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</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)良的高溫持久強度及抗氧化性，國內無(wú)法生產(chǎn)，還完全依賴(lài)進(jìn)口。高溫自重條件的長(cháng)時(shí)間作用使得不銹鋼光亮退火生產(chǎn)線(xiàn)運行過(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:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">可靠運行，縮短更換馬弗的時(shí)間，準備了兩支馬弗</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)際運行過(guò)程中相繼出現缺陷而無(wú)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馬弗進(jìn)行修復將有助于確保正常生產(chǎn)，具有重要的工程應用價(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(cháng)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;;">及燒嘴燃燒不均導致的溫度不均勻等因素作用下，會(huì )在使用過(guò)程中出現縮頸、壁厚減薄、焊縫開(kāi)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;">對于由于高溫蠕變引起的伸長(cháng)、縮頸、厚度減薄、截面變形、彎曲、鼓包等缺陷，可以通過(guò)切除失效部位的措施進(jìn)行修復。為此，在修復前首先對馬弗管進(jìn)行**測量以確定修復工藝和修復后的驗收標準。其次，對缺陷部位切除后進(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;;">管缺陷主要表現為：道環(huán)形焊縫開(kāi)裂，二次吊裝法蘭設計缺陷及產(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首先用手工切割機截去道焊縫兩側各</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(cháng)度應按著(zhù)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(cháng)度達</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;;">④二次吊裝法蘭結構及安裝部位進(jìn)行了重新設計，將整段法蘭焊接結構改為分段法蘭焊接結構方式。</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)，采用的修復方案具體如下：①從二次吊裝法蘭處用等離子切割機切割開(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:&quot;Times New Roman&quot;;mso-hansi-font-family:&quot;Times New Roman&quot;;">②采用著(zhù)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)砂輪片切割機對馬弗管進(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(cháng)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;;">，對接時(shí)必須按橢圓形還原對接，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(zhù)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(cháng)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(cháng)度達到設計要求</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</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(méi)有合適的材料，因而只對*為嚴重的鼓包采用與燒穿相同的方法進(jìn)行了整段切除、對焊，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，根據相應的缺陷形式，通過(guò)對其材質(zhì)強度、焊接的評定，根據制定的修復方案進(jìn)行了馬弗管的修復，使其達到使用的標準。</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，根據材質(zhì)強度評定和制定的修復方案，完成了馬弗管的修復。該修復的馬弗管連續運行了</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。下機后對所有焊縫進(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)現有新的裂紋出現，還可以繼續使用。現場(chǎng)應用情況表明按照上述修復工藝方案進(jìn)行修復取得了成功，同時(shí)也驗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(mǎn)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>