法兰生产制造大纲 Flange Manufacturing Description

No.

PHASE

DESCRIPTION

1

Identification of base material

材料鉴定

Pipe to ASTM A105/A105

MDS C34S

Manufacturer:Shanxi Taigang Stainless Steel Co., Ltd

Pipe to ASTM A350/LF2

MDS C44

Manufacturer:Shanxi Taigang Stainless Steel Co., Ltd

Pipe to ASTM A694/F65

MDS CH64S

Manufacturer:Shanxi Taigang Stainless Steel Co., Ltd

Pipe to ASTM A694/F70

MDS CH64S

Manufacturer:Shanxi Taigang Stainless Steel Co., Ltd

Pipe to ASTM A812/F316

MDS S14

Manufacturer:Shanxi Taigang Stainless Steel Co., Ltd

Pipe to ASTM A182/F51/F60

MDS D44

Manufacturer:Shanxi Taigang Stainless Steel Co., Ltd

Pipe to ASTM A182/F53

MDS D54

Manufacturer:Shanxi Taigang Stainless Steel Co., Ltd

Pipe to ASTM A182/F55

MDS D54

Manufacturer:Shanxi Taigang Stainless Steel Co., Ltd

Pipe to ASTM B564/N06625

MDS N14

Manufacturer:Zhongxing Energy Equipment Co.,Ltd

2

Inspection of the pipe

原材料检查

1. Raw materials shall meet the requirements of relevant standards and technical specifications.

2, the surface of raw materials should be free of oil, excessive rust corrosion and obvious dent defects, low melting point metal pollution.

3, check the quality certificate of raw materials, furnace number, batch number, specifications, manufacturers and implementation standards.

4, raw materials with steel wire brush for mechanical rust removal, so that it meets the requirements of non-destructive testing.

5, raw material size detection (length, width, thickness).

6, the round steel after entering the factory, should be ultrasonic reinspection, grade I is qualified.

7, physical and chemical testing, the steel plate into the factory according to the furnace batch number, specifications for chemical element analysis, mechanical properties, hardness test, test results should meet the requirements of raw material standards.

8, after re-inspection according to the factory regulations for serial number registration

1、原材料应符合相关标准和技术规范书的要求。

2、原材料表面应无油污，过多的锈腐蚀物和明显的凹痕缺陷，低熔点金属污染等。

3、查验原材料的质证书、炉号、批号、规格，生产厂家及执行标准。

4、原材料用钢丝刷进行机械除锈，使之满足无损检测的要求。

5、原材料进行尺寸检测（长度、宽度、厚度）。

6、进厂后的圆钢，应进行超声波复检，Ⅰ级为合格。

7、理化检测，对进厂的钢板按炉批号、规格进行化学元素分析、力学性能、硬度测试，试验结果应符合原材料标准要求。

8、复检后按厂规进行编号登记入册

3

PMI 采购经理

100% raw material.

4

Cutting切割

Material according to the user's specifications for stainless steel material is most appropriate to use the gantry band sawing machine for cold cutting, should not use plasma and other thermal cutting method to cut material, to ensure that the waste of materials and avoid causing the fracture or heat affected zone metallographic changes; Prevent defects such as hardening layer or cracks caused by improper operation in the cutting process. After cutting, use the grinding wheel to polish the port and remove the burrs and edges. Carbon steel material is cut by oxygen-acetylene flame or saw machine, and the necessary identification is transplanted according to the specification and material of the material and the geometric size of the broken blank is inspected piece by piece.

材料按用户的规格尺寸对于不锈钢材料的下料最宜采用龙门带锯床进行冷切割下料，不宜用等离子等热切割的方法断料，以保证减少材料的浪费并避免造成断口处或热影响区金相组织发生变化；防止材料在切割过程出现淬硬层或因操作不当造成裂纹等缺陷。切割后用砂轮磨光机对端口处进行打磨，去除端口毛刺及棱角。碳钢材料采用氧--乙炔火焰或锯床下料，在下料过程中要求按材料的规格和材质等不同进行必要的标识移植并且对断好的坯料的几何尺寸进行逐件检验。

5

Forge

锻制

Flange blank forging. According to the forging process requirements of the corresponding material, the qualified blank is heated in the heating furnace and then forged, and the blank of large pipe fittings is freely forged under the cleat hammer. All flange blanks must meet the requirements of Class II forgings. The billets of different materials are carried out according to the process card requirements of the corresponding heating temperature and holding time.

法兰坯料锻制。法兰按相应材料的锻造工艺要求将合格坯料放在加热炉中加热后进行锻造，大型管件的坯料要在夹板锤下进行自由锻造。所有法兰坯料均需达到II级锻件以上要求。不同材质的坯料按相应加热温度和保温时间的工艺卡要求进行。

6

Heat treatment

热处理

Pipe blank (flange blank) heat treatment, according to the heat treatment process of different materials, the pipe formed by hot (cold) processing and the forged flange blank heat treatment, in order to achieve stress relief, fine organization, improve the strength of the material, toughness and other comprehensive properties. The heat treatment process is executed according to the heat treatment process card. Heat treatment process steps according to the following requirements:

1. Check the components of the heat treatment furnace: burner, thermometer, fan, oil pump system, truck device, furnace door lifting device, etc. should be in normal standby state, and the fuel amount of the oil depot should meet the use of heat treatment.

2. Furnace loading: (1) The workpiece should be padded about 400mm high, the arrangement should not make the workpiece pressure each other, the interval of 150mm to prevent deformation to facilitate uniform cooling. According to the shape of the reasonable layout, and draw the layout size sketch, while writing the number to do a good record. (2) The flange should be flat on the platform to prevent the bending pipe from deformation after heating. (3) Adjust the firewall so that the flame is not directly sprayed onto the workpiece.

3. Check whether the furnace sand seal is good before ignition. If there are gaps, apply refractory soil or aluminum silicate high temperature asbestos to seal it.

4. If the heat treatment furnace is ignited for a cold furnace, half of the nozzle should be used (that is, one nozzle is lit at every interval), if the furnace is ignited, all the nozzle can be ignited, and the heating rate and constant temperature time cooling method should be in line with the heat treatment process.

5. Adjust the oil supply and air volume of the flue valve and the oil nozzle, so that the temperature of the heat treatment furnace is uniform, the temperature of each thermocouple is balanced, and the operator records the furnace temperature every 15 minutes.

6. The operator should regularly visit, check the operation of the oil furnace, observe the combustion of the furnace with the observation hole, adjust the nozzle air volume and oil volume in time when the combustion is not good, and compare the optical pyrometer when the furnace temperature indication is found to be in doubt, and find out the cause for treatment.

7. Close all the oil nozzle and damper before the workpiece is released, and fill in the heat treatment process Parameter Record.

8. The normalizing and tempering of heat treatment can be divided into two times, such as a continuous process, the temperature of the bend pipe after normalizing must be reduced to below 300℃ before tempering work can be carried out.

9. The same furnace must only be loaded with the same material or flange of the corresponding specification.

10. Phase inspection shall not be less than one per furnace; Hardness test shall not be less than two pieces per furnace, each piece shall not be less than 3 points, the test part is located in the base metal on the tension side, the maximum deformation area.

管件毛坯（法兰坯料）热处理，按不同材料的热处理工艺对经热（冷）加工成型的管件及锻造完成的法兰坯料进行热处理，以达到消除应力、细化组织、提高材料的强度、韧性等综合性能。热处理工艺按热处理工艺卡执行。热处理的工艺步骤按以下要求：

1.检查热处理炉各部件：火嘴、温度计、风机、油泵系统、台车装置、炉门升降装置等应处于正常备用状态，油库燃料量应满足热处理使用。

2.装炉：（1）工件要垫高400mm左右，排列不应使工件互相受压，间隔150mm防止变形便于冷却均匀散热。根据形状合理进行布局，并绘布置尺寸草图，同时编写号码做好记录。（2）法兰应在台车上垫平，防止弯管受热后产生变形。（3）调整挡火墙，使火焰不直接喷射到工件上。

3.点火前查看炉膛砂封是否良好，如有缝隙应用耐火土或硅酸铝高温石棉加以密封。

4.热处理炉如为冷炉点火时，宜采用半数火咀（即每间隔一个火咀点燃一个，如为炉点火可将全部火咀点燃，注意升温速度恒温时间冷却方式等应符合热处理工艺。

5.调节烟道阀门和油嘴给油量及风量,使热处理炉温度均匀，各热电偶温度均衡，操作人员每间隔15分钟记录一次炉温。

6.操作人员应经常巡视,检查油炉运行情况,利用观察孔观察炉膛燃烧情况，燃烧不好时及时对火咀风量和油量进行调整，如发现炉膛温度指示有疑问时应用光学高温计进行比较，查出原因进行处理。

7.工件出炉前关闭所有油嘴和风门，填写好《热处理工艺参数记录》。

8.热处理的正火和回火可以分两次进行,如一次连续进行时,正火完后弯管温度必须降至300℃以下才可进行回火工作。

9.同一炉必须只装同一种材质、或相应规格的法兰。

10.相检验每炉不得少于一只；硬度检验每炉不得少于两件，每件不得少于3个点，检测部分分别位于受拉侧的母材，最大变形区。

7

Process

加工

Machining molding, according to different pipe specifications, models and other requirements, according to the corresponding standard requirements of the use of lathes, drilling machines and other machinery to machined the blank, so that pipe products meet the standard requirements of the appearance and geometric size of the specified range. The inspection department inspects the product according to the standard geometric dimensions and tolerances. Stainless steel pipe fittings shall be pickled and passivated after machining, and intergranular corrosion detection shall be carried out if necessary.

机加工成型，根据不同管件的规格、型号等要求，按相应的标准要求利用车床、钻床等机械对坯料进行机加工成型，使管件产品达到标准要求的外观和几何尺寸规定范围。检测部门对产品按标准的几何尺寸和型位公差要求进行检验。不锈钢管件在机加工完成后进行酸洗钝化处理，必要时要进行晶间腐蚀检测。

8

Sampling

取样

These products are sampled for physical and chemical testing.

对这些产品取样进行物理和化学测试。

9

Surface treatment

表面处理

1. The surface of the flange shall not have cracks, overheating, etc., and the surface shall have no hard points.

2. The inner and outer surfaces of the flange should be smooth, without defects that damage the strength and appearance, such as scars, scratches, heavy skin, etc., the defects found in the inspection should be repaired and removed, and the grinding place should be smooth until the defects are eliminated by coloring or magnetic powder detection, and the thickness after grinding should meet the specified requirements.

3. Pits with a depth of more than 3.15mm on the flange end body and pits with a depth of more than 1.5mm on the weld are not allowed to be trimmed by hammering.

4. Defect repair

The sharp notch gouges and scratches on the pipe body whose depth is less than 5% of the nominal wall thickness should be smoothed, and the smooth and isolated circular bottom marks should not be smoothed.

5. Any cracks, overburning, overheating or hard points on the flange are not allowed to repair the defects of the flange body.

6. The geometric size inspection shall be carried out according to the corresponding standard size requirements.

1.法兰表面不得有裂纹、过烧过热等存在,表面应无硬点。

2.法兰内外表面应光滑、无有损强度及外观的缺欠,如结疤、划痕、重皮等，检查发现的缺欠应修磨清除，修磨处应圆滑直至用着色或磁粉探伤确认缺欠消除为止，修磨后的厚度应符合规定要求。

3.法兰端体上深度超过3.15mm的凹坑,焊缝上深度超过1.5mm的凹坑不允许采用锤击方法修整。

4.缺陷的修补

管体上深度小于公称壁厚5%的尖缺口凿痕及划痕应圆滑修磨,平滑孤立的圆底痕迹不必修磨.

5.法兰上的任何裂纹、过烧、过热或硬点不允许修补法兰管体的缺陷不允许焊接修补.

6.几何尺寸检验按照相应标准尺寸要求进行.

10

Appearance detection

外观检测

① The product shall not have cracks, overburning, overheating and other phenomena, and the surface shall have no hard points.

② The transition area of the product is not allowed to have obvious folds.

③ Any defects on the product tube body are not allowed to be repaired by welding.

①产品不得有裂纹、过烧、过热等现象存在，表面应无硬点。

②产品过渡区不允许有明显褶皱。

③产品管体上的任何缺陷不允许焊接修补。

11

Size detection

尺寸检测

The relevant inspection personnel of the company shall carry out dimensional inspection according to the drawing and relevant standard requirements of pipe fittings, and meet the tolerance requirements.

由公司相关检测人员，根据图纸及管件的相关标准要求进行尺寸检测，并满足其公差要求。

12

Surface treatment

表面处理

The internal and external surfaces of the product should be smooth, without damaging strength and appearance defects, such as scars, scratches, heavy skin, etc., should be trimmed after defects are found, and the thinning amount at the grinding place should not be less than 93.5% of the original wall thickness, and the grinding place should be smooth and verified by colorant or magnetic powder inspection until the defects are removed.

产品内外表面应光滑，无有损强度及外观缺陷，如结疤、划痕、重皮等，发现缺陷后应修磨处理，修磨处的减薄量不小于原壁厚的93.5%，修磨处应圆滑并用着色剂或磁粉探伤确认缺陷清除为止。

13

Nondestructive testing

无损检测

After heat treatment, the company shall carry out X-ray inspection of the weld according to the standard requirements, and the result shall meet the standard requirements. The magnetic particle or penetration test shall be carried out on the reducing tube body, and the test result shall meet the standard requirements.

在热处理后，由公司持有相关资质证书人员，根据标准要求对焊缝进行射线检测，结果应符合标准要求，对异径管本体进行磁粉或渗透检测，检测结果应符合标准要求。

14

Pickling passivation treatment

酸洗钝化处理

The stainless steel pipe fittings should be pickled and passivated

对不锈钢管件应进行酸洗钝化处理

15

Identification

标识

Marked with a stencil brush or low stress impression, the outer wall is clearly marked with the standard requirements in order.

用模板喷刷或低应力印模进行标记，在外壁按顺序清楚的标明标准要求的内容。

16

Stacking and transportation

堆放及运输

During transportation, it is not allowed to contact with any part of the carriage to avoid bumping.

在运输过程中运输过程中不能与车厢的任何部分接触，避免磕碰。