WO2023231407A1 - Cb2 cast steel part operation state supervision and management method - Google Patents
Cb2 cast steel part operation state supervision and management method Download PDFInfo
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- 238000007726 management method Methods 0.000 title claims abstract description 18
- 229910001208 Crucible steel Inorganic materials 0.000 title abstract description 7
- 238000007689 inspection Methods 0.000 claims abstract description 87
- 238000003466 welding Methods 0.000 claims abstract description 77
- 238000000034 method Methods 0.000 claims abstract description 39
- 230000032683 aging Effects 0.000 claims abstract description 36
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- 238000009434 installation Methods 0.000 claims description 8
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- 238000005259 measurement Methods 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
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- 150000002739 metals Chemical class 0.000 claims description 2
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- 238000004321 preservation Methods 0.000 claims description 2
- 238000007542 hardness measurement Methods 0.000 claims 1
- 238000010438 heat treatment Methods 0.000 description 5
- 239000006249 magnetic particle Substances 0.000 description 3
- 238000012544 monitoring process Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 229910000734 martensite Inorganic materials 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000013098 chemical test method Methods 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
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- 238000005516 engineering process Methods 0.000 description 1
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- 150000001247 metal acetylides Chemical class 0.000 description 1
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
- G06Q10/063—Operations research, analysis or management
- G06Q10/0639—Performance analysis of employees; Performance analysis of enterprise or organisation operations
- G06Q10/06395—Quality analysis or management
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/20—Administration of product repair or maintenance
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q50/00—Systems or methods specially adapted for specific business sectors, e.g. utilities or tourism
- G06Q50/04—Manufacturing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Definitions
- This application belongs to the technical field of operation supervision and management, and relates to a method for supervision and management of the operation status of CB2 steel castings.
- 620°C units 620°C high-efficiency ultra-supercritical units
- the currently widely used improved martensitic heat-resistant steel can no longer meet the needs of important components such as the intermediate pressure cylinder, main steam/reheat valve housing, etc. Therefore, new CB2 steel with better performance must be used to manufacture castings such as medium-pressure cylinders and main steam/reheat valve housings.
- CB2 cast steel is a new material developed abroad and is mainly used in my country's 620°C high-efficiency ultra-supercritical units.
- the application is in its infancy.
- It is urgent to propose a set of The effective CB2 steel casting operation supervision and management method enables comprehensive control of the safety and quality of high-temperature steam turbine steel castings, fundamentally eliminates the risk of operational safety accidents of steam turbine steel castings, and ensures the operational safety of ultra-supercritical units.
- the purpose of this application is to overcome the shortcomings of the above-mentioned prior art and provide a method for supervising and managing the operating status of CB2 steel castings, which can comprehensively control the safety and quality of CB2 steel castings.
- the CB2 steel casting operating status supervision and management method described in this application includes the following steps:
- step 1) publish the audit results to the central control computers in other production workshops through the LAN.
- step 3 the detection and aging rating results are entered into the handheld terminal, and then released to the central control computer in each production workshop through the local area network.
- step 1) The specific operations of step 1) are:
- step 11) The specific operations of step 11) are: conduct macro inspection, wall thickness measurement, non-destructive testing, hardness test and metallographic inspection of the CB2 steel castings entering the factory.
- the inspection of welding quality in step 2) includes pre-weld inspection and verification, inspection, inspection process supervision, welding quality verification and verification, and witnessing the repair of unqualified welds.
- step 3 the specific operations for inspecting the welding quality and aging rating of running CB2 steel castings are:
- the specific process of metallographic structure aging rating includes:
- the CB2 steel casting operation status supervision and management method described in this application will supervise and control the incoming quality, installation and operation quality of CB2 steel castings, and timely discover and eliminate various types of quality problems during installation and operation. Defects and safety hazards, ensure the reliable quality of CB2 steel castings when they enter the factory and are in service, fundamentally eliminate the occurrence of safety accidents, ensure the safe operation of steam turbine steel castings of ultra-supercritical units under high temperature and high pressure, and realize the control of CB2 steel castings Comprehensive control of the safety and quality of parts.
- Figure 1 is a flow chart of this application.
- FIG. 1 A schematic structural diagram of an embodiment disclosed in the present application is shown in the accompanying drawings.
- the drawings are not drawn to scale, with certain details exaggerated and may have been omitted for purposes of clarity.
- the shapes of the various regions and layers shown in the figures and the relative sizes and positional relationships between them are only exemplary. In practice, there may be deviations due to manufacturing tolerances or technical limitations, and those skilled in the art will base their judgment on actual situations. Additional regions/layers with different shapes, sizes, and relative positions can be designed as needed.
- the CB2 steel casting operating status supervision and management method described in this application includes the following steps:
- step 1) The specific operations of step 1) are:
- step 11) The specific operations of step 11) are: conduct macro inspection, wall thickness measurement, non-destructive testing, hardness test and metallographic inspection of the CB2 steel castings entering the factory.
- the inspection of welding quality in step 2) includes pre-weld inspection and verification, inspection, inspection process supervision, welding quality verification and verification, and witnessing the repair of unqualified welds.
- Supervise welding quality through on-site inspection and video inspection of the welding process including: 21) Inspection of welding process documents before installation and welding, verification of welder welding proficiency, verification of welding material library and welding equipment proficiency; 22) Certification of on-site personnel inspection and review of conditions, welding consumables recycling records, drying and insulation conditions, welding environment, equipment and process parameters; 23) Inspection and supervision of the weld quality inspection process; 24) Welding quality inspection and verification; 25) Witness the repair of defective welds.
- step 3 the specific operations for inspecting the welding quality and aging rating of running CB2 steel castings are:
- Metallographic structure aging rating includes: 311) Metallographic structure aging rating; 312) Aging Organize, supervise operations and handle measures.
- the inspection content includes: 11) macroscopic inspection; 12) spectrum test; 13) wall thickness measurement; 14) non-destructive testing; 15) hardness test; 16) metallographic inspection, etc. Focus on the gate, riser, section mutation and bolt inner hole wall, etc.
- the acceptance review documents include: 21) product quality certificate, 22) commodity inspection certificate of imported steel castings, 23) technical data (including: drawings, material grades, billet manufacturers, chemical Composition, billet smelting, casting and heat treatment process, mechanical properties, metallographic structure, non-destructive testing, repair welding and heat treatment records, etc.).
- Inspection and verification before welding include:
- the verification content includes: 2a) personnel qualifications, such as welder certificates, heat treatment, non-destructive personnel and physical and chemical personnel certificates; 2b) welder pre-job practice and welding ability examination records.
- Welding material library and welding equipment proficiency verification includes: 3a) Calibration records and validity periods of production equipment and instruments such as electric welding machines, heat treatment heating elements, thermocouples, compensation wires, temperature control cabinets, and thermometers; 3b ) Calibration certificates and validity periods of non-destructive testing equipment and physical and chemical testing instruments; 3c) Welding material warehouse management system, welding material warehouse thermometer and hygrometer monitoring records, welding material quality certificates and re-inspection reports, and welding material barrel receipt records .
- 3a) Calibration records and validity periods of production equipment and instruments such as electric welding machines, heat treatment heating elements, thermocouples, compensation wires, temperature control cabinets, and thermometers
- 3b Calibration certificates and validity periods of non-destructive testing equipment and physical and chemical testing instruments
- 3c) Welding material warehouse management system, welding material warehouse thermometer and hygrometer monitoring records, welding material quality certificates and re-inspection reports, and welding material barrel receipt records includes: 3a) Calibration records
- welding quality inspection and verification includes: 41) Weld appearance quality inspection; 42) Weld quality spot inspection, including: 4a) Spectral testing; 4b) Non-destructive testing; 4c) Hardness and metallographic inspection;
- Verification of weld quality after repair 5a) non-destructive testing of welds; 5b) hardness test; c) metallographic inspection.
- Metallographic structure aging rating including:
- the aging rating is carried out by comprehensively considering the evolution of the lath structure of the martensitic structure of the CB2 steel and the distribution of carbides in different areas. It is divided into two categories from the original state to complete aging. Level 5 refers to aging levels 1 to 5 respectively.
Abstract
The present application discloses a CB2 cast steel part operation state supervision and management method, comprising the following steps: 1) carrying out quality inspection on a CB2 cast steel part entering the factory, inputting the inspection result into a central control machine, and then publishing the inspection result to central control machines of other production workshops; 2) performing reinspection according to the quality inspection result input into the central control machine, carrying out welding treatment on the CB2 cast steel part which meets standards after being reinspected, inspecting the welding quality, inputting the inspection result of the welding quality into the central control machine, and then sending the inspection result to the central control machines of the other production workshops; at the same time, acquiring video information in the welding process, and then sending the video information to the central control machines of the other production workshops; and 3) regularly inspecting the welding quality of the operating CB2 cast steel part and performing aging rating, inputting the inspection and aging rating results into a handheld terminal, and then publishing the inspection and aging rating results to the central control machine of each production workshop. According to the method, the safety quality of the CB2 cast steel part can be comprehensively managed and controlled.
Description
相关申请的交叉引用Cross-references to related applications
本申请要求在2022年5月30日提交中国国家知识产权局、申请号为202210602660.1、发明名称为“一种CB2铸钢件运行状态监督管理方法”的中国专利申请的优先权，其全部内容通过引用的方式并入本文中。This application requires the priority of a Chinese patent application submitted to the State Intellectual Property Office of China on May 30, 2022, with the application number 202210602660.1 and the invention title "A method for supervising and managing the operating status of CB2 steel castings". All its contents have been approved. Incorporated herein by reference.
本申请属于运行监督管理技术领域，涉及一种CB2铸钢件运行状态监督管理方法。This application belongs to the technical field of operation supervision and management, and relates to a method for supervision and management of the operation status of CB2 steel castings.
为进一步提高火电机组的热效率、降低发电煤耗、节能减排，我国自2013年以来大力发展、建设620℃高效超超临界机组(以下简称“620℃机组”)。对于620℃机组，由于汽轮机中压缸的蒸汽温度从600℃提高至620℃，目前广泛应用的改良型马氏体耐热钢已无法满足中压缸、主汽/再热阀壳等重要部件的服役要求，由此必须采用性能更优的新型CB2钢制造中压缸、主汽/再热阀壳等铸件。CB2铸钢属于国外开发的新材料，且主要在我国620℃高效超超临界机组上应用，应用处于初级阶段，对于机组投运后CB2铸钢件的运行监督管理缺乏经验，亟需提出一套行之有效的CB2铸钢件运行监督管理方法，从而使汽轮机高温铸钢件安全质量得到全面管控，在根本上消除汽轮机铸钢件的运行安全事故风险，保证超超临界机组的运行安全性。In order to further improve the thermal efficiency of thermal power units, reduce coal consumption for power generation, save energy and reduce emissions, my country has vigorously developed and constructed 620°C high-efficiency ultra-supercritical units (hereinafter referred to as "620°C units") since 2013. For 620°C units, as the steam temperature of the turbine intermediate pressure cylinder increases from 600°C to 620°C, the currently widely used improved martensitic heat-resistant steel can no longer meet the needs of important components such as the intermediate pressure cylinder, main steam/reheat valve housing, etc. Therefore, new CB2 steel with better performance must be used to manufacture castings such as medium-pressure cylinders and main steam/reheat valve housings. CB2 cast steel is a new material developed abroad and is mainly used in my country's 620°C high-efficiency ultra-supercritical units. The application is in its infancy. There is a lack of experience in the operation supervision and management of CB2 steel castings after the unit is put into operation. It is urgent to propose a set of The effective CB2 steel casting operation supervision and management method enables comprehensive control of the safety and quality of high-temperature steam turbine steel castings, fundamentally eliminates the risk of operational safety accidents of steam turbine steel castings, and ensures the operational safety of ultra-supercritical units.
因此，如何提供一种能够解决上述问题的CB2铸钢件运行监督管理方法是本领域技术人员亟需解决的问题。Therefore, how to provide a CB2 steel casting operation supervision and management method that can solve the above problems is an urgent problem that those skilled in the art need to solve.
发明内容Contents of the invention
本申请的目的在于克服上述现有技术的缺点，提供了一种CB2铸钢件运行状态监督管理方法，该方法能够对CB2铸钢件的安全质量进行全面管 控。The purpose of this application is to overcome the shortcomings of the above-mentioned prior art and provide a method for supervising and managing the operating status of CB2 steel castings, which can comprehensively control the safety and quality of CB2 steel castings.
为达到上述目的，本申请所述的CB2铸钢件运行状态监督管理方法包括以下步骤：In order to achieve the above purpose, the CB2 steel casting operating status supervision and management method described in this application includes the following steps:
1)对入厂的CB2铸钢件进行质量检验，并将审核结果录入至中控机中，再发布至其他生产车间的中控机中；1) Conduct quality inspection on the CB2 steel castings entering the factory, enter the audit results into the central control computer, and then publish them to the central control computers in other production workshops;
2)对录入中控机的质量检验结果进行复核，对复核合格后的CB2铸钢件进行焊接处理，并对焊接质量进行检测，再将焊接质量的检测结果输入到中控机中，然后发送至其他生产车间的中控机中；与此同时，采集焊接过程中的视频信息，然后发送至其他生产车间的中控机中；2) Review the quality inspection results entered into the central control machine, weld the CB2 steel castings that have passed the review, and test the welding quality. Then input the welding quality test results into the central control machine and then send them. to the central control computers in other production workshops; at the same time, the video information during the welding process is collected and then sent to the central control computers in other production workshops;
3)定期对运行的CB2铸钢件的焊接质量进行检查以及老化评级，并将检测及老化评级结果录入手持终端中，然后发布至各生产车间的中控机中。3) Regularly inspect the welding quality and aging rating of running CB2 steel castings, enter the inspection and aging rating results into the handheld terminal, and then publish them to the central control computer in each production workshop.
步骤1)中，将审核结果通过局域网发布至其他生产车间的中控机中。In step 1), publish the audit results to the central control computers in other production workshops through the LAN.
步骤3)中，将检测及老化评级结果录入手持终端中，然后通过局域网发布至各生产车间的中控机中。In step 3), the detection and aging rating results are entered into the handheld terminal, and then released to the central control computer in each production workshop through the local area network.
步骤1)的具体操作为：The specific operations of step 1) are:
11)对入厂的CB2铸钢件进行复检；11) Re-inspect the CB2 steel castings entering the factory;
12)对入厂的CB2铸钢件的质量证明书、CB2铸钢件的商检合格证明单以及技术资料进行核对，然后将核对结果输入到中控机中。12) Check the quality certificate of CB2 steel castings entering the factory, the commodity inspection certificate and technical data of CB2 steel castings, and then input the verification results into the central control computer.
步骤11)的具体操作为：对入厂的CB2铸钢件进行宏观检查、壁厚测量、无损检测、硬度测试及金相检验。The specific operations of step 11) are: conduct macro inspection, wall thickness measurement, non-destructive testing, hardness test and metallographic inspection of the CB2 steel castings entering the factory.
步骤2)中焊接质量的检测包括焊前检查与验证、巡检、检验过程监督、焊接质量核查验证以及不合格焊缝返修见证。The inspection of welding quality in step 2) includes pre-weld inspection and verification, inspection, inspection process supervision, welding quality verification and verification, and witnessing the repair of unqualified welds.
监督焊接质量采用现场检查及焊接过程视频检查包括以下包括：Supervise welding quality through on-site inspection and video inspection of the welding process, including the following:
21)安装焊接前对焊接工艺文件进行检查，对焊工焊接能力验证，对焊材库及焊接设备能力验证；21) Before installation and welding, check the welding process documents, verify the welding ability of the welder, and verify the ability of the welding material library and welding equipment;
22)对现场人员持证情况、焊材领用记回收记录、烘干和保温情况、焊接环境、设备及工艺参数进行巡检复核；22) Conduct inspections and reviews of on-site personnel’s certification status, welding consumables recycling records, drying and heat preservation conditions, welding environment, equipment and process parameters;
23)焊缝质量检验过程的巡检监督；23) Inspection and supervision of the weld quality inspection process;
24)焊接质量核查验证；24) Welding quality inspection and verification;
25)对不合格焊缝返修的见证。25) Witness the repair of unqualified welds.
步骤3)中对运行的CB2铸钢件的焊接质量进行检查以及老化评级的具体操作为：In step 3), the specific operations for inspecting the welding quality and aging rating of running CB2 steel castings are:
31)在役金属监督检查；31) Supervision and inspection of metals in service;
32)裂纹挖除与修复旁站监理；32) Crack excavation and repair side station supervision;
33)金相组织老化评级。33) Metallographic structure aging rating.
金相组织老化评级的具体过程包括：The specific process of metallographic structure aging rating includes:
311)金相组织老化评级；311) Metallographic structure aging rating;
312)老化组织监督运行与处理措施。312) Aging organization supervision operation and treatment measures.
本申请具有以下有益效果：This application has the following beneficial effects:
本申请所述的CB2铸钢件运行状态监督管理方法在具体操作时，对CB2铸钢件的入厂质量、安装及运行质量进行监督及控制，及时发现并消除安装、运行中存在各类质量缺陷及安全隐患，确保CB2铸钢件入厂和服役运行中质量可靠，从根本上消除安全事故发生，保障超超临界机组汽轮机铸钢件在高温、高压下的运行安全，实现对CB2铸钢件的安全质量的全面管控。During specific operations, the CB2 steel casting operation status supervision and management method described in this application will supervise and control the incoming quality, installation and operation quality of CB2 steel castings, and timely discover and eliminate various types of quality problems during installation and operation. Defects and safety hazards, ensure the reliable quality of CB2 steel castings when they enter the factory and are in service, fundamentally eliminate the occurrence of safety accidents, ensure the safe operation of steam turbine steel castings of ultra-supercritical units under high temperature and high pressure, and realize the control of CB2 steel castings Comprehensive control of the safety and quality of parts.
为了更清楚地说明本申请实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本申请的实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据提供的附图获得其他的附图。In order to explain the embodiments of the present application or the technical solutions in the prior art more clearly, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are only This is an embodiment of the present application. For those of ordinary skill in the art, other drawings can be obtained based on the provided drawings without exerting creative efforts.
图1为本申请的流程图。Figure 1 is a flow chart of this application.
为了使本技术领域的人员更好地理解本申请方案，下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本申请一部分的实施例，不是全部的实施例，而并非要限制本申请公开的范围。此外，在以下说明中，省略了对公知结构和技术的描述，以避免不必要的混淆本申请公开的概念。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都应当属于本申请保护的范围。In order to enable those in the technical field to better understand the solutions of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only The embodiments are part of the present application, not all the embodiments, and are not intended to limit the scope of disclosure of the present application. Furthermore, in the following description, descriptions of well-known structures and technologies are omitted to avoid unnecessarily confusing the concepts disclosed in this application. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative efforts should fall within the scope of protection of this application.
在附图中示出了根据本申请公开实施例的结构示意图。这些图并非是按比例绘制的，其中为了清楚表达的目的，放大了某些细节，并且可能省略了某些细节。图中所示出的各种区域、层的形状及它们之间的相对大小、位置关系仅是示例性的，实际中可能由于制造公差或技术限制而有所偏差，并且本领域技术人员根据实际所需可以另外设计具有不同形状、大小、相对位置的区域/层。A schematic structural diagram of an embodiment disclosed in the present application is shown in the accompanying drawings. The drawings are not drawn to scale, with certain details exaggerated and may have been omitted for purposes of clarity. The shapes of the various regions and layers shown in the figures and the relative sizes and positional relationships between them are only exemplary. In practice, there may be deviations due to manufacturing tolerances or technical limitations, and those skilled in the art will base their judgment on actual situations. Additional regions/layers with different shapes, sizes, and relative positions can be designed as needed.
参考图1，本申请所述的CB2铸钢件运行状态监督管理方法，包括以下步骤：Referring to Figure 1, the CB2 steel casting operating status supervision and management method described in this application includes the following steps:
1)对入厂的CB2铸钢件进行质量检验，并将审核结果录入至中控机中，并通过局域网发布至其他生产车间的中控机中；1) Conduct quality inspection on the CB2 steel castings entering the factory, enter the audit results into the central control computer, and publish them to the central control computers in other production workshops through the LAN;
2)对录入中控机的质量检验结果进行复核，对复核合格后的CB2铸钢件进行焊接处理，并对焊接质量进行检测，再将焊接质量的检测结果输入到中控机中，然后发送至其他生产车间的中控机中，与此同时，采集焊接过程中的视频信息，然后发送至其他生产车间的中控机中；2) Review the quality inspection results entered into the central control machine, weld the CB2 steel castings that have passed the review, and test the welding quality. Then input the welding quality test results into the central control machine and then send them. to the central control computers in other production workshops. At the same time, the video information during the welding process is collected and then sent to the central control computers in other production workshops;
3)定期对运行的CB2铸钢件的焊接质量进行检查以及老化评级，并将检测及老化评级结果录入手持终端中，然后通过局域网发布至各生产车间的中控机中。3) Regularly inspect the welding quality and aging rating of running CB2 steel castings, enter the inspection and aging rating results into the handheld terminal, and then publish them to the central control computer in each production workshop through the LAN.
步骤1)的具体操作为：The specific operations of step 1) are:
11)对入厂的CB2铸钢件进行复检；11) Re-inspect the CB2 steel castings entering the factory;
12)对入厂的CB2铸钢件的质量证明书、CB2铸钢件的商检合格证明单以及技术资料进行核对，然后将核对结果输入到中控机中。12) Check the quality certificate of CB2 steel castings entering the factory, the commodity inspection certificate and technical data of CB2 steel castings, and then input the verification results into the central control computer.
步骤11)的具体操作为：对入厂的CB2铸钢件进行宏观检查、壁厚测量、无损检测、硬度测试及金相检验。The specific operations of step 11) are: conduct macro inspection, wall thickness measurement, non-destructive testing, hardness test and metallographic inspection of the CB2 steel castings entering the factory.
步骤2)中焊接质量的检测包括焊前检查与验证、巡检、检验过程监督、焊接质量核查验证以及不合格焊缝返修见证。The inspection of welding quality in step 2) includes pre-weld inspection and verification, inspection, inspection process supervision, welding quality verification and verification, and witnessing the repair of unqualified welds.
监督焊接质量采用现场检查及焊接过程视频检查，具体包括：21)安装焊接前对焊接工艺文件进行检查，对焊工焊接能力验证，对焊材库及焊接设备能力验证；22)对现场人员持证情况、焊材领用记回收记录、烘干和保温情况、焊接环境、设备及工艺参数进行巡检复核；23)焊缝质量检验过程的巡检监督；24)焊接质量核查验证；25)对不合格焊缝返修的见证。Supervise welding quality through on-site inspection and video inspection of the welding process, including: 21) Inspection of welding process documents before installation and welding, verification of welder welding proficiency, verification of welding material library and welding equipment proficiency; 22) Certification of on-site personnel inspection and review of conditions, welding consumables recycling records, drying and insulation conditions, welding environment, equipment and process parameters; 23) Inspection and supervision of the weld quality inspection process; 24) Welding quality inspection and verification; 25) Witness the repair of defective welds.
步骤3)中对运行的CB2铸钢件的焊接质量进行检查以及老化评级的具体操作为：In step 3), the specific operations for inspecting the welding quality and aging rating of running CB2 steel castings are:
31)在役金属监督检查；32)裂纹挖除与修复旁站监理；33)金相组织老化评级，其中，金相组织老化评级的具体过程包括：311)金相组织老化评级；312)老化组织监督运行与处理措施。31) In-service metal supervision and inspection; 32) Crack excavation and repair side station supervision; 33) Metallographic structure aging rating. Among them, the specific process of metallographic structure aging rating includes: 311) Metallographic structure aging rating; 312) Aging Organize, supervise operations and handle measures.
实施例一Embodiment 1
本实施例的具体过程为：The specific process of this embodiment is:
一、制造质量入厂检验1. Incoming factory inspection of manufacturing quality
采用现场检验和文件见证监控方式开展CB2铸钢件的入厂检查，分为如下步骤：The factory inspection of CB2 steel castings is carried out using on-site inspection and document witness monitoring, which is divided into the following steps:
1.CB2铸钢件的入厂复检，检查内容包含：11)宏观检查；12)光谱测试；13)壁厚测量；14)无损检测；15)硬度测试；16)金相检验等，检查重点关注浇口、冒口处、截面突变处及螺栓内孔壁等。1. Factory re-inspection of CB2 steel castings. The inspection content includes: 11) macroscopic inspection; 12) spectrum test; 13) wall thickness measurement; 14) non-destructive testing; 15) hardness test; 16) metallographic inspection, etc. Focus on the gate, riser, section mutation and bolt inner hole wall, etc.
2.CB2铸钢件的验收，验收审核文件内容包含：21)产品质量证明书，22)进口铸钢件的商检合格证明，23)技术资料(包括：图纸、材料牌号、坯料制造商，化学成分，坯料冶炼、铸造及热处理工艺、力学性能、金相组织、无损检测、补焊及热处理记录等)。2. For the acceptance of CB2 steel castings, the acceptance review documents include: 21) product quality certificate, 22) commodity inspection certificate of imported steel castings, 23) technical data (including: drawings, material grades, billet manufacturers, chemical Composition, billet smelting, casting and heat treatment process, mechanical properties, metallographic structure, non-destructive testing, repair welding and heat treatment records, etc.).
二、安装焊接质量监督2. Installation and welding quality supervision
采用现场检查和文件见证监控方式开展CB2铸钢件安装焊接质量监督，分为如下步骤：On-site inspection and document witness monitoring are used to carry out CB2 steel casting installation and welding quality supervision, which is divided into the following steps:
1.焊前检查与验证，检查与验证内容包含：1. Inspection and verification before welding. Inspection and verification include:
11)安装焊接前对焊接工艺文件进行检查；11) Check the welding process documents before installation and welding;
12)对人员焊接能力验证，验证内容包含：2a)人员资质，如焊工证、热处理、无损人员和理化人员证书；2b)焊工岗前练习及焊接能力考试记录。12) For personnel welding ability verification, the verification content includes: 2a) personnel qualifications, such as welder certificates, heat treatment, non-destructive personnel and physical and chemical personnel certificates; 2b) welder pre-job practice and welding ability examination records.
13)焊材库及焊接设备能力验证，验证内容包含：3a)电焊机、热处理加热元件、热电偶、补偿导线、控温柜、测温仪等生产设备及仪器的校验记录及有效期；3b)无损探伤设备、理化检验仪器的校验证书及有效期；3c)焊材库管理制度、焊材库温度计和湿度计监测记录、焊材质量证明书与复检报告、焊材桶的领用记录。13) Welding material library and welding equipment proficiency verification, the verification content includes: 3a) Calibration records and validity periods of production equipment and instruments such as electric welding machines, heat treatment heating elements, thermocouples, compensation wires, temperature control cabinets, and thermometers; 3b ) Calibration certificates and validity periods of non-destructive testing equipment and physical and chemical testing instruments; 3c) Welding material warehouse management system, welding material warehouse thermometer and hygrometer monitoring records, welding material quality certificates and re-inspection reports, and welding material barrel receipt records .
2.巡检，检查内容包含：2. Inspection, including:
21)现场人员持证情况；21) Certificate holding status of on-site personnel;
22)焊材领用记回收记录、烘干和保温情况；22) Welding consumables recycling records, drying and insulation conditions;
23)焊接环境，包括防风、防潮、防雨、防雪措施以及环境温度；23) Welding environment, including windproof, moistureproof, rainproof, snowproof measures and ambient temperature;
24)设备及工艺参数。24) Equipment and process parameters.
3.检验过程监督，监督包含对渗透、射线、超声及磁粉等焊缝质量检验记录和报告，以及对硬度和金相组织检验结果的审查；3. Supervision of the inspection process, including inspection records and reports on weld quality inspection such as penetration, radiography, ultrasonic and magnetic particle, as well as review of hardness and metallographic structure inspection results;
4.焊接质量核查验证，工作包含：41)焊缝外观质量检查；42)焊缝质量抽查检验，内容包括:4a)光谱检测；4b)无损检测；4c)硬度及金相检验；4. Welding quality inspection and verification, the work includes: 41) Weld appearance quality inspection; 42) Weld quality spot inspection, including: 4a) Spectral testing; 4b) Non-destructive testing; 4c) Hardness and metallographic inspection;
5.不合格焊缝的返修见证，包含如下：5. Witness the repair of unqualified welds, including the following:
51)返修缺陷的处理情况现场见证；51) On-site witness of the handling of repair defects;
52)返修质量的检验情况监督；52) Supervise the inspection status of repair quality;
53)以返修后焊缝质量的验证：5a)焊缝的无损检测；5b)硬度测试；c)金相检验。53) Verification of weld quality after repair: 5a) non-destructive testing of welds; 5b) hardness test; c) metallographic inspection.
三、运行监督管理与老化评级3. Operation supervision and management and aging rating
采用现场检验和旁站监理的方式开展CB2铸钢件运行监督管理与老化评级，分为以下步骤：The operation supervision and management and aging rating of CB2 steel castings are carried out through on-site inspection and side station supervision, which are divided into the following steps:
1.在役金属监督检查，包含：1. In-service metal supervision and inspection, including:
11)目视检查，对高温去变截面处、螺栓孔部位检查是否存在机械损伤、裂纹等；12)无损检测；13)硬度测试；14)金相检验。11) Visual inspection, check whether there is mechanical damage, cracks, etc. at high-temperature deformed sections and bolt holes; 12) Non-destructive inspection; 13) Hardness test; 14) Metallographic inspection.
2.裂纹挖除与修复旁站监理，包含：2. Crack excavation and repair side station supervision, including:
21)修复前状态验证，对裂纹挖除处进行超声检测，对表面进行磁粉或渗透检测；21) Verify the condition before repair, conduct ultrasonic testing on the crack excavation area, and conduct magnetic particle or penetrant testing on the surface;
22)补焊过程质量控制；22) Quality control of repair welding process;
23)修复后焊缝质量复检，对修复处进行超声检查，对表面进行磁粉或渗透检测，并对补焊处进行硬度测试和金相检验；23) Re-inspect the weld quality after repair, conduct ultrasonic inspection on the repaired area, conduct magnetic particle or penetrant testing on the surface, and conduct hardness test and metallographic inspection on the repaired welding area;
3.金相组织老化评级，包含：3. Metallographic structure aging rating, including:
31)老化评级，当CB2铸钢件运行10万小时后，综合考虑CB2钢马氏体组织板条结构演变和碳化物在不同区域分布情况的方法进行老化评级，从原始态至完全老化分为5级，分别为老化1级至5级。31) Aging rating. After the CB2 steel casting has been operated for 100,000 hours, the aging rating is carried out by comprehensively considering the evolution of the lath structure of the martensitic structure of the CB2 steel and the distribution of carbides in different areas. It is divided into two categories from the original state to complete aging. Level 5 refers to aging levels 1 to 5 respectively.
32)老化组织监督运行与处理措施，包括：3a)当CB2钢金相组织老化 达到4级，且硬度下降明显，进行材质评定和寿命评估；3b)当CB2钢金相组织老化达到5级，且硬度下降显著，进行CB2铸钢件更换。32) Aging structure supervision operation and treatment measures, including: 3a) When the aging of the CB2 steel metallographic structure reaches level 4 and the hardness drops significantly, conduct material evaluation and life assessment; 3b) When the aging of the CB2 steel metallographic structure reaches level 5, And the hardness dropped significantly, so CB2 steel castings were replaced.
本说明书中各个实施例采用递进的方式描述，每个实施例重点说明的都是与其他实施例的不同之处，各个实施例之间相同相似部分互相参见即可。对于实施例公开的装置而言，由于其与实施例公开的方法相对应，所以描述的比较简单，相关之处参见方法部分说明即可。Each embodiment in this specification is described in a progressive manner. Each embodiment focuses on its differences from other embodiments. The same and similar parts between the various embodiments can be referred to each other. As for the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple. For relevant details, please refer to the description in the method section.
对所公开的实施例的上述说明，使本领域专业技术人员能够实现或使用本申请。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本申请的精神或范围的情况下，在其它实施例中实现。因此，本申请将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be practiced in other embodiments without departing from the spirit or scope of the application. Therefore, the present application is not to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (9)
- 一种CB2铸钢件运行状态监督管理方法，其特征在于，包括以下步骤：A method for supervising and managing the operating status of CB2 steel castings, which is characterized by including the following steps:1)对入厂的CB2铸钢件进行质量检验，并将审核结果录入至中控机中，再发布至其他生产车间的中控机中；1) Conduct quality inspection on the CB2 steel castings entering the factory, enter the audit results into the central control computer, and then publish them to the central control computers in other production workshops;2)对录入中控机的质量检验结果进行复核，对复核合格后的CB2铸钢件进行焊接处理，并对焊接质量进行检测，再将焊接质量的检测结果输入到中控机中，然后发送至其他生产车间的中控机中；与此同时，采集焊接过程中的视频信息，然后发送至其他生产车间的中控机中；2) Review the quality inspection results entered into the central control machine, weld the CB2 steel castings that have passed the review, and test the welding quality. Then input the welding quality test results into the central control machine and then send them. to the central control computers in other production workshops; at the same time, the video information during the welding process is collected and then sent to the central control computers in other production workshops;3)定期对运行的CB2铸钢件的焊接质量进行检查以及老化评级，并将检测及老化评级结果录入手持终端中，然后发布至各生产车间的中控机中。3) Regularly inspect the welding quality and aging rating of running CB2 steel castings, enter the inspection and aging rating results into the handheld terminal, and then publish them to the central control computer in each production workshop.
- 根据权利要求1所述的CB2铸钢件运行状态监督管理方法，其特征在于，步骤1)中，将审核结果通过局域网发布至其他生产车间的中控机中。The method for supervising and managing the operating status of CB2 steel castings according to claim 1, characterized in that in step 1), the audit results are released to central control machines in other production workshops through the local area network.
- 根据权利要求1所述的CB2铸钢件运行状态监督管理方法，其特征在于，步骤3)中，将检测及老化评级结果录入手持终端中，然后通过局域网发布至各生产车间的中控机中。The CB2 steel casting operation status supervision and management method according to claim 1, characterized in that in step 3), the detection and aging rating results are entered into the handheld terminal, and then released to the central control computer in each production workshop through the local area network .
- 根据权利要求1所述的CB2铸钢件运行状态监督管理方法，其特征在于，步骤1)的具体操作为：The CB2 steel casting operation status supervision and management method according to claim 1, characterized in that the specific operation of step 1) is:11)对入厂的CB2铸钢件进行复检；11) Re-inspect the CB2 steel castings entering the factory;12)对入厂的CB2铸钢件的质量证明书、CB2铸钢件的商检合格证明单以及技术资料进行核对，然后将核对结果输入到中控机中。12) Check the quality certificate of CB2 steel castings entering the factory, the commodity inspection certificate and technical data of CB2 steel castings, and then input the verification results into the central control computer.
- 根据权利要求4所述的CB2铸钢件运行状态监督管理方法，其特征在于，步骤11)的具体操作为：对入厂的CB2铸钢件进行宏观检查、壁厚测量、无损检测、硬度测试及金相检验。The CB2 steel casting operation status supervision and management method according to claim 4, characterized in that the specific operation of step 11) is: macroscopic inspection, wall thickness measurement, non-destructive testing, and hardness testing of the CB2 steel castings entering the factory and metallographic examination.
- 根据权利要求1所述的CB2铸钢件运行状态监督管理方法，其特征在于，步骤2)中焊接质量的检测包括焊前检查与验证、巡检、检验过程监督、焊接质量核查验证以及不合格焊缝返修见证。The CB2 steel casting operation status supervision and management method according to claim 1, characterized in that the detection of welding quality in step 2) includes pre-welding inspection and verification, inspection, inspection process supervision, welding quality verification and unqualified Witness of weld repair.
- 根据权利要求1所述的CB2铸钢件运行状态监督管理方法，其特征在于，监督焊接质量采用现场检查及焊接过程视频检查包括以下包括：The method for supervising and managing the operating status of CB2 steel castings according to claim 1, characterized in that, supervising the welding quality using on-site inspection and welding process video inspection includes the following:21)安装焊接前对焊接工艺文件进行检查，对焊工焊接能力验证，对焊材库及焊接设备能力验证；21) Before installation and welding, check the welding process documents, verify the welding ability of the welder, and verify the ability of the welding material library and welding equipment;22)对现场人员持证情况、焊材领用记回收记录、烘干和保温情况、焊接环境、设备及工艺参数进行巡检复核；22) Conduct inspections and reviews of on-site personnel’s certification status, welding consumables recycling records, drying and heat preservation conditions, welding environment, equipment and process parameters;23)焊缝质量检验过程的巡检监督；23) Inspection and supervision of the weld quality inspection process;24)焊接质量核查验证；24) Welding quality inspection and verification;25)对不合格焊缝返修的见证。25) Witness the repair of unqualified welds.
- 根据权利要求1所述的CB2铸钢件运行状态监督管理方法，其特征在于，步骤3)中对运行的CB2铸钢件的焊接质量进行检查以及老化评级的具体操作为：The method for supervising and managing the operating status of CB2 steel castings according to claim 1, characterized in that the specific operations of inspecting the welding quality and aging rating of the running CB2 steel castings in step 3) are:31)在役金属监督检查；31) Supervision and inspection of metals in service;32)裂纹挖除与修复旁站监理；32) Crack excavation and repair side station supervision;33)金相组织老化评级。33) Metallographic structure aging rating.
- 根据权利要求1所述的CB2铸钢件运行状态监督管理方法，其特征在于，金相组织老化评级的具体过程包括：The CB2 steel casting operation status supervision and management method according to claim 1, characterized in that the specific process of metallographic structure aging rating includes:311)金相组织老化评级；311) Metallographic structure aging rating;312)老化组织监督运行与处理措施。312) Aging organization supervision operation and treatment measures.
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| CN115018302A (en) * | 2022-05-30 | 2022-09-06 | 西安热工研究院有限公司 | CB2 steel casting running state supervision and management method |
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