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鋼管生產(chǎn)技術(shù)的進(jìn)步一方面在用戶需求的推動(dòng)下不斷進(jìn)行了新產(chǎn)品開發(fā)，從生產(chǎn)企業(yè)的高效低成本化出發(fā)促進(jìn)了新技術(shù)開發(fā)。
On the one hand, the progress of steel pipe production technology has been pushed forward by the user's demand, which promotes the development of new technology from the point of view of high efficiency and low cost of production enterprises.
1.無縫鋼管的生產(chǎn)技術(shù)
1. Production Technology of Seamless Steel Pipe
對日本無縫鋼管生產(chǎn)廠來說，這10年間乃是擺脫慢性虧損的階段，在激烈的市場競爭下出現(xiàn)了外商合資和兩廠合并等重大變革。近年來由于油氣開發(fā)轉(zhuǎn)向深海和CO2、H2S濃度高的惡劣環(huán)境，促進(jìn)了13Cr等高合金鋼管的開發(fā)。
For Japan's seamless steel pipe production plant, this decade is a stage to get rid of chronic losses. Under the fierce market competition, there have been major changes such as foreign joint ventures and merger of the two factories. In recent years, oil and gas development has shifted to the harsh environment with high concentration of CO2 and H2S in deep sea, which has promoted the development of 13Cr high alloy steel pipes.
(1)穿孔。有兩項(xiàng)成果：一是交叉穿孔機(jī)的穿孔技術(shù)，二是擴(kuò)管穿孔技術(shù)。前者為適應(yīng)以13Cr為中心的高合金鋼管的生產(chǎn)而開發(fā)成功，有利于抑制穿孔時(shí)伴生的剪斷形變而為多數(shù)廠所采用。并配套開發(fā)出高溫強(qiáng)度高的芯棒，今后考慮開發(fā)含Ti、Zn、Mo合金的超長壽命芯。后者亦開發(fā)很久，因用曼內(nèi)斯曼穿孔機(jī)穿孔時(shí)管端質(zhì)量不佳，致擴(kuò)管率(穿孔外徑/管坯外徑)僅達(dá)1.2～1.3，而交叉穿孔則可達(dá)1.4～2.0，使壁厚/外徑比由7%變薄至3%，對下道工序的軋管十分有利，使軋管機(jī)架由原來的7臺(tái)減為5臺(tái)，對簡化軋管工序和節(jié)約設(shè)備投資均有利。
(1) Perforation. There are two achievements: one is the piercing technology of cross piercing machine, the other is the expanding piercing technology. The former has been successfully developed to adapt to the production of 13Cr-centered high alloy steel pipes, which is conducive to restraining the shear deformation associated with perforation and has been adopted by most factories. The core rod with high strength at high temperature has been developed, and the development of ultra-long life core containing Ti, Zn and Mo alloys will be considered in the future. The latter has also been developed for a long time. Because of the poor quality of the pipe end when perforated by Mannesmann piercing mill, the expansion rate (perforated outer diameter/blank outer diameter) is only 1.2-1.3, while the cross-perforation is 1.4-2.0, which makes the wall thickness/outer diameter ratio from 7% to 3%. It is very advantageous to the rolling pipe in the next process, and reduces the pipe mill stand from 7 to 5. Simplifying pipe rolling process and saving equipment investment are beneficial.
(2)連續(xù)軋管。由于回程連續(xù)軋管技術(shù)可產(chǎn)出表面性能好、壁厚精度高的超大徑無縫鋼管，逐步代替了芯棒軋管機(jī)。加上穿孔機(jī)的工作負(fù)荷加大，為連續(xù)軋管減少道次創(chuàng)造了條件，更加速了節(jié)約投資的5～4機(jī)架的連續(xù)軋管機(jī)的推廣。加之機(jī)架配置亦由X式改為VH式，進(jìn)一步實(shí)現(xiàn)了緊湊化和節(jié)約設(shè)備投資。
(2) Continuous rolling of pipes. Because of the excellent surface properties and high wall thickness accuracy of super-large diameter seamless steel tube produced by backhaul continuous rolling technology, the mandrel mill is gradually replaced. With the increase of the workload of the piercing mill, the conditions for reducing the pass number of continuous rolling pipe are created, and the promotion of the 5-4 stand continuous rolling pipe mill which saves investment is accelerated. In addition, the rack configuration has been changed from X type to VH type, which further realizes compactness and saves equipment investment.
作為提高產(chǎn)品形狀精度的技術(shù)，除不斷提高計(jì)算機(jī)的高精度控制外，并出現(xiàn)了高精度的三輥軋機(jī)。為下工序的拉伸減徑軋制時(shí)減少管端切頭損失，又開發(fā)成功通過軸壓下和計(jì)算機(jī)控制的薄壁管端連續(xù)軋管技術(shù)。
(3)拉伸減徑軋制使過去長期存在的兩個(gè)問題均基本得到解決。是長度方向管端壁偏厚問題，由于連續(xù)軋管薄壁化和速度控制已基本解決;其次是外徑壓下時(shí)產(chǎn)生的內(nèi)部張力問題，通過研究軋輥形狀和張力的影響，采取了15°配置的斜輥機(jī)和4輥減徑機(jī)的解決方案。
(4)今后技術(shù)開發(fā)的主要方向是生產(chǎn)高合金管、降低設(shè)備費(fèi)用、提高壁厚和外徑的精度及其及搞好節(jié)能。
2.焊管的生產(chǎn)技術(shù)
(1)電焊管。近10年來的主要技術(shù)進(jìn)步如下：(a)生產(chǎn)范圍擴(kuò)大。2003年建成可生產(chǎn)管線用高強(qiáng)度、高變形焊管的14″電焊管機(jī)組，為生產(chǎn)厚壁管的26″電焊管機(jī)組的改造亦已完成;(b)提高焊接可靠性技術(shù)方面，除對已開發(fā)的焊接控制系統(tǒng)高精度化外，還開發(fā)成功氣體保護(hù)焊技術(shù);(c)在提效降本方面的重大突破是開發(fā)成功柔性成型軋機(jī)(簡稱FF軋機(jī))，已用于中小徑管的生產(chǎn)。它通過對軋輥和管坯接觸點(diǎn)的依次比較好的控制而實(shí)現(xiàn)了柔性成型，使換輥和調(diào)整時(shí)間大幅縮短，同時(shí)由加工產(chǎn)生的形變亦得到了控制;(d)激光焊接在合金管和厚壁管的生產(chǎn)上得到了應(yīng)用;(e)復(fù)合成型管在汽車部件上的應(yīng)用和電焊管生產(chǎn)上應(yīng)用了高頻加熱減徑并進(jìn)行在線熱處理技術(shù)。
(2)UOE鋼管。隨著主用途管線的變化不斷開發(fā)成功提高效率和保證質(zhì)量的技術(shù)和設(shè)備。近年由于天然氣開發(fā)轉(zhuǎn)向邊遠(yuǎn)地區(qū)和深海，為節(jié)約管線投資而實(shí)現(xiàn)高壓化和小型化，從而促進(jìn)了UOE鋼管的高強(qiáng)度化和極厚壁化。為保超高強(qiáng)度化，在開發(fā)成功相關(guān)的煉鋼技術(shù)和中厚板生產(chǎn)應(yīng)用TMCP新技術(shù)的基礎(chǔ)上，UOE管亦開發(fā)成功配套的成型技術(shù)，使X80～X100、X120等產(chǎn)品陸續(xù)量產(chǎn)。在厚壁化方面，為防止在深海敷設(shè)彎曲時(shí)出現(xiàn)折損，針對確保焊縫處的韌性進(jìn)行了有關(guān)材料和焊接技術(shù)的開發(fā)。
(3)爐焊管和螺旋焊管。10年來變化不大。
