This project focuses on the manufacturing supervision and inspection of X100 submerged arc welded steel pipe and the design of pressure pipeline valve type test methods. According to the characteristics of the production process of X100 submerged arc welded steel pipe, its inspection and testing technology were studied, including material physical and chemical properties inspection, steel plate appearance inspection, ultrasonic, radiographic, magnetic particle flaw detection and hydraulic testing. At the same time, training and assessment of welding process assessment personnel were standardized. Finally, detailed rules for supervision and inspection of X100 steel pipes were prepared. According to the design requirements of standards such as TSG D7002-2006 "Pressure Pipe Components Type Test Rules", a wide range of adaptability pressure test devices and fire resistance test devices have been developed, and they have been cooperated with relevant data collection and safety protection measures to form a set. A safe, reliable and accurate recordable test system is suitable for testing a variety of valves.
The project has achieved the following technical indicators and achieved the original intention of establishing the project:
(1) Transformation of X100 steel pipe online equipment, preparation of supervision and inspection rules, and revision of welding process qualification;
(2) To shorten the testing time, exhaust the test valve through the vacuum pumping system, reduce the testing time to less than 10 minutes and speed up the testing speed;
(1) Realize automatic control of the test process, and perform operation control by inputting the currently common valve models and specifications into the database, including parameter setting, input and automatic setting of valve types and models;
(2) Realize automatic data collection and test results processing during valve testing;
(3) The device adopts safety protection doors and safety interlocking devices;
(4) Realize monitoring of the test process and research on risk identification and alarm, including multi-directional monitoring and image data collection;
(5) Achieve bar code production and collection after the test;
(6) Achieve the integration of opening and closing tests and torque testing, including testing and collection where torque can always be adjusted and maintained within a certain range during the valve opening and closing process;
(7) The pressure test, temperature detection and control, and leakage detection of the valve fire resistance test device are realized;
The X100 Steel Pipe Supervision and Inspection Rules are the first domestic manufacturing supervision and inspection plan for ultra-high strength pipeline steel pipes, providing guarantees for the repeatability and stability of batch product production. Pressure pipeline valve type test equipment has broken through several key points in the research of valve pressure test technology such as vacuum pumping, automatic data acquisition, safety protection and interlocking, bar code production and collection, and opening and closing torque integration. At present, many domestic valve manufacturers have used the valve testing equipment developed to conduct pressure testing on products in production. This not only saves testing time for enterprises, but also provides traceability to the barcode system of all testing data, which provides evidence for enterprises and testing institutions to follow. The test equipment is also adopted and applied by third-party inspection agencies.
The eight models of equipment developed by this project have been successfully trial-produced and have been used in valve companies and type testing institutions. Published 3 papers and applied for 8 patents. The formulation of China's first X100 steel pipe supervision and inspection rules fills domestic gaps and provides guarantee for product quality. The development of pressure pipeline valve testing equipment is at the international first-class level and has created tens of millions of economic benefits for the Shanghai City Special Inspection Institute and equipment manufacturing units.