the tee-joint product, the length dimension can be freely selected in the length direction of the sleeve according to the construction and installation requirements, and flexible installation on a construction site is facilitated. Other dimensions of the present invention are not limited and will not be described in detail herein.
And S200, performing second welding on the circumferential welding seam of the first prefabricated sleeve tee product to obtain a second prefabricated sleeve tee product, wherein the second welding is outer welding and specifically comprises outer welding filling and cover Surface (SAW).
Step S300, carrying out third welding on the three-way product and the sleeve circumferential welding seam to obtain a third prefabricated sleeve three-way product; specifically, before the third welding, circumferential weld joints need to be subjected to inner welding cleaning and polishing, then the third welding is carried out, the third welding is inner welding, and the main process is inner welding capping;
s400, detecting the circumferential weld of a third prefabricated sleeve tee product; in some preferred embodiments, the testing of the circumferential weld includes ultrasonic testing, X-ray testing, magnetic particle testing. And if the circumferential weld joint detection is qualified, continuing to perform the step S500, if the circumferential weld joint detection is unqualified, performing repair and repair welding, and after the repair and repair welding is completed, continuing to perform the circumferential weld joint detection. It is to be understood that the repair and repair welding may be performed using common general knowledge and will not be described herein.
And S500, performing tempering heat treatment on the third prefabricated sleeve tee product to obtain a fourth prefabricated sleeve tee product. Specifically, the process parameters of the tempering heat treatment may be performed with reference to a conventional heat treatment process.
Further, the preparation method of the three-way product of the invention also comprises the following steps: step S600, groove machining is carried out on a fourth prefabricated sleeve tee product, and the fourth prefabricated sleeve tee product is detected; specifically, it is used for detecting whole fourth prefabricated sleeve tee bend product, and the content of software testing includes size detection, ultrasonic detection, magnetic particle testing.
Step S700, adding an anticorrosive mark after the surface of the fourth prefabricated sleeve tee product is subjected to rust removal treatment;
and step S800, packaging and warehousing the fourth prefabricated sleeve tee product.
It can be understood that the first pre-sleeve tee product, the second pre-sleeve tee product, the third pre-sleeve tee product and the fourth pre-sleeve tee product in the above tee product manufacturing method can be collectively referred to as pre-sleeve tee products, the structure of which can be referred to as fig. 2, fig. 2 is a partial cross-sectional view of the pre-sleeve tee product and the connecting pipeline when the pre-sleeve tee product is connected, and the above four products have no difference in structure, and the terms "first", "second", "third" and "fourth" should be broadly understood, and are only used for distinguishing staged products generated by process steps in the manufacturing method, and are only used for descriptive purposes, but not for indicating or implying relative importance.
In order to be capable of adapting to the service environment condition of the pipeline and ensure that the physical and chemical performance indexes of the prefabricated sleeve tee joint product, such as the strength, the toughness, the hardness and the like, meet the technical specification requirement. In the present invention, "first welding" in step S100, "second welding" in step S200, and "third welding" in step S300 are all performed by using a preformed welding wire, specifically, the preformed welding wire has the following composition: by mass, C: 0.03% -0.06%, Si: 0.05% -0.256%, Mn: 0.80% -1.40%, P: 0% -0.015%, S: 0% -0.010%, Ni: 2.8% -3.8%, Cr: 0.05% -0.10%, V: 0.003% -0.008% of Mo: 0.10% -0.50%, Ti: 0.002% -0.006%, B: 0% -0.0006%. The component design effectively ensures that the impact energy of a welding line and a heat affected zone at minus 45 ℃ is not less than 50J, the tensile strength of the welding line is not less than 625MPa, and the hardness of the welding line is not more than 280HV 10.
Meanwhile, the welding is performed by adopting the above prefabricated welding wire and adopting the process of manual arc welding and submerged automatic arc welding (SMAW + SAW), and the welding process is shown in Table 1. The impact energy of the welding seam and the heat affected zone at the temperature of minus 45 ℃ is not less than 50J, the tensile strength of the welding seam is not less than 625MPa, the hardness of the welding seam is not more than 280HV10, and other properties meet the requirements of relevant technical specifications.
In some preferred embodiments, the welding process of the first weld is root welding, which includes a welding process: and controlling the welding current, the arc voltage and the diameter of the filling material in the process parameters of the Nth welding layer to be larger than the process parameters of the (N-1) th welding layer, wherein N is a positive integer. For example, when N is 2, the welding process of the first welding needs to control the welding current, the arc voltage and the diameter of the filling material in the process parameters of the second root welding layer to be larger than those of the first root welding layer, and in a preferred embodiment of the invention, the process parameters of the first root welding layer in the welding process of the first welding include controlling the welding current to be between 110A and 130A, controlling the arc voltage to be between 22V and 26V and selecting the diameter of the filling material to be 3.2 mm. Preferably, the filler material is type C.
In other preferred embodiments, the welding process of the second welding comprises: controlling the welding current in the process parameters of the first filling welding layer to be A1Arc voltage of U1A welding speed of V1(ii) a Controlling the welding current in the process parameters of the Mth filling welding layer to be A2Arc voltage of U2A welding speed of V2Wherein M is more than or equal to 2; i.e. to control the process parameters of the second and above layers of solder. A. the1∈(480-30A，480+30A)、U1∈(30-2V，30+2V)、V1∈(550-30mm/min，550+30A mm/min)；A2∈(520-30A，520+30A)、U2∈(32-2V，32+2V)、V2∈(500-30mm/min，500+30A mm/min)。
Preferably, the welding process of the second welding further comprises controlling the technological parameters of the outer welding cover surface, the technological parameters of the outer welding cover surface are the same as the welding technological parameters of the third welding, and the welding process of the third welding comprises controlling the welding current to be A3Arc voltage of U3A welding speed of V3；A3∈(520-30A，520+30A)、U3∈(32-2V，32+2V)、V3∈(450-30mm/min，450+30A mm/min)。
Specifically, the welding process in the method for preparing the three-way product of the invention is shown in table 1.
TABLE 1
As can be seen from table 1, the welding process in the method for preparing a three-way product of the present invention has other technical requirements, including: controlling the interlayer temperature to be 80-250 ℃ in the welding process; controlling the elongation of the welding wire not to be larger than 80 mm; the drying temperature of the welding rod and the welding flux is 340-; before internal welding, defects such as welding beading, air holes, undercut and the like are removed by adopting a grinding mode, and if necessary, a gouging mode can be used for removing the defects.
The lowest service environment temperature of the prefabricated sleeve tee product (fourth prefabricated sleeve tee product) prepared by the method for preparing the tee product is-45 ℃, the impact energy of a welding line and a heat affected zone is not less than 50J, the tensile strength of the welding line is not lower than 625MPa, the hardness of the welding line is not more than 280HV10, and other physical and chemical properties can meet the requirements of related technical specifications.
The invention also provides a prefabricated tee product, namely a fourth prefabricated sleeve tee product prepared by the tee product preparation method. Since the manufacturing method is disclosed in the above embodiment, the same advantages as above are provided, and no further description is provided herein, further, the weld joint welding quality of the finished product (fourth pre-sleeve tee product) prepared by the present invention can meet the NB/T47013 2015 specification requirements, the X-ray detection level is not lower than two levels, and the ultrasonic detection and magnetic particle detection levels are not lower than one level.
The prefabricated sleeve tee product provided by the invention has the advantages that the unique structural size can ensure the applicability of the product in a construction site, meanwhile, a tee product preparation method is provided for preparing the prefabricated sleeve tee product, a special submerged arc welding wire for circumferential weld seam welding of the prefabricated sleeve tee product is designed, all properties of the weld seam can meet the requirements of relevant technical specifications, the safety and the reliability of the prefabricated sleeve tee product are ensured, in addition, special welding equipment for the circumferential weld seam of the prefabricated sleeve tee is also designed, and the automatic submerged arc welding of the circumferential weld seam is realized.
On the other hand, the prefabricated sleeve tee product has irregular structural shape: (1) the branch side of the branch pipe has large-degree unbalance loading; (2) the sleeve pipes at the two ends of the three-way product are not parallel and concentric. Meanwhile, during the welding and rotating process of the workpiece (three-way product, sleeve or prefabricated sleeve three-way product), the problems of uneven rotating speed, vertical jumping of the workpiece and the like inevitably exist. The invention provides special welding equipment for prefabricating sleeve tee joints, which comprises a base 100, a lifting type slewing mechanism 200, a carrier roller 300, a welding device 400 and the like, and is shown in figure 3. Specifically, the elevating rotation mechanism 200 is disposed at one end of the base 100 for fixing one end of the pre-manufactured sleeve tee product, and the roller 300 is movably disposed above the base. Specifically, in the preferred embodiment of the present invention, the base 100 is provided with a track, and the two idler rollers 300 form a group, and in the preferred embodiment of the present invention, the base 100 is provided with two groups of idler rollers, that is, four groups of idler rollers, which are spaced apart from each other and uniformly distributed on the base 100 for supporting the workpiece, it can be understood that the number of the groups of idler rollers of the present invention can be flexibly set according to the length or size of the workpiece, for example, the groups can be set as one group, two groups, three groups, etc., and meanwhile, the distribution of the idler rollers should avoid interfering with the rotation of the three-way product (the branch pipe is easily interfered when rotating). An embodiment of bearing roller running roller is for only including the running roller in this application, and another embodiment is for including running roller and running roller strutting arrangement, in the drawing of this application schematic, adopts the second kind of embodiment, and the bearing roller running roller includes running roller and running roller strutting arrangement promptly, and the running roller is installed in running roller strutting arrangement's top and has around self axis pivoted degree of freedom, and the axis of running roller is on a parallel with the setting of base 100.
Taking a group of idler rollers as an example, referring to the attached drawings, two idler rollers in a group are respectively a driving rotary roller 310 and a driven rotary roller 320, the driving rotary roller 310 and the driven rotary roller 320 are respectively disposed at two sides of a workpiece, an axis distance between the driving rotary roller 310 and the driven rotary roller 320 is L, a vertical distance between a main tube axis of a three-way product and an axis of the roller is h, that is, a minimum distance (vertical distance) from a connecting line between the axes of the driving rotary roller 310 and the driven rotary roller 320 to the main tube axis of the three-way product is h, L/h is 2tan α, and α is (50 °, 75 °). That is, the angle between the driving rotary roller 310 and the driven rotary roller 320 and the center of the workpiece 500 is θ, θ is 2 α, and θ is (100 ° and 150 °). This structural design can increase the frictional force between work piece and the rotatory running roller, prevents to produce quick displacement in the twinkling of an eye between work piece and the rotatory running roller to can eliminate the influence of work piece unbalance loading. Further, when θ is smaller than 100 °, the workpiece and the rotating roller are unstable, and when θ is larger than 150 °, the friction between the workpiece and the rotating roller is too large, which easily causes wear.
When the roller is not in operation, the driving rotary roller 310 and the driven rotary roller 320 are used to support the three-way product, so that the two ends of the three-way product are located on the same horizontal plane to keep balance and stability. The axis of the driving rotary roller 310 is parallel to the axis of the workpiece, when the carrier roller is in a working state, the driving rotary roller 310 rotates around the axis of the driving rotary roller, the driving rotary roller can drive the workpiece to rotate passively, and then the driven rotary roller 320 rotates passively, so that the position of the welding seam of the workpiece is adjusted in an auxiliary mode. The idler roller 300 further comprises a driving mechanism, the driving rotary roller 310 rotates around the axis of the driving mechanism, and the rotation angle of the workpiece can be accurately controlled by controlling the rotation period or the arc length of the driving rotary roller 310. Preferably, the driving mechanism is a high-precision motor reducer, the transmission precision of the reducer is high, and the return error of the gear is not more than 40 arc minutes. The mechanism design can ensure that the speed of the workpiece is uniform when the workpiece rotates at any position, and the influence on welding cannot be generated.
Welding set 400 sets up in one side of base 100, and welding set 400 can walk along the orbital extending direction of base 100, and welding set 400 can walk along the length direction of prefabricated sleeve tee bend product promptly to carry out the welding of sleeve and tee bend product hoop welding seam through welded joint 410.
Specifically, the lifting type swing mechanism 200 is mainly used for limiting axial spiral movement of the prefabricated sleeve tee product in the welding rotation process, and ensuring that the welding seam offset meets the welding process requirement. The elevating swing mechanism 200 comprises a cross universal coupling 210, a swing disc 220, an elevating slide plate 230 and a bed head box 240; the rotary disc 220 is provided with a plurality of fixing members, the fixing members are uniformly arranged on the periphery of the rotary disc 220 along the circumferential direction, the fixing members are movably arranged on the rotary disc 220 so as to be suitable for workpieces with different pipe diameters, and the fixing members on the rotary disc 220 are used for fixing one end of a prefabricated sleeve tee product. Further, the rotary disk 220 is mounted on the bed head box 240 through the lifting slide plate 230, and the lifting slide plate 230 is used for adjusting the height of the rotary disk 220, so that the rotary disk can be suitable for workpieces with different pipe diameters. The axial direction and the radial direction of the lifting rotary mechanism 200 can be automatically adjusted, thereby eliminating the problem that the sleeves 600 at the two ends of the three-way product 500 are not concentric and parallel. The special welding equipment for the prefabricated sleeve tee joint further comprises a controller, and the controller can be in communication connection with the carrier roller, the cross universal coupling and the lifting sliding plate through communication links respectively.
The following describes in detail a specific embodiment of a method for manufacturing a tee joint product based on the above-described welding equipment dedicated for prefabricating sleeve and tee joints of the present invention:
step S100, preparing a three-way product 500 and sleeves 600 with preset sizes, wherein the wall thickness of each sleeve 600 is the same as that of a connecting pipeline 700, and welding the two ends of the three-way product 500 with the splicing gaps of the two sleeves 600 for the first time to obtain a first prefabricated sleeve three-way product; the first weld specific weld process parameters are referenced in table 1.
Step S200, arranging the first prefabricated sleeve tee product on the special welding equipment for the prefabricated sleeve tee, so that the fixing claws on the rotary disc 220 fix the first pre-manufactured sleeve tee product, and the circumferential weld seam of the first pre-manufactured sleeve tee product is welded for the second time, specifically, by controlling the active rotation roller 310 to rotate around its own axis, the rotary disc 220 is driven by the first pre-sleeve tee product to rotate passively through the cross universal joint 210, so as to complete the second welding to the circumferential welding seam, and drive the traveling mechanism of the welding device 400 to travel, so that the welding head 410 can weld two circumferential welds of the pre-manufactured sleeve tee product, and obtaining a second prefabricated sleeve tee product, further, welding for the second time comprises outer welding filling and capping, and the specific welding process parameters refer to table 1 and are not described herein again.
Step S300, similarly, performing third welding on the circumferential welding seam by controlling the special welding equipment for the prefabricated sleeve tee joint according to the operation method to obtain a third prefabricated sleeve tee joint product, wherein the third welding is inner welding, and the technological parameters can refer to figure 1;
s400, detecting the circumferential weld of a third prefabricated sleeve tee product; in some preferred embodiments, the testing of the circumferential weld includes ultrasonic testing, X-ray testing, magnetic particle testing.
And S500, performing tempering heat treatment on the third prefabricated sleeve tee product to obtain a fourth prefabricated sleeve tee product. Specifically, the process parameters of the tempering heat treatment may be performed with reference to a conventional heat treatment process.
Step S600, groove machining is carried out on a fourth prefabricated sleeve tee product, and the fourth prefabricated sleeve tee product is detected; specifically, it is used for detecting whole fourth prefabricated sleeve tee bend product, and the content of software testing includes size detection, ultrasonic detection, magnetic particle testing.
Step S700, adding an anticorrosive mark after the surface of the fourth prefabricated sleeve tee product is subjected to rust removal treatment;
and step S800, packaging and warehousing the fourth prefabricated sleeve tee product.
In the technical solution in the embodiment of the present application, at least the following technical effects and advantages are provided:
the method for preparing the tee joint product realizes factory prefabrication of circumferential weld joint welding between the tee joint product and the sleeve (connecting pipe section), can effectively solve the problem of unequal wall thickness between the tee joint product and the connecting pipeline, is convenient for construction site operation, and improves the safety and the service life of the pipeline.
The lengths of the sleeves at two ends of the prefabricated sleeve tee product are respectively 500-2000 mm (straight pipe sections), and the wall thickness of the sleeves is the same as that of the connecting pipeline. The structural design can realize equal wall thickness butt joint of the sleeve and the connecting pipeline on one hand, and on the other hand can freely select the length dimension in the length direction of the sleeve according to the construction and installation requirements on the premise of ensuring the safety of a three-way product, thereby facilitating flexible installation of a construction site.
The special submerged arc welding wire, namely the prefabricated welding wire, designed by the invention can adapt to the service environment condition of the pipeline, ensure that the physical and chemical performance indexes of the product, such as the strength, toughness and hardness of the welding line meet the requirements of technical specifications, and realize the welding of the circumferential welding line between the three-way product and the sleeve.
The special welding equipment for the prefabricated sleeve tee joint can solve the problems that a pipe branch side of a prefabricated sleeve tee joint product has a large-degree unbalance loading due to irregular structural shape, and workpieces are uneven in rotation speed and jump up and down in the welding rotation process caused by the fact that sleeves at two ends of the tee joint are not parallel and concentric. Meanwhile, the roller of the carrier roller can increase the friction force between the workpiece and the rotating roller, so that the workpiece and the rotating roller are prevented from generating instant rapid displacement, and the influence of eccentric loading of the workpiece is eliminated.
It should be noted that in the description of the present invention, the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. indicating the directions or positional relationships are based on the directions or positional relationships shown in the drawings, which are only for convenience of description, and do not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
Furthermore, it should be noted that, in the description of the present invention, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
The terms "comprises," "comprising," or any other similar term are intended to cover a non-exclusive inclusion, such that a process, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, article, or apparatus.
So far, the technical solutions of the present invention have been described in connection with the preferred embodiments shown in the drawings, but it is easily understood by those skilled in the art that the scope of the present invention is obviously not limited to these specific embodiments. Equivalent changes or substitutions of related technical features can be made by those skilled in the art without departing from the principle of the invention, and the technical scheme after the changes or substitutions can fall into the protection scope of the invention.
Claims (9)
1. A preparation method of a three-way product is characterized by comprising the following steps:
step S100, preparing a three-way product and sleeves with preset sizes, wherein the wall thickness of each sleeve is the same as that of a connecting pipeline, and welding the two ends of the three-way product with splicing gaps of the two sleeves for the first time to obtain a first prefabricated sleeve three-way product;
step S200, performing second welding on the circumferential welding seam of the first prefabricated sleeve tee product to obtain a second prefabricated sleeve tee product, wherein the second welding comprises external welding filling and capping;
step S300, performing third welding on the circumferential welding seam to obtain a third prefabricated sleeve tee product, wherein the third welding is inner welding;
step S400, detecting circumferential welding seams of the third prefabricated sleeve tee product;
step S500, carrying out tempering heat treatment on the third prefabricated sleeve tee product to obtain a fourth prefabricated sleeve tee product;
step S600, groove machining is carried out on the fourth prefabricated sleeve tee product, and the fourth prefabricated sleeve tee product is detected;
and S700, adding an anticorrosive mark after the surface of the fourth prefabricated sleeve tee product is subjected to rust removal treatment.
2. The method for manufacturing a three-way product according to claim 1, wherein the "first welding" in the step S100, the "second welding" in the step S200, and the "third welding" in the step S300 are performed by a preformed welding wire, and the preformed welding wire comprises, in mass%, in the total mass of the preformed welding wire:
C：0.03％-0.06％、Si：0.05％-0.256％、Mn：0.80％-1.40％、P：0％-0.015％、S：0％-0.010％、Ni：2.8％-3.8％、Cr：0.05％-0.10％、V：0.003％-0.008％、Mo：0.10％-0.50％、Ti：0.002％-0.006％、B：0％-0.0006％。
3. the method for manufacturing a three-way product according to claim 1, wherein the inspection in step S400 includes ultrasonic inspection, X-ray inspection, and magnetic particle inspection.
4. The method for manufacturing a three-way product according to claim 2, wherein the inspection in step S600 comprises size inspection, ultrasonic inspection, and magnetic particle inspection.
5. The method for manufacturing a three-way product according to claim 1, wherein the welding process of the first welding comprises: and controlling the welding current, the arc voltage and the diameter of the filling material in the process parameters of the Nth welding layer to be larger than the process parameters of the (N-1) th welding layer, wherein N is a positive integer.
6. The method for manufacturing a three-way product according to claim 1, wherein the welding process of the second welding comprises: controlling the welding current in the process parameters of the first filling welding layer to be A1Arc voltage of U1A welding speed of V1(ii) a Controlling the welding current in the process parameters of the Mth filling welding layer to be A2Arc voltage of U2A welding speed of V2Wherein M is more than or equal to 2;
A1∈(480-30A，480+30A)、U1∈(30-2V，30+2V)、V1∈(550-30mm/min，550+30A mm/min)；
A2∈(520-30A，520+30A)、U2∈(32-2V，32+2V)、V2∈(500-30mm/min，500+30A mm/min)。
7. the method for manufacturing a three-way product according to claim 6, wherein the welding process of the second welding further comprises controlling the process parameters of the outer welding cap surface, the process parameters of the outer welding cap surface are the same as the welding process parameters of the third welding, and the welding process of the third welding comprises controlling the welding current to be A3Arc voltage of U3A welding speed of V3；
A3∈(520-30A，520+30A)、U3∈(32-2V，32+2V)、V3∈(450-30mm/min，450+30A mm/min)。
8. The method of claim 1, wherein the length of said sleeve is L, L e (500mm, 2000 mm).
9. A prefabricated tee product, characterized in that the prefabricated tee product is the fourth prefabricated sleeve tee product prepared based on the tee product preparation method of any one of claims 1-8.
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