Steel pipe pile manufacturing process

Abstract

The invention relates to the technical field of steel pipe piles, in particular to a steel pipe pile manufacturing process which comprises the following steps: S1, blanking: during blanking, a pile cylinder number, a factory material mark and a material number are transplanted to the inner surface of a cylinder body or a plate by a steel seal knocking method and are framed out by a color pen; s2, scribing: scribing a longitudinal equant inspection line for detecting the size of the steel pipe pile cylinder according to the drawing requirements and the corresponding data, and punching and marking the longitudinal equant inspection line; s3, rolling the barrel, wherein the barrel is pre-bent before being rolled; s4, the cylinder is rolled to be round, wherein the one-time bending amount is not suitable to be too large in the round rolling process; s5, the cylinder body is rounded, wherein after the cylinder body is rounded, the corner angle is checked through an inner clamping sample plate with the chord length of 1000 mm; according to the invention, during welding construction, a welding process of multi-layer batch welding is adopted, so that the construction difficulty increased due to the fact that personnel enter the inner wall for construction can be reduced, and the welding quality can be better facilitated.

Description

Technical Field

[0001] The invention relates to the technical field of steel pipe piles, and in particular to a steel pipe pile manufacturing process. Background Art

[0002] The foundation of the offshore wind turbine conductor frame is made of steel pipe piles inserted into the mud as the bearing unit. The conductor frame is connected to the steel pipe piles above the mud surface and reinforced. When the water depth is deep, the steel pipe piles need to be driven into the bottom of the water, which involves an underwater piling process of tens of meters deep. Due to the large outer diameter and thick wall of the steel pipe piles, the on-site welding workload is large, the quality requirements are high, and the construction conditions are harsh. Summary of the invention

[0003] The purpose of the present invention is to provide a steel pipe pile manufacturing process to address the defects of the prior art, which can provide reliable technical support for the welding of steel pipe piles.

[0004] To achieve the above object, the present invention provides the following technical solutions:

[0005] A steel pipe pile manufacturing process comprises the following steps:

[0006] S1. Cutting: When cutting, use the method of stamping to transplant the pile number, factory material mark, and material number on the inner surface of the cylinder or plate and frame them with a colored pen;

[0007] S2. Marking: Mark the longitudinal equal-division inspection lines for the steel pipe pile cylinder size inspection according to the drawing requirements and corresponding data, and punch and mark them for easy use in size inspection and alignment during the assembly stage;

[0008] S3. Cylinder rolling: The cylinder should be pre-bent before rolling. Use a template to draw pre-bending lines at both ends of the plate. The arc length of the pre-bent part is equal to 1 / 2 of the distance between the two axes of the plate rolling machine + (20-50) mm. After the plate is pre-bent, use a template with a chord length equal to 1 / 6 of the diameter and a length of not less than 300 mm to check the arc;

[0009] S4. Cylinder rolling: The amount of bending during the rolling process should not be too large, especially for steel plates with higher strength.

[0010] S5. Cylinder rounding: After the cylinder is rounded, use a 1000mm chord length inner card sample to check the edge angle. It is qualified if it does not exceed 2mm. The chord length of the roundness inspection sample should be greater than 1 / 3 of the inner diameter of the cylinder. The gap between the sample and the cylinder should not exceed 2mm.

[0011] S6, Cylinder assembly:

[0012] a) When assembling the cylinder, the longitudinal seams between adjacent cylinder sections shall be staggered by 180° according to the structural drawing requirements, and the longitudinal seams shall be on two straight lines;

[0013] b) When assembling the cylinder, use the assembling machine to carry out horizontal installation section by section. If there is an error in the circumference of the second cylinder section that is assembled, the deviation should be evenly distributed to avoid the excessive error of the local misalignment;

[0014] c) When assembling the cylinder, hammering, welding of tie bars, pressing, clamping, etc. are not allowed on the outside of the cylinder, and no traces of jacks are allowed;

[0015] d) After aligning two cylinders in each group, measure the straightness once. If any deviation is found, adjust the gap between the aligners to ensure the straightness.

[0016] e) The edge angle of each butt joint shall be checked with a ruler of not less than 300m in length, and its value shall be ≤δn / 10+2mm, and the misalignment shall be <1 / 4δn;

[0017] f) When connecting the cylinders to form a team, due to the large diameter, first measure the pre-marked equal lines, connect the two lines into a cross shape, check their ovality, and then assemble them according to the requirements after the ovality is qualified;

[0018] g) An eight-meter-long anti-corrosion section is divided on the cylinder body and sent to the painting room for sandblasting and painting. After the anti-corrosion construction is completed, the anti-corrosion section and the remaining sections are connected as a whole on the roller frame;

[0019] S7. Welding: Ensure that the welding line energy does not exceed 3.9KJ / mm to avoid excessive welding deformation and changes in the structure and mechanical properties of the weld heat affected zone.

[0020] As a preferred technical solution of the present invention, the step S7 comprises the following steps:

[0021] S71. For the longitudinal and circumferential joints and welding test plates of the pile foundation cylinder, arc-starting and arc-extinguishing plates must be provided. The cylinder assembly quality must be inspected and qualified before welding can be carried out. Forcible assembly should be avoided during assembly and positioning to prevent cracks in the tack weld and reduce internal stress.

[0022] S72. The longitudinal seams and butt circumferential seams of the cylinder body should be welded by submerged arc automatic welding and double-sided welding. After the single-sided groove welding is completed, the other side should be cleaned by air planing (whitening), and the weld should be cleaned and processed before welding;

[0023] S73. The longitudinal and transverse welds of the cylinder are not allowed to have defects such as pores, slag, undercut, and incomplete penetration. If problems are found during inspection, they must be repaired by air gouging. Direct repair welding is not allowed.

[0024] S74. The welder's stamp should be promptly stamped on the inner side of the cylinder, 50mm away from the weld;

[0025] S75. The weld should be polished until the metallic luster is exposed. The longitudinal and transverse welds should be preheated. The other side can be welded only after the internal welding is completed and cooled. The welding cannot be moved before the welding is completed.

[0026] S76. When welding, use the multi-layer batch welding method. Before welding, the weld should be polished and cleaned. The preheating requirements refer to the relevant welding process requirements;

[0027] S77. Post-weld slow cooling and post-weld heat treatment requirements shall be carried out in accordance with the technical specifications and welding process requirements;

[0028] S78. After the final welding is completed, the weld should be ground, with a weld excess height of 0 to 3 mm. The weld surface should not be uneven, the undercut should be ≤ 0.5 mm, and there should be no weld bumps, pores, or arc pits. Weld repairs are allowed if the weld fails the inspection, but no more than twice.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] The present invention adopts a multi-layer batch welding process during welding construction, which can reduce the construction difficulty increased by personnel entering the inner wall for construction, and can be more beneficial to the welding quality. It can also prevent the verticality of the pile body from not meeting the requirements due to welding, and at the same time can reduce manual labor, shorten the construction period, and reduce construction costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a process flow chart of the present invention. Figure 2 It is a structural schematic diagram of the horizontal installation method of the present invention; DETAILED DESCRIPTION

[0032] The preferred embodiments of the present invention are described in detail below in conjunction with the accompanying drawings so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the protection scope of the present invention.

[0033] In the description of the present invention, unless otherwise specified, "plurality" means two or more than two; the orientations or positional relationships indicated by the terms "upper", "lower", "left", "right", "inner", "outer", "front end", "rear end", "head", "tail", etc. are based on the orientations or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", "third", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0034] Example

[0035] A steel pipe pile manufacturing process, reference Figure 1 As shown, the following steps are included:

[0036] S1. Cutting: When cutting, use the method of stamping to transplant the pile number, factory material mark, and material number on the inner surface of the cylinder or plate and frame them with a colored pen;

[0037] The grooves shall be processed by semi-automatic cutting machines. The weld groove surface shall be polished to a surface roughness of Ra50μm. Impurities such as floating rust, oxides, and oil stains shall be removed within 20mm on both sides of the groove.

[0038] Among them, the allowable deviation of the steel plate thickness used in steel pipe piles is:

[0039]

[0040] S2. Marking: Mark the longitudinal equal-division inspection lines for the steel pipe pile cylinder size inspection according to the drawing requirements and corresponding data, and punch and mark them for easy use in size inspection and alignment during the assembly stage;

[0041] The limit deviation of steel plate marking is:

[0042] Serial number project Limit deviation(mm) 1 Width and Length ±1 2 Diagonal relative difference 2 3 Relative difference of corresponding edges 1 4 Sag (curve part) ±0.5

[0043] S3. Cylinder rolling: The cylinder should be pre-bent before rolling. Use a template to draw pre-bending lines at both ends of the plate. The arc length of the pre-bent part is equal to 1 / 2 of the distance between the two axes of the plate rolling machine + (20-50) mm. After the plate is pre-bent, use a template with a chord length equal to 1 / 6 of the diameter and a length of not less than 300 mm to check the arc;

[0044] S4. Rolling the cylinder: Before rolling, the surface of the steel plate should be cleaned, and both ends of the steel plate should be polished with a portable grinding wheel to remove rust and other debris, and then the plate should be placed straight to prevent misalignment. Be sure to carefully check and be familiar with the processing parameters of each plate according to the drawings provided by the design department, and control the processing size of each plate within the allowable range after processing;

[0045] The amount of bending during rolling should not be too large, especially for steel plates with higher strength.

[0046] The end faces of the longitudinal seams should be kept flush, with the distance between the joint roots at 1 to 2 mm. Angular edges should be avoided, and the sample should be matched. The staggered ends of the tube sections should not exceed 1 mm.

[0047] After passing the inspection, positioning welding is carried out. The length of positioning welding is generally about 50mm. Pay attention to the uniform distribution of welding points on the circumference and ensure that the longitudinal seam does not crack;

[0048] S5. Cylinder rounding: When rounding, it should be placed on a plate rolling machine with different widths according to the diameter and length of the cylinder section, and rolled repeatedly, and checked with an inspection sample;

[0049] After the cylinder is rounded, use a 1000mm chord length internal card sample to check the edge angle, and it is qualified if it does not exceed 2mm; the chord length of the roundness inspection sample should be greater than 1 / 3 of the inner diameter of the cylinder, and the gap between the sample and the cylinder should not exceed 2mm.

[0050] When calibrating the cylinder after welding, it must be ensured that the difference between the maximum diameter and the minimum diameter on the same end face is ≤0.05% Dnom.

[0051] S6, Cylinder assembly:

[0052] a) When the cylinder is assembled, the longitudinal seams between adjacent cylinder sections shall be staggered by 180° according to the structural drawing requirements, and the longitudinal seams shall be on two straight lines (the two plates of the cylinder section shall be staggered by 90° up and down when splicing);

[0053] b) When assembling the cylinder, use the assembling machine to carry out horizontal installation section by section. If there is an error in the circumference of the second cylinder section that is assembled, the deviation should be evenly distributed to avoid the excessive error of the local misalignment;

[0054] c) When assembling the cylinder, hammering, welding of tie bars, pressing, clamping, etc. are not allowed on the outside of the cylinder, and no traces of jacks are allowed;

[0055] d) After aligning two cylinders in each group, measure the straightness once. If any deviation is found, adjust the gap between the aligners to ensure the straightness.

[0056] e) The edge angle of each butt joint shall be checked with a ruler of not less than 300m in length, and its value shall be ≤δn / 10+2mm, and the misalignment shall be <1 / 4δn;

[0057] f) When connecting the cylinders to form a team, due to the large diameter, first measure the pre-marked equal lines, connect the two lines into a cross shape, check their ovality, and then assemble them according to the requirements after the ovality is qualified;

[0058] g) An eight-meter-long anti-corrosion section is divided on the cylinder body and sent to the painting room for sandblasting and painting. After the anti-corrosion construction is completed, the anti-corrosion section and the remaining sections are connected as a whole on the roller frame;

[0059] S7. Welding: Ensure that the welding line energy does not exceed 3.9KJ / mm to avoid excessive welding deformation and changes in the structure and mechanical properties of the weld heat affected zone.

[0060] As a preferred technical solution of the present invention, the step S7 comprises the following steps:

[0061] S71. For the longitudinal and circumferential joints and welding test plates of the pile foundation cylinder, arc-starting and arc-extinguishing plates must be provided. The cylinder assembly quality must be inspected and qualified before welding can be carried out. Forcible assembly should be avoided during assembly and positioning to prevent cracks in the tack weld and reduce internal stress.

[0062] S72. The longitudinal seams and butt circumferential seams of the cylinder body should be welded by submerged arc automatic welding and double-sided welding. After the single-sided groove welding is completed, the other side should be cleaned by air planing (whitening), and the weld should be cleaned and processed before welding;

[0063] S73. The longitudinal and transverse welds of the cylinder are not allowed to have defects such as pores, slag, undercut, and incomplete penetration. If problems are found during inspection, they must be repaired by air gouging. Direct repair welding is not allowed.

[0064] S74. The welder's stamp should be promptly stamped on the inner side of the cylinder, 50mm away from the weld;

[0065] S75. The weld should be polished until the metallic luster is exposed. The longitudinal and transverse welds should be preheated. The other side can be welded only after the internal welding is completed and cooled. The welding cannot be moved before the welding is completed.

[0066] S76. When welding, use the multi-layer batch welding method. Before welding, the weld should be polished and cleaned. The preheating requirements refer to the relevant welding process requirements;

[0067] S77. Post-weld slow cooling and post-weld heat treatment requirements shall be carried out in accordance with the technical specifications and welding process requirements;

[0068] S78. After the final welding is completed, the weld should be ground, with a weld excess height of 0 to 3 mm. The weld surface should not be uneven, the undercut should be ≤ 0.5 mm, and there should be no weld bumps, pores, or arc pits. Weld repairs are allowed if the weld fails the inspection, but no more than twice.

[0069] Weld inspection and testing

[0070] 1. All welds shall be visually inspected in accordance with the provisions of NB / T47014-2011 (including the use of a 10x magnifying glass). The weld wave shall be uniform, the weld edge shall smoothly transition to the parent material, and the butt weld excess height shall not exceed 3mm unless otherwise specified in the drawing. There shall be no cracks, slag inclusions, unfused welds, or pores, weld bumps, arc pits, or undercuts on the weld surface.

[0071] 2. All welds involved should be subjected to 100% ultrasonic testing (UT), and welds at K-type nodes, X-type nodes, and longitudinal welds should be subjected to an additional 20% MT testing.

[0072] Weld defect treatment

[0073] Based on the weld defects identified during the inspection, the defect repair locations and repair measures are proposed. The NDT work should be carried out 48 hours after welding.

[0074] Anticorrosion treatment

[0075] 1. Taking into account the actual situation that steel pipe piles are exposed to corrosive environment, according to the requirements of "Paints and varnishes: Corrosion protection of steel structures by paint protection systems" (ISO12944-2) on the classification of anti-corrosion environment, the steel pipe piles from the top of the pile to a certain depth below the mud surface (elevation is -8.0m): the internal corrosion type is C5-M, and the external corrosion type is Im2.

[0076] 2. Paint system for steel pipe piles: The inner and outer surfaces of the test piles (S1, S2), the inner and outer surfaces of the anchor piles (M1~M6), the inner and outer surfaces of the reference piles (J1, J2) and the outer surfaces of the reference piles (J3, J4) from the top of the pile to the elevation of -8.0m are coated with 2-3 coats of marine engineering epoxy heavy anti-corrosion coating with a total dry film thickness of 500μm.

[0077] 3. Surface treatment and anti-corrosion coating construction require that the construction be carried out indoors in a well-ventilated and well-lit room. The relative humidity of the air should be lower than 85%, and the substrate temperature should be at least 3°C ​​higher than the dew point temperature.

[0078] 4. The ambient temperature range for normal temperature anti-corrosion coating construction is 5℃~40℃; when the ambient temperature is -5℃~5℃, winter coating must be used for construction, and the construction process shall be carried out according to the instructions provided by the coating supplier. Anti-corrosion coating construction is strictly prohibited when the temperature is below -5℃.

[0079] The present invention adopts a multi-layer batch welding process during welding construction, which can reduce the construction difficulty increased by personnel entering the inner wall for construction, and can be more beneficial to the welding quality. It can also prevent the verticality of the pile body from not meeting the requirements due to welding, and at the same time can reduce manual labor, shorten the construction period, and reduce construction costs.

[0080] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "connected" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0081] The above-mentioned embodiments only express several implementation methods of the present invention, and the description is relatively specific and detailed, but it cannot be understood as limiting the scope of the invention patent. It should be pointed out that for ordinary technicians in this field, several modifications and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention.

Claims

1. A steel pipe pile manufacturing process, characterized in that: The steps include: S1. Cutting: When cutting, use the method of stamping to transplant the pile number, factory material mark, and material number on the inner surface of the cylinder or plate and frame them with a colored pen; S2. Marking: Mark the longitudinal equal-division inspection lines for the steel pipe pile cylinder size inspection according to the drawing requirements and corresponding data, and punch and mark them for easy use in size inspection and alignment during the assembly stage; S3. Cylinder rolling: The cylinder should be pre-bent before rolling. Use a template to draw pre-bending lines at both ends of the plate. The arc length of the pre-bent part is equal to 1 / 2 of the distance between the two axes of the plate rolling machine + (20-50) mm. After the plate is pre-bent, use a template with a chord length equal to 1 / 6 of the diameter and a length of not less than 300 mm to check the arc; S4. Cylinder rolling: The amount of bending during the rolling process should not be too large, especially for steel plates with higher strength. S5. Cylinder rounding: After the cylinder is rounded, use a 1000mm chord length inner card sample to check the edge angle. It is qualified if it does not exceed 2mm. The chord length of the roundness inspection sample should be greater than 1 / 3 of the inner diameter of the cylinder. The gap between the sample and the cylinder should not exceed 2mm. S6, Cylinder assembly: a) When assembling the cylinder, the longitudinal seams between adjacent cylinder sections shall be staggered by 180° according to the structural drawing requirements, and the longitudinal seams shall be on two straight lines; b) When assembling the cylinder, use the assembling machine to carry out horizontal installation section by section. If there is an error in the circumference of the second cylinder section that is assembled, the deviation should be evenly distributed to avoid the excessive error of the local misalignment; c) When assembling the cylinder, hammering, welding of tie bars, pressing, clamping, etc. are not allowed on the outside of the cylinder, and no traces of jacks are allowed; d) After aligning two cylinders in each group, measure the straightness once. If any deviation is found, adjust the gap between the aligners to ensure the straightness. e) The edge angle of each butt joint shall be checked with a ruler of not less than 300m in length, and its value shall be ≤δn / 10+2mm, and the misalignment shall be <1 / 4δn; f) When connecting the cylinders to form a team, due to the large diameter, first measure the pre-marked equal lines, connect the two lines into a cross shape, check their ovality, and then assemble them according to the requirements after the ovality is qualified; g) An eight-meter-long anti-corrosion section is divided on the cylinder body and sent to the painting room for sandblasting and painting. After the anti-corrosion construction is completed, the anti-corrosion section and the remaining sections are connected as a whole on the roller frame; S7. Welding: Ensure that the welding line energy does not exceed 3.9KJ / mm to avoid excessive welding deformation and changes in the structure and mechanical properties of the weld heat affected zone.

2. A steel pipe pile manufacturing process according to claim 1, characterized in that: The step S7 includes the following steps: S71. For the longitudinal and circumferential joints and welding test plates of the pile foundation cylinder, arc-starting and arc-extinguishing plates must be provided. The cylinder assembly quality must be inspected and qualified before welding can be carried out. Forcible assembly should be avoided during assembly and positioning to prevent cracks in the tack weld and reduce internal stress. S72. The longitudinal seams and butt circumferential seams of the cylinder body should be welded by submerged arc automatic welding and double-sided welding. After the single-sided groove welding is completed, the other side should be cleaned by air planing (whitening), and the weld should be cleaned and processed before welding; S73. The longitudinal and transverse welds of the cylinder are not allowed to have defects such as pores, slag, undercut, and incomplete penetration. If problems are found during inspection, they must be repaired by air gouging. Direct repair welding is not allowed. S74. The welder's stamp should be promptly stamped on the inner side of the cylinder, 50mm away from the weld; S75. The weld should be polished until the metallic luster is exposed. The longitudinal and transverse welds should be preheated. The other side can be welded only after the internal welding is completed and cooled. The welding cannot be moved before the welding is completed. S76. When welding, use the multi-layer batch welding method. Before welding, the weld should be polished and cleaned. The preheating requirements refer to the relevant welding process requirements; S77. Post-weld slow cooling and post-weld heat treatment requirements shall be carried out in accordance with the technical specifications and welding process requirements; S78. After the final welding is completed, the weld should be ground, with a weld excess height of 0 to 3 mm. The weld surface should not be uneven, the undercut should be ≤ 0.5 mm, and there should be no weld bumps, pores, or arc pits. Weld repairs are allowed if the weld fails the inspection, but no more than twice.

Images