摘要：<span style="font-family:宋體;font-size:small;"> </span> <p style="margin:0cm 0cm 0pt;"> <span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;"><span style="font-size:small;">不銹鋼帶鋼光亮退火馬弗爐缺陷分析及修復(fù)</span></span> </p> <span style="font-family:宋體;font-size:small;"> </span> <p style="margin:0cm 0cm 0pt;"> <span style="font-size:small;"><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">爐中馬弗管尺寸大</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(&lt;1820mm×28500mm)</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">、質(zhì)量大</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(20000kg)</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">，馬弗管正常使用溫度為</span><span style="font-family:'Times New Roman';"><span lang="EN-US">1000</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">℃以上，*高工作溫度可以達(dá)到</span><span style="font-family:'Times New Roman';"><span lang="EN-US">1200</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">℃。由于馬弗管用材料為高溫鎳基耐熱合金，該材料具有優(yōu)異的力學(xué)性能，尤其是優(yōu)良的高溫持久強(qiáng)度及抗氧化性，國(guó)內(nèi)無法生產(chǎn)，還完全依賴進(jìn)口。高溫自重條件的長(zhǎng)時(shí)間作用使得不銹鋼光亮退火生產(chǎn)線運(yùn)行過程中產(chǎn)生多種缺陷而影響生產(chǎn)。實(shí)際生產(chǎn)中，為確保</span><span style="font-family:'Times New Roman';"><span lang="EN-US">BAL</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">可靠運(yùn)行，縮短更換馬弗的時(shí)間，準(zhǔn)備了兩支馬弗</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">分別表示為</span><span style="font-family:'Times New Roman';"><span lang="EN-US">A1</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">和</span><span style="font-family:'Times New Roman';"><span lang="EN-US">A2)</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">，兩支馬弗</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">一用一備</span><span style="font-family:'Times New Roman';"><span lang="EN-US">)</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">在實(shí)際運(yùn)行過程中相繼出現(xiàn)缺陷而無法正常使用，新制造一支馬弗需要大約</span><span style="font-family:'Times New Roman';"><span lang="EN-US">1</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">年的時(shí)間且價(jià)值昂貴。因而分析各種缺陷的原因并對(duì)馬弗進(jìn)行修復(fù)將有助于確保正常生產(chǎn)，具有重要的工程應(yīng)用價(jià)值。</span></span> </p> <span style="font-family:宋體;font-size:small;"> </span> <p style="margin:0cm 0cm 0pt;"> <span style="font-size:small;"><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">馬弗管在長(zhǎng)時(shí)間高溫、自重</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(20000kg)</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">及燒嘴燃燒不均導(dǎo)致的溫度不均勻等因素作用下，會(huì)在使用過程中出現(xiàn)縮頸、壁厚減薄、焊縫開裂、截面變形、香蕉狀彎曲、鼓包等缺陷。</span></span> </p> <span style="font-family:宋體;font-size:small;"> </span> <p style="margin:0cm 0cm 0pt;"> <span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;"><span style="font-size:small;">對(duì)于由于高溫蠕變引起的伸長(zhǎng)、縮頸、厚度減薄、截面變形、彎曲、鼓包等缺陷，可以通過切除失效部位的措施進(jìn)行修復(fù)。為此，在修復(fù)前首先對(duì)馬弗管進(jìn)行**測(cè)量以確定修復(fù)工藝和修復(fù)后的驗(yàn)收標(biāo)準(zhǔn)。其次，對(duì)缺陷部位切除后進(jìn)行焊接。</span></span> </p> <span style="font-family:宋體;font-size:small;"> </span> <p style="margin:0cm 0cm 0pt;"> <span style="font-size:small;"><span style="font-family:'Times New Roman';"><span lang="EN-US">A1</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">管缺陷主要表現(xiàn)為：道環(huán)形焊縫開裂，二次吊裝法蘭設(shè)計(jì)缺陷及產(chǎn)生處局部鼓包，香蕉狀彎曲，</span><span style="font-family:'Times New Roman';"><span lang="EN-US">A</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">段的嚴(yán)重縮頸、壁厚減薄、大面積龜裂和截面變形。因而充分考慮上述缺陷特點(diǎn)，采用的修復(fù)方案為</span><span style="font-family:'Times New Roman';"><span lang="EN-US">:</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">①首先用手工切割機(jī)截去道焊縫兩側(cè)各</span><span style="font-family:'Times New Roman';"><span lang="EN-US">100mm</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">左右的筒體，重新焊接</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">具體切除長(zhǎng)度應(yīng)按著色檢查裂紋情況后再定</span><span style="font-family:'Times New Roman';"><span lang="EN-US">);</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">②用手工切割機(jī)切二次吊裝法蘭，并截去鼓包段約</span><span style="font-family:'Times New Roman';"><span lang="EN-US">400mm</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">，人工校正筒體端面平整度，然后雙面倒角后對(duì)接</span><span style="font-family:'Times New Roman';"><span lang="EN-US">;</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">③采用厚度</span><span style="font-family:'Times New Roman';"><span lang="EN-US">15mm</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">的替代材料制成筒體焊接在馬弗管尾部至馬弗管總長(zhǎng)度達(dá)</span><span style="font-family:'Times New Roman';"><span lang="EN-US">28522mm;</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">④二次吊裝法蘭結(jié)構(gòu)及安裝部位進(jìn)行了重新設(shè)計(jì)，將整段法蘭焊接結(jié)構(gòu)改為分段法蘭焊接結(jié)構(gòu)方式。</span></span> </p> <span style="font-family:宋體;font-size:small;"> </span> <p style="margin:0cm 0cm 0pt;"> <span style="font-size:small;"><span style="font-family:'Times New Roman';"><span lang="EN-US">A2</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">管缺陷主要表現(xiàn)為：二次吊裝法蘭處燒穿，多處鼓包缺陷，香蕉狀彎曲，</span><span style="font-family:'Times New Roman';"><span lang="EN-US">A</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">段的嚴(yán)重縮頸、壁厚減薄、大面積龜裂和截面變形。因而充分考慮上述缺陷特點(diǎn)，采用的修復(fù)方案具體如下：①?gòu)亩蔚跹b法蘭處用等離子切割機(jī)切割開馬弗管</span><span style="font-family:'Times New Roman';"><span lang="EN-US">;</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">②采用著色滲透檢查方法檢查馬弗管穿孔處裂紋確定切割的尺寸，采用手動(dòng)砂輪片切割機(jī)對(duì)馬弗管進(jìn)行切割</span><span style="font-family:'Times New Roman';"><span lang="EN-US">;</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">③對(duì)表面切口按照焊接坡口要求打磨，由于馬弗管切口斷面已成橢圓形</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">長(zhǎng)軸約</span><span style="font-family:'Times New Roman';"><span lang="EN-US">1900mm</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">，短軸約</span><span style="font-family:'Times New Roman';"><span lang="EN-US">1700mm)</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">，對(duì)接時(shí)必須按橢圓形還原對(duì)接，然后進(jìn)行手工焊接</span><span style="font-family:'Times New Roman';"><span lang="EN-US">;</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">④采用著色滲透檢查方法檢查焊縫質(zhì)量</span><span style="font-family:'Times New Roman';"><span lang="EN-US">;</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">⑤在馬弗管底部焊接一定長(zhǎng)度的替代鋼板</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(&lt;1820mm×900mm</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">，厚度</span><span style="font-family:'Times New Roman';"><span lang="EN-US">15mm)</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">使馬弗爐總長(zhǎng)度達(dá)到設(shè)計(jì)要求</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">約</span><span style="font-family:'Times New Roman';"><span lang="EN-US">28500mm);</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">⑥二次吊裝法蘭處理與</span><span style="font-family:'Times New Roman';"><span lang="EN-US">A1</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">馬弗管相同</span><span style="font-family:'Times New Roman';"><span lang="EN-US">;</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">⑦</span><span style="font-family:'Times New Roman';"><span lang="EN-US">A2</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">馬弗爐已出現(xiàn)</span><span style="font-family:'Times New Roman';"><span lang="EN-US">7</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">處鼓包，由于沒有合適的材料，因而只對(duì)*為嚴(yán)重的鼓包采用與燒穿相同的方法進(jìn)行了整段切除、對(duì)焊，其余部位的鼓包只能進(jìn)行定期跟蹤滲透探傷檢查。</span></span> </p> <span style="font-family:宋體;font-size:small;"> </span> <p style="margin:0cm 0cm 0pt;"> <span style="font-size:small;"><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">對(duì)于</span><span style="font-family:'Times New Roman';"><span lang="EN-US">A1</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">馬弗管已使用</span><span style="font-family:'Times New Roman';"><span lang="EN-US">3</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">年，根據(jù)相應(yīng)的缺陷形式，通過對(duì)其材質(zhì)強(qiáng)度、焊接的評(píng)定，根據(jù)制定的修復(fù)方案進(jìn)行了馬弗管的修復(fù)，使其達(dá)到使用的標(biāo)準(zhǔn)。</span></span> </p> <span style="font-family:宋體;font-size:small;"> </span> <p style="margin:0cm 0cm 0pt;"> <span style="font-size:small;"><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">對(duì)于</span><span style="font-family:'Times New Roman';"><span lang="EN-US">A2</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">馬弗管使用了近</span><span style="font-family:'Times New Roman';"><span lang="EN-US">2</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">年，根據(jù)材質(zhì)強(qiáng)度評(píng)定和制定的修復(fù)方案，完成了馬弗管的修復(fù)。該修復(fù)的馬弗管連續(xù)運(yùn)行了</span><span style="font-family:'Times New Roman';"><span lang="EN-US">17</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">個(gè)月，使用狀態(tài)一直良好。下機(jī)后對(duì)所有焊縫進(jìn)行</span><span style="font-family:'Times New Roman';"><span lang="EN-US">X</span></span><span style="font-family:宋體;mso-ascii-font-family:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">光探傷，未發(fā)現(xiàn)有新的裂紋出現(xiàn)，還可以繼續(xù)使用。現(xiàn)場(chǎng)應(yīng)用情況表明按照上述修復(fù)工藝方案進(jìn)行修復(fù)取得了成功，同時(shí)也驗(yàn)證了所選鎳基高溫合金與替代材料焊接的焊接性能在高溫作用下完全可滿足使用。</span></span> </p> <span style="font-family:宋體;font-size:small;"> </span> <p style="margin:0cm 0cm 0pt;"> <span lang="EN-US"><span style="font-family:'Times New Roman';font-size:small;">&nbsp;</span></span> </p> <span style="font-family:宋體;font-size:small;"> </span>