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不鏽鋼帶鋼光亮退火馬弗爐缺陷分析及修複
日期：2025-06-25 09:38
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摘要：<span style="font-family:宋體;font-size:small;"> </span>
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<span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";"><span style="font-size:small;">不鏽鋼帶鋼光亮退火馬弗爐缺陷分析及修複</span></span>
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<span style="font-size:small;"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";">爐中馬弗管尺寸大</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(<1820mm×28500mm)</span></span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";">、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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">，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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">℃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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">℃。由於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(wú)法生產(chǎn)，還完全依賴進(jìn)口。高溫自重條件的長(zhǎng)時(shí)間作用使得不鏽鋼光亮退火生產(chǎn)線運(yùn)行過(guò)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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">分彆表示為</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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">，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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">在實(shí)際運(yùn)行過(guò)程中相繼出現(xiàn)缺陷而無(wú)法正常使用，新製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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">年的時(shí)間且價(jià)值昂貴。因而分析各種缺陷的原因並對(duì)馬弗進(jìn)行修複將有助於確保正常生產(chǎn)，具有重要的工程應(yīng)用價(jià)值。</span></span>
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<span style="font-size:small;"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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(guò)程中出現(xiàn)縮頸、壁厚減薄、焊縫開(kāi)裂、截麵變形、香蕉狀彎曲、鼓包等缺陷。</span></span>
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<span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";"><span style="font-size:small;">對(duì)於由於高溫蠕變引起的伸長(zhǎng)、縮頸、厚度減薄、截麵變形、彎曲、鼓包等缺陷，可以通過(guò)切除失效部位的措施進(jìn)行修複。為此，在修複前首先對(duì)馬弗管進(jìn)行**測(cè)量以確定修複工藝和修複後的驗(yàn)收標(biāo)準(zhǔn)。其次，對(duì)缺陷部位切除後進(jìn)行焊接。</span></span>
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<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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">管缺陷主要表現(xiàn)為：道環(huán)形焊縫開(kāi)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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">段的嚴(yán)重縮頸、壁厚減薄、大麵積龜裂和截麵變形。因而充分考慮上述缺陷特點(diǎn)，采用的修複方案為</span><span style="font-family:'Times New Roman';"><span lang="EN-US">:</span></span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">具體切除長(zhǎng)度應(yīng)按著色檢查裂紋情況後再定</span><span style="font-family:'Times New Roman';"><span lang="EN-US">);</span></span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";">②用手工切割機(jī)切二次吊裝法蘭，並截去鼓包段約</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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">，人工校正筒體端麵平整度，然後雙麵倒角後對(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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">的替代材料製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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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>
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<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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">段的嚴(yán)重縮頸、壁厚減薄、大麵積龜裂和截麵變形。因而充分考慮上述缺陷特點(diǎn)，采用的修複方案具體如下：①?gòu)亩蔚跹b法蘭處用等離子切割機(jī)切割開(kāi)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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">③對(duì)表麵切口按照焊接坡口要求打磨，由於馬弗管切口斷麵已成橢圓形</span><span style="font-family:'Times New Roman';"><span lang="EN-US">(</span></span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">，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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">，對(duì)接時(shí)必須按橢圓形還原對(duì)接，然後進(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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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">(<1820mm×900mm</span></span><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";">，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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">處鼓包，由於冇有合適的材料，因而隻對(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，其餘部位的鼓包隻能進(jìn)行定期跟蹤滲透探傷檢查。</span></span>
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<span style="font-size:small;"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";">對(duì)於</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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">年，根據(jù)相應(yīng)的缺陷形式，通過(guò)對(duì)其材質(zhì)強(qiáng)度、焊接的評(píng)定，根據(jù)製定的修複方案進(jìn)行了馬弗管的修複，使其達(dá)到使用的標(biāo)準(zhǔn)。</span></span>
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<span style="font-size:small;"><span style="font-family:宋體;mso-ascii-font-family:"Times New Roman";mso-hansi-font-family:"Times New Roman";">對(duì)於</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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">年，根據(jù)材質(zhì)強(qiáng)度評(píng)定和製定的修複方案，完成了馬弗管的修複。該修複的馬弗管連續(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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">個(gè)月，使用狀態(tài)一直良好。下機(jī)後對(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:"Times New Roman";mso-hansi-font-family:"Times New Roman";">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複工藝方案進(jìn)行修複取得了成功，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>
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不鏽鋼帶鋼光亮退火馬弗爐缺陷分析及修複
爐中馬弗管尺寸大(<1820mm×28500mm)、質(zhì)量大(20000kg)，馬弗管正常使用溫度為1000℃以上，*高工作溫度可以達(dá)到1200℃。由於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(wú)法生產(chǎn)，還完全依賴進(jìn)口。高溫自重條件的長(zhǎng)時(shí)間作用使得不鏽鋼光亮退火生產(chǎn)線運(yùn)行過(guò)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BAL可靠運(yùn)行，縮短更換馬弗的時(shí)間，準(zhǔn)備了兩支馬弗(分彆表示為A1和A2)，兩支馬弗(一用一備)在實(shí)際運(yùn)行過(guò)程中相繼出現(xiàn)缺陷而無(wú)法正常使用，新製造一支馬弗需要大約1年的時(shí)間且價(jià)值昂貴。因而分析各種缺陷的原因並對(duì)馬弗進(jìn)行修複將有助於確保正常生產(chǎn)，具有重要的工程應(yīng)用價(jià)值。
馬弗管在長(zhǎng)時(shí)間高溫、自重(20000kg)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(guò)程中出現(xiàn)縮頸、壁厚減薄、焊縫開(kāi)裂、截麵變形、香蕉狀彎曲、鼓包等缺陷。
對(duì)於由於高溫蠕變引起的伸長(zhǎng)、縮頸、厚度減薄、截麵變形、彎曲、鼓包等缺陷，可以通過(guò)切除失效部位的措施進(jìn)行修複。為此，在修複前首先對(duì)馬弗管進(jìn)行**測(cè)量以確定修複工藝和修複後的驗(yàn)收標(biāo)準(zhǔn)。其次，對(duì)缺陷部位切除後進(jìn)行焊接。
A1管缺陷主要表現(xiàn)為：道環(huán)形焊縫開(kāi)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，A段的嚴(yán)重縮頸、壁厚減薄、大麵積龜裂和截麵變形。因而充分考慮上述缺陷特點(diǎn)，采用的修複方案為:①首先用手工切割機(jī)截去道焊縫兩側(cè)各100mm左右的筒體，重新焊接(具體切除長(zhǎng)度應(yīng)按著色檢查裂紋情況後再定);②用手工切割機(jī)切二次吊裝法蘭，並截去鼓包段約400mm，人工校正筒體端麵平整度，然後雙麵倒角後對(duì)接;③采用厚度15mm的替代材料製成筒體焊接在馬弗管尾部至馬弗管總長(zhǎng)度達(dá)28522mm;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。
A2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，A段的嚴(yán)重縮頸、壁厚減薄、大麵積龜裂和截麵變形。因而充分考慮上述缺陷特點(diǎn)，采用的修複方案具體如下：①?gòu)亩蔚跹b法蘭處用等離子切割機(jī)切割開(kāi)馬弗管;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;③對(duì)表麵切口按照焊接坡口要求打磨，由於馬弗管切口斷麵已成橢圓形(長(zhǎng)軸約1900mm，短軸約1700mm)，對(duì)接時(shí)必須按橢圓形還原對(duì)接，然後進(jìn)行手工焊接;④采用著色滲透檢查方法檢查焊縫質(zhì)量;⑤在馬弗管底部焊接一定長(zhǎng)度的替代鋼板(<1820mm×900mm，厚度15mm)使馬弗爐總長(zhǎng)度達(dá)到設(shè)計(jì)要求(約28500mm);⑥二次吊裝法蘭處理與A1馬弗管相同;⑦A2馬弗爐已出現(xiàn)7處鼓包，由於冇有合適的材料，因而隻對(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，其餘部位的鼓包隻能進(jìn)行定期跟蹤滲透探傷檢查。
對(duì)於A1馬弗管已使用3年，根據(jù)相應(yīng)的缺陷形式，通過(guò)對(duì)其材質(zhì)強(qiáng)度、焊接的評(píng)定，根據(jù)製定的修複方案進(jìn)行了馬弗管的修複，使其達(dá)到使用的標(biāo)準(zhǔn)。
對(duì)於A2馬弗管使用了近2年，根據(jù)材質(zhì)強(qiáng)度評(píng)定和製定的修複方案，完成了馬弗管的修複。該修複的馬弗管連續(xù)運(yùn)行了17個(gè)月，使用狀態(tài)一直良好。下機(jī)後對(duì)所有焊縫進(jìn)行X光探傷，未發(fā)現(xiàn)有新的裂紋出現(xiàn)，還可以繼續(xù)使用?，F(xiàn)場(chǎng)應(yīng)用情況表明按照上述修複工藝方案進(jìn)行修複取得了成功，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。
