热处理生产线简介(翻译) (2).doc

热处理生产线简介Brief Introduction of Heat Treatment Production Line一、概述Summary我公司投资6000万元建设的油井管热处理生产线，设计生产能力10万吨/年，可以对各种规格、各种钢级的油井管实现淬火回火、正火、正火+回火等多种热处理工艺。We invested 60 million RMB for this tubing and casing treatment production line. Our annual production ability is 100 thousand tons and we have many kinds of heat treatment technics for all kinds and specifications of tubing and casing, such as Quenching + Tempering, normalizing, normalizing+Tempering and so on.钢级：J55、Q55、N80-1类、N80Q、P110以及抗腐蚀材料 L80和C95等。Grade: J55, Q55, N80-1, N80Q, P110 and anti- cauterization material L80 , C95 and so on.直径：114.3-273mmDiameter: 114.3-273mm外加厚油管两端的外径按APISPEC5CT标准O.D of EUE tubing according to API SPEC 5CT Standard长度：8-13MLength: 8-13M壁厚：5.21-20.24mmWall Thickness: 5.21-20.24mm壁厚公差：+15%-12.5%Wall Thickness Tolerance: +15%-12.5%钢管外径公差：1%O.D Tolerance: 1%单根最大重量：1200KGMax Weight of Single Pipe: 1200 KG二、设备情况Equipment Condition热处理生产线配有步进式热处理炉、淬火机、矫直机和自旋式步进冷床，全线自动化控制水平高，热处理质量稳定可靠。Our heat treatment production line is equiped Step-wise Heat Treatment Furnace, Quenching Machine, Straightening Machine and Self-spin Step-wise Colling Machine. The high level automatization control system ensures steady and first class heat treatment quality.1、热处理炉 Heat treatment Furnace步进式热处理炉以冷净煤气为燃料，采用德国施能烧嘴，炉内气氛易于控制，炉温可控制在5以内。Step-wise Heat treatment Furnace uses cold and clean coal gas as fuel, adopts Germany KROMSCHRODER Burner which could ensure the temperature in the furance less than 5. 淬火炉和回火炉均采用步进梁式炉。装出料方式：侧进，侧出；炉子布料：单排连续布料或间隔布料。Quenching Furance and Tempering Furance both adopt Step-wise Walking Beam Furance. Mode of Loading and unloading Material: Side Loading, Side unloading. Material Display in the Furance: Single Row Continuesly Display or Interval Display活动梁和固定梁均为耐热铸钢，顶面带齿形面。每次步进时，钢管都能转动一角度，使钢管加热均匀，并防止在炉内弯曲变形。步进梁能进行正循环、踏步、等高、单动、点动、半自动、自动等功能，升降时对钢管轻托轻放，前进时缓起缓停，无振动冲击和失控现象。同时，具有等高及踏步功能，踏步时向钢管在原齿槽内不断转动。Walking Beam and Fixed Beam both are fire-endurable cast steel with tooth form on the top. In the process step, steel pipes will be turned for an angle to get symmetrical heating up and avoid bending and distortion in the furnace. Step-wise Beam can carry through Positive Cycle, Mark Time, Equality Height, Single Move, Point Move, Semiautomatic, Automatic functions and so on. Steel pipes are lifted and put lightly when elevating and subsiding, and they are removed and stopped slowly when moving forward. In the process, there is no librating impact and out control phenomenon. And the mechine also has coequal height and Mark Time function to ensure the steel pipes constant turning in the tooth form alveolus.2、淬火机 Quenching Machine淬火机具有内喷外淋的功能，外淋水流量大，内喷水速度快，淬火效果好。淬火机可以实现以下功能：Quenching machine has perfect quenching effect and equiped large flux inner spraying and speedy outer pouring fuction. It can achieve below functions: 外淋+旋转+内喷淬火 Outer pouring + circumgyrate + inner spraying quenching 淬火后具有空水功能（带压缩空气吹扫） Water emptying function after quenching (with air compressor) 氧化皮采大部分被回水带走，剩余部分停炉时清理 Mostly Oxidation Surface are washed away by backwater, the rest will be cleaned when the furnace stops working. 内喷采用锥形聚能喷嘴（根据处理的钢管不同而不同） Inner spraying adopts powerfull taper nozzles ( The nozzles are depend on different steel pipes) 淬火前温度850左右，淬火后温度低于80 The temperature is about 850 before quenching and will below 80 after quenching. 淬火后钢管端头直度2 mm/m，保证钢管顺利进入回火炉。 After quenching, the straight tolerance of the steel pipes end should be 2 mm/m to ensure the pipe can be placed in the Tempering furnace successfully.3、矫直机Straightening Machine矫直设备采用国内先进的八立柱、四滑架、六辊快开式矫直机，具有机身稳定，矫直速度快，矫直效果好的特点。Straightening Equipments adopt advanced eight upright column, four slide rack, six rollers rapid opening straightening machine. The mechine is steady, and it has fast straightening speed and perfect straightening effect.矫直辊采用了2-2-2的对辊辊系，矫直工艺曲线可以实现上弯或下弯式两种方式。Straightening rollers adopt 2-2-2 rollers so that the straightening technics can be achieved to up bend mode and down bend mode.采用四立柱滑架结构。矫直辊座安装在动梁上，每个活动梁在四个立柱中垂直滑动，保证矫直过程的稳定。克服了两滑架机型受力偏载的缺点。It adopts four upright column slide rack structure.Straightening rollers are installed on the moving beams and every moving beam can slide upright in every four upright column which ensures the stability in the process of straightening. And it conquers the shortcoming of pressure excursion of the two sliding racks.采用中心单快开缸压下、两侧双缸平衡带快速抬起的快开结构，设备简洁、配管少、维护方便。It adopts center single rapid opening jar pressure, two sides double jars balance with rapid uplift rapid opening structutre. The eqipment with less tubings is concision and expediently maintained.每个矫直辊分别采用两个独立的锁紧油缸进行锁紧，保证锁紧的可靠性。Every straightening roller separately adopts two solely lock clasp gas jars which ensures the dependability of lock clasp.采用新型线性齿轮传动角度调节机构，传动速比大、传动过程稳定、角度调节精度高、角度指示准确。It adopts new type of linear gears driving angle adjustment which has the features of large driving speed ratio, steady driving process, high precision of angle adjustment and exact angle directions.拉杆和套筒组合立柱与上下固定梁的联结为预应力方式，增大了机架刚性。The connection of pull-rod and sleeve combination upright column and fluctuate fixed beam is the mode of pre-stress which could increase the rigidity of rack.采用新型下横梁（底座）结构，下辊快开液压缸和下辊压下调节装置均安装在下横梁上面，使得安装和维护方便。It adopts new type of down beam (foundation) structure. Down roller rapid hydraulic jar and down roller pressure adjustment setting both are installed on the down beam to make sure its convenient installation and maintenance.计算机系统具有独特的调整参数预设定、修正和机械自动调整功能：确定钢管来料参数的情况下根据矫直后精度要求，利用数学模型或表格参数确定预设定参数，并带有屏幕显示。根据矫直后钢管状态对调整参数进行修正、优化和存储。所有设定的工艺参数均可记录、打印、输出。The computer system has unique function: pre-setting and correcting adjustive parameter, and mechanical autoregulation. When we confirm the parameter of material pipes, according to the request of precision afther the straightening, the system can confirm the pre-setting parameter with mathematic model or form paremeter and still can show them in the screen. It also can correct, optimize and store the adjustive parameter as per the condition of steel pipes after straightening. All of the setting technics prameters can be recorded, typed and exported.电控系统中的两台主电机采用交流变频调速系统，主电机空载时速度同步。负载时力矩平衡，有利于降低矫直辊不均匀磨损，提高矫直过程的稳定性和矫直精度。The two core electric machineries of the electronic control system adopt alternating frequency conversion timing system. When the two core electric machineries are unloaded, the speeds of the two machineries are synchro. The moments are balance when they are loaded, which is propitious to reduce the asymmetric abrasion of the straightening roller and enhance the stability of the straightening process and the straightening precision.4、自旋转冷床Self-rolling cooling machine tool自旋式步进冷床结构独特，油井管在冷却过程中可以以较快的速度旋转，冷却速度稳定均匀，并具有自矫直功能。Self-rolling cooling machine tool has particular structure. When the casing is in the process of cooling, it can circumrotate in a high speed. The cooling speed is steady and symmetrical. And the mechine tool has self-straightening function.一、 热处理工艺流程Flow and flow chart of heat treatment technics原料钢管由车间起重机吊运至热处理线上料台架上，人工打开捆带后将钢管平铺在上料台架上，后由拨料器逐根将钢管拨入辊道，辊道将钢管纵向送至淬火炉辊道。送料辊道与入炉辊道均为倾斜布置，以便使钢管边纵向前进边旋转。淬火炉为纵进纵出步进式加热炉。Raw material pipes are carried to the material scaffolding of the heat treatment line by the crane in the plant and are placed on the material line scaffolding after unfolding of bundling belt by workmen. After that, material lift machine will lift the material pipes step by step into the roller path which will carry the pipes lengthways to the quenching furnace roller path. Material sending roller path and furnace entering roller path both are designed to be acclivitous which could help the pipes circumrotate when they are forwarded lengthways. Quenching furnace is vertical in and out step-wise heat-up furnace.钢管进入淬火炉后，根据钢管的热处理工艺制度的要求，在炉子内边步进边加热，直至步进至炉子尾部出料辊道，炉子出料辊道将钢管边旋转纵向输送至输出辊道。Accroding to the requirements of heat treatment technics system, when the pipes are forwarded in the quenching furnace, they are heated in the forwarding until they are forwarded to the material discharge roller path at end of furnace. Material discharge roller path will carry the revolving pipes to the output roller path vertically.当钢管需要进行淬火时，淬火装置前的移钢机逐根将钢管移送至水淬装置。水淬装置采用内喷外淋、压轮压住旋转淬火方式，根据水淬工艺，分别控制水淬装置内喷、外淋水量和冷却时间，以实现对钢管最终组织和性能的控制。随后，钢管横向移送至水淬装置后台架，进行空水，空水后钢管拨入回火炉入炉辊道，纵向输送，进入回火炉。When the pipes need to be quenched, the steel moving machines in the front of quenching equipments will carry the pipes to the water quenching equipment. The equipment adopts inner spray and outerpouring, and the revolving pressing quenching mode which control the water stream of inner spray, outerpouring and cooling time seperately as per the water quenching technics to realize the control of the final organization and capability of the steel pipes. After that, pipes are carried breadthwise to the racks behind the water quenching machine to empty the water and then, pipes are carried vertically to tempering furnace by tempering furnace entering roller path.当钢管需要进行正火处理时，由出炉辊道将钢管逐根运至正火链式冷床输送辊道处，上料机构逐根将钢管移送至正火冷床上，进行冷却、收集。如钢管需要正火+回火，由翻钢板将钢管到放至冷床输出辊道，后由辊道运送至回火炉进行回火处理。The pipes are carried to normalizing chain delivering roller path of the cooling mechine tool one by one when they need normalizing treatment. The material supplying machines carry the pipes to the normalizing cooling mechine tool to do the cooling and collecting. If the pipes need normalizing + tempering, pipes carrying plate will carry them to the output roller path of the cooling mechine tool. Then the pipes are carried to the tempering furnace by the roller path to do the tempering treatment.回火炉为纵进纵出步进式加热炉，钢管入炉后，根据钢管的热处理工艺制度要求，在炉子内边步进边加热，直至步进至炉子尾部的出料辊道。炉子出料辊道将钢管边旋转边纵向输送至链式冷床进行冷却。Tempering furnace is vertical input and output step-wise heating up furnace. As per the requirements of the heat treatment technic system, the pipes are step-wised and heated up in the furnace until they are carried to the output roller path at the end of the furnace. Material discharge roller path will carry the revolving pipes to the chain cooling mechine tool vertically.在淬火炉出炉辊道上布置有高压水除鳞装置，钢管通过除鳞箱的同时，将表面氧化铁皮清除干净。High-pressure water cleaning equipment is designed on the quenching furnace output roller path. Ferric oxide on the surface of the pipes will be cleaned up after they pass through the cleaning box.对于温矫的钢管，要求矫直温度400左右，此时冷床以较合适的速度快速将钢管移送至矫直机前，以控制和保证矫直温度。To the temprerature correcting pipes, the straightening temperature is about 400. Here the cooling mechine tool will carry the pipes to the straightening machines at a suitable fast speed to control and ensure the straightening temperature.经矫直后的钢管进入其后的冷床，对于温矫后的钢管实现均匀的冷却，通过冷床进行后部的人工检查工序。随后，钢管进入吸灰装置工位，将钢管内部的氧化铁皮等杂质清理干净，收集入库。 After straightening, the pipes will be carried to the cooling machine tool to realize the symmetrical cooling and then carry out the inspection by the workman through the cooling mechine tool. Subsequently, the pipes enter into the dust cleaning line to clean the inner ferric oxide and so on impurity, and then they will be gathered in the warehouse. 全管体相控阵超声检测系统Full body pipe PA Inspection system 应用：全管体相控阵超声检测系统检测全管体上纵向、横向、斜向和分层等缺陷，同时测量壁厚。Application: Full body pipe PA inspection system is used for the detection of longitudinal defects, transverse defects withoblique detection capability and wall thickness measurements wit