API 5LD для зварного покриття та сталевих труб з футеруванням,Плакована або футерована труба CRA

Специфікація плакованих труб

Плаковані труби, також відомий як плаковані труби або CRA (Стійкий до корозії сплаву) Плаковані труби, складаються з основної труби з вуглецевої або легованої сталі з внутрішнім або зовнішнім шаром корозійностійкого сплаву. Ці труби поєднують механічну міцність сталевої основи з корозійною стійкістю сплаву, making them ideal for harsh environments in industries such as oil and gas, Хімічна обробка, і виробництво електроенергії.

Основні характеристики

1. Основні матеріали:

   • API 5L Grade B, Х42, Х46, X52, X56, X60, X65, X70, X80
   • ASTM А106 гр.Б, ASTM A333 Gr.6, ASTM A335 Cr-Mo alloys (P5, P11, P22, P9, P91)

2. Cladding Materials:

   • Нержавіюча сталь: SS 304/304L, SS 316/316L, SS 317/317L, двухшпиндельный 2205, двухшпиндельный 2506, Супер дуплекс 2507, Сплав 254 МИ, 904L
   • сплави нікелю : Incoloy 825, INCONEL 625, INCONEL 59, Сплав 31, AL6XN, Сплав 20, Монель 400
   • Інші сплави: Hastelloy C-276, Сорти титану 2, 5, 7, 9, 12, Цирконій R60702, різні мідні сплави

3. виробничі стандарти:

   • API 5LD
   • ASTM A240, A263, A264, A265, B898, B424, B443, B619, B622, B675, B265, B551

4. Розміри:

   • Діапазон діаметрів труб: Ф50мм-Ф1800мм
   • Товщина стінки вкладиша: 0.5мм-3,5 мм
   • Довжина: ≤15м

5. Обробка поверхні :

   • Композитна технологія цифрової підводної дефлаграції
   • Hydraulic composite technology
   • Pipe end surfacing and inner wall boring

6. Перевірка та тестування:

   • Ультразвуковий контроль (OUT)
   • Радіографічне тестування (RT)
   • Гідростатичні випробування
   • Механічні випробування (На розрив, Твердість, Вплив)
   • Випробування на корозію

Процес облицювання труб

Cladding involves bonding a corrosion-resistant alloy (CRA) to a carbon steel or alloy steel base pipe. This process can be achieved through various methods, each with its own advantages and applications:

Cladding Methods

1. Гаряча прокатка:

   • Involves rolling the CRA and base material together at high temperatures to achieve a metallurgical bond.

2. Коекструзія:

   • Both materials are extruded together, ensuring a tight bond through simultaneous deformation.

3. накладення шва:

   • CRA is welded onto the base material, creating a layer of corrosion-resistant metal.

4. Вибухове склеювання:

   • Uses controlled explosions to bond the CRA to the base material. This method is particularly useful for large or complex shapes.

5. Порошкова металургія:

   • CRA powder is applied to the base material and then sintered to create a bond.

6. механічне склеювання:

   • Involves expanding or shrinking the CRA liner to fit tightly within the base pipe. This method is less strong than metallurgical bonding but is useful for certain applications.

Process Steps

1. Base Pipe Preparation:

   • Cleaning and inspection of the base pipe to ensure it meets required standards.

2. Cladding Application:

   • Applying the CRA layer using one of the methods mentioned above.

3. термічна обробка:

   • To relieve stresses and ensure a strong bond between the materials.

4. Механічна обробка:

   • Final shaping, surfacing, and inspection to meet dimensional and quality specifications.

5. Тестування та перевірка:

   • Comprehensive testing to ensure the integrity and performance of the cladded pipe.

Що таке плаковані труби?

A cladded pipe is a composite pipe that combines the mechanical strength of a carbon steel or alloy steel base pipe with the corrosion resistance of a CRA layer. The cladding process bonds the CRA to the base material, offering enhanced durability and resistance to corrosive environments. These pipes are crucial in industries where both mechanical strength and corrosion resistance are essential, таких як нафта і газ, нафтохімічної, і морські програми.

Діапазон розмірів облицювальних сталевих труб

Cladded steel pipes come in a variety of sizes to meet different industrial requirements:

• Діапазон діаметрів труб: Ф50мм-Ф1800мм
• Товщина стінки вкладиша: 0.5мм-3,5 мм
• Довжина: До 15 метрів

Діапазон розмірів облицювальних сталевих труб (Continued)

These dimensions ensure that cladded pipes can be tailored to specific applications, providing the necessary robustness and corrosion resistance required for their intended use. The flexibility in size range allows for customization to meet the specific needs of various industrial processes.

Прайс лист плакованих труб

The price of cladded pipes can vary significantly based on several factors, including the base material, the type of CRA used, the dimensions of the pipe, and the manufacturing process. Here is a general guide on how these factors influence the cost:

• основний матеріал:

  • ВУГЛЕЦЕВОЇ СТАЛІ: Загалом дешевше.
  • Леговані сталі: Higher cost due to enhanced mechanical properties.

• Матеріал CRA:

  • Нержавіюча сталь (наприклад, 304/304L, 316/316L): Moderate cost.
  • сплави нікелю (наприклад, INCONEL 625, Hastelloy C-276): Higher cost due to superior corrosion resistance.
  • Specialty Alloys (наприклад, титан, Цирконій): Highest cost due to unique properties.

• Розміри труб:

  • Larger diameters and thicker walls increase the material cost.
  • Longer pipes require more extensive manufacturing processes.

• ВИРОБНИЧИЙ ПРОЦЕС:

  • Simple mechanical bonding methods are less expensive.
  • Advanced processes like explosion bonding or weld overlay are more costly.

For specific pricing, it is recommended to contact manufacturers or suppliers who can provide detailed quotes based on the exact specifications required.

Обробка поверхні обшивки труб

Surface treatment of cladded pipes is crucial to ensure the longevity and performance of the pipe in service. The surface treatment process includes:

1. прибирання:

   • Removal of any contaminants, rust, or scale from the surface to ensure a clean bonding surface.

2. Шорсткість поверхні:

   • Techniques like grit blasting or sandblasting are used to roughen the surface, improving the adhesion of the CRA layer.

3. Application of CRA:

   • The CRA layer is applied using methods like weld overlay, Гаряча прокатка, or explosion bonding.

4. Post-Cladding Treatment:

   • Heat treatment to relieve stresses and enhance the bond between the CRA and base material.
   • Final machining and polishing to achieve the desired surface finish.

5. Перевірка та тестування:

   • Неруйнівний контроль (НК) methods such as ultrasonic testing (OUT) and radiographic testing (RT) are used to check for defects.
   • Visual inspections to ensure surface quality.

CRA Cladded Pipe Material

CRA cladded pipes use a variety of corrosion-resistant materials, each selected based on the specific requirements of the application:

• Нержавіюча сталь:

  • SS 304/304L, SS 316/316L, SS 317/317L
  • двухшпиндельный 2205, двухшпиндельный 2506, Супер дуплекс 2507
  • Сплав 254 МИ, 904L

• сплави нікелю :

  • Incoloy 825, INCONEL 625, INCONEL 59
  • Сплав 31, AL6XN, Сплав 20
  • Монель 400

• Інші сплави:

  • Hastelloy C-276
  • Сорти титану 2, 5, 7, 9, 12
  • Цирконій R60702
  • різні мідні сплави

The choice of CRA material depends on factors such as the type of corrosion (наприклад, кісточки, crevice, stress corrosion cracking), operating temperature, and chemical environment.

Types of Cladded Pipes

Cladded pipes can be categorized based on the cladding method and the type of CRA used:

Based on Cladding Method

1. Weld Overlay Clad Pipes:

   • CRA is welded onto the base pipe, suitable for high-pressure applications.

2. Explosion Bonded Clad Pipes:

   • Uses explosive force to bond the CRA to the base pipe, ideal for complex shapes and large diameters.

3. Hot Rolled Clad Pipes:

   • CRA and base material are rolled together at high temperatures, ensuring a strong metallurgical bond.

4. Mechanically Bonded Lined Pipes:

   • CRA liner is mechanically fitted inside the base pipe, less expensive but with lower bond strength.

Based on CRA Material

1. Stainless Steel Clad Pipes:

   • Commonly used for their excellent corrosion resistance and mechanical properties.

2. Nickel Alloy Clad Pipes:

   • Highly resistant to corrosion in aggressive environments, such as high-temperature and high-pressure conditions.

3. Titanium Clad Pipes:

   • Extremely resistant to corrosion from seawater and chemicals.

4. Zirconium Clad Pipes:

   • Used in applications involving strong acids due to their exceptional corrosion resistance.

Cladding Steel Pipes Tests and Inspection (Continued)

To ensure the quality and integrity of cladded pipes, a comprehensive range of tests and inspections are conducted during and after the manufacturing process. These tests are designed to verify the mechanical properties, стійкість до корозії, and overall reliability of the pipes.

Неруйнівний контроль (НК)

1. Ультразвуковий контроль (OUT):

   • Used to detect internal defects and measure the thickness of the cladding layer.
   • Ensures there are no discontinuities or voids in the bond between the cladding and base material.

2. Радіографічне тестування (RT):

   • Utilizes X-rays or gamma rays to identify internal flaws such as cracks or inclusions.
   • Provides a detailed image of the internal structure of the pipe.

3. Магнітопорошковий контроль (MPI):

   • Suitable for detecting surface and near-surface defects in ferromagnetic materials.
   • The pipe is magnetized, and ferrous particles are applied to reveal defects.

4. Dye Penetrant Inspection (DPI):

   • A liquid dye is applied to the surface, which penetrates any surface-breaking defects.
   • Excess dye is removed, and a developer is applied to draw out the dye from defects for visual inspection.

Механічні випробування

1. Випробування на розтяг:

   • Measures the tensile strength, Плинності, and elongation of the cladded pipe.
   • Ensures the pipe meets mechanical property requirements.

2. Випробування на твердість:

   • Determines the hardness of both the cladding and base materials.
   • Common methods include Rockwell, Brinell, and Vickers hardness tests.

3. Тестування на вплив:

   • Evaluates the toughness of the material by measuring its ability to absorb energy during fracture.
   • Typically conducted at various temperatures to simulate service conditions.

Випробування на корозію

1. Salt Spray Test:

   • Exposes the cladded pipe to a salt spray environment to evaluate its resistance to corrosion.
   • Commonly used for stainless steel and other corrosion-resistant alloys.

2. Pitting and Crevice Corrosion Tests:

   • Assesses the susceptibility of the cladded material to localized corrosion phenomena.
   • Involves exposing the material to specific environments that promote pitting or crevice corrosion.

3. Intergranular Corrosion Test:

   • Determines the resistance of the cladded material to corrosion along grain boundaries.
   • Important for materials that may be exposed to high temperatures or corrosive chemicals.

Dimensional and Visual Inspections

1. Перевірка розмірів:

   • Ensures the cladded pipe meets specified dimensional tolerances, including diameter, Товщина стінки, і довжина.
   • Uses tools such as calipers, micrometers, and coordinate measuring machines (CMMs).

2. Візуальний огляд:

   • Conducted to identify surface defects, weld quality, and overall appearance.
   • Typically performed by trained inspectors using visual aids and magnification tools.

Pipe Cladding and Insulation Tolerance

Cladding and insulation tolerances are critical to ensure the cladded pipes perform as expected in their intended applications. Tolerances are specified for various dimensions and properties to maintain consistency and quality.

Key Tolerances

1. Cladding Thickness Tolerance:

   • The thickness of the cladding layer must be uniform and within specified limits.
   • Typical tolerance ranges from ±0.1 to ±0.5 mm, depending on the application and cladding method.

2. Pipe Diameter Tolerance:

   • Ensures the outer diameter of the cladded pipe meets specified requirements.
   • Common tolerance is ±1% of the nominal diameter.

3. Wall Thickness Tolerance:

   • The total wall thickness (base material plus cladding) must be within defined limits.
   • Standard tolerance is ±10% of the nominal wall thickness.

4. Length Tolerance:

   • The overall length of the cladded pipe must match specified dimensions.
   • Typical tolerance is ±50 mm for lengths up to 12 метрів.

5. Ovality Tolerance:

   • Measures the deviation from a perfect circular cross-section.
   • Ovality tolerance is usually within 1-2% of the nominal diameter.

6. Straightness Tolerance:

   • Ensures the pipe is straight and free from excessive bending.
   • Acceptable deviation is generally within 3-5 mm per meter of length.

Advantages of Cladded Pipe (Continued)

3. Ефективність витрат:

   • Compared to using solid CRA pipes, cladded pipes are more economical as they use less expensive base materials while still providing the necessary corrosion resistance.

4. Extended Service Life:

   • The combination of a durable base pipe and a corrosion-resistant cladding layer significantly extends the service life of the pipes in harsh environments.

5. Універсальність:

   • Cladded pipes can be customized to meet specific requirements, including different cladding materials and thicknesses, making them suitable for a wide range of applications.

6. Зменшене технічне обслуговування:

   • The superior corrosion resistance of the cladding layer reduces the need for frequent maintenance and repairs, leading to lower operational costs over time.

7. високотемпературна продуктивність:

   • Many CRA materials used in cladding can withstand high temperatures, making cladded pipes suitable for high-temperature applications.

8. Improved Safety:

   • The high strength and corrosion resistance of cladded pipes enhance the safety and reliability of pipelines, reducing the risk of leaks and failures.

Common Differences between Clad and Lined Pipe

While both clad and lined pipes are designed to provide corrosion resistance, they differ in their construction, Продуктивність, і програми.

ОДЯГНЕНИЙ ТРУБИ

1. Будівництво:

   • Consists of a carbon steel or alloy steel base pipe with a CRA layer metallurgically bonded to it.
   • The cladding process ensures a strong bond between the materials.

2. Продуктивність:

   • Offers superior mechanical strength and corrosion resistance.
   • Suitable for high-pressure and high-temperature applications.

3. Додатка:

   • Used in harsh environments such as oil and gas, нафтохімічної, and chemical processing industries.
   • Ideal for applications where both mechanical strength and corrosion resistance are critical.

4. Вартість:

   • Generally more expensive than lined pipes due to the complex manufacturing process.

ОБЛИЦЬОВАНА ТРУБИ

1. Будівництво:

   • Consists of a carbon steel or alloy steel base pipe with a CRA liner mechanically fitted inside.
   • The liner is not metallurgically bonded to the base pipe.

2. Продуктивність:

   • Provides good corrosion resistance but lower mechanical strength compared to clad pipes.
   • Suitable for lower pressure and temperature applications.

3. Додатка:

   • Commonly used in water treatment, стічні води, and low-pressure chemical transport.
   • Ideal for applications where corrosion resistance is needed, but mechanical strength is less critical.

4. Вартість:

   • Typically less expensive than clad pipes due to the simpler manufacturing process.

Max Temperature of CRA Clad Pipes

The maximum temperature that CRA cladded pipes can withstand depends on the specific CRA material used in the cladding. Here are some examples:

• З НЕРЖАВІЮЧОЇ СТАЛІ (наприклад, 316L):

  • Maximum temperature: Approximately 600°C (1112° F)

• двухшпиндельная нержавіюча сталь (наприклад, 2205):

  • Maximum temperature: Approximately 300°C (572° F)

• INCONEL 625:

  • Maximum temperature: Approximately 980°C (1796° F)

• Hastelloy C-276:

  • Maximum temperature: Approximately 650°C (1202° F)

• титан (наприклад, Сорт 2):

  • Maximum temperature: Approximately 350°C (662° F)

The specific maximum temperature for a given application should be verified with the manufacturer, considering factors such as operating conditions, тиск, and chemical environment.

Cladding Around Pipe Hardfacing Layer Chart

Hardfacing is a surface coating process used to enhance the wear resistance of cladded pipes. The hardfacing layer is typically applied to areas subject to severe wear and abrasion. Here is an example chart displaying various hardfacing materials and their typical applications:

Hardfacing Material	Склад	Додаток
Stellite 6	Co-Cr-W alloy	High wear and abrasion resistance
Карбід вольфраму	WC-Co	Extreme wear and impact resistance
Карбід хрому	Cr3C2-NiCr	High-temperature wear resistance
сплави на основі нікелю	Ni-Cr-B-Si alloys	Corrosion and wear resistance
Cobalt-Based Alloys	Co-Cr-W-C alloys	High wear and thermal shock resistance

Hardfacing layers are applied using methods such as:

• Зварювання:

  • Techniques like plasma-transferred arc (PTA) welding or MIG welding.

• Термічне напилення:

  • Methods like high-velocity oxy-fuel (HVOF) spraying or plasma spraying.

Inconel Cladded Pipe Flatness Tolerances

Flatness tolerances for Inconel cladded pipes ensure that the pipes meet the geometric requirements necessary for their proper function and fit within a system. These tolerances are critical for maintaining the integrity and performance of the pipeline, especially in high-pressure and high-temperature applications where Inconel is commonly used.

Typical Flatness Tolerances

1. Straightness Tolerance:

   • The deviation from a straight line, measured over the length of the pipe.
   • Common tolerance: ±1 mm per meter of pipe length, with a maximum deviation often specified based on the total length.

2. Ovality Tolerance:

   • The measure of how much the pipe’s cross section deviates from a perfect circle.
   • Common tolerance: ±1% of the nominal diameter.

3. Surface Flatness:

   • Ensures the cladded layer is uniformly flat, which is essential for proper sealing and connection in flanged joints.
   • Specific tolerances depend on the application and standards but generally fall within a few millimeters over the length of the pipe.

Industry Standards

Flatness tolerances for Inconel cladded pipes are often governed by industry standards such as:

• ASME B31.3: Process Piping
• API 5LD: Specification for CRA Clad or Lined Steel Pipe
• ASTM B775: Standard Specification for Nickel and Nickel Alloy Welded Pipe

These standards provide detailed guidelines on acceptable flatness tolerances and testing methods to ensure compliance.

Clad Material Specification

When specifying clad materials for pipes, several key parameters must be considered to ensure the desired performance and durability. The specification typically includes the following details:

основний матеріал

1. Тип матеріалу:

   • ВУГЛЕЦЕВОЇ СТАЛІ, легована сталь, or other suitable base materials.

2. Сорт:

   • Specific grade of the base material, such as ASTM A106 Grade B or API 5L X65.

3. Механічні Властивості:

   • Плинності, Межа міцності, Відносне подовження, і твердість.

Матеріал обшивки

1. Тип матеріалу:

   • Specific CRA such as Inconel 625, Hastelloy C-276, or Stainless Steel 316L.

2. Товщина:

   • Required thickness of the cladding layer, typically specified in millimeters or inches.

3. Bonding Method:

   • The process used for bonding the cladding to the base material, such as weld overlay, Вибухове склеювання, or hot rolling.

Additional Specifications

1. термічна обробка:

   • Any required post-cladding heat treatments to relieve stresses and enhance material properties.

2. Вимоги до тестування:

   • Specific non-destructive testing (НК) методи, such as ultrasonic testing (OUT) or radiographic testing (RT).
   • Mechanical testing requirements, such as tensile tests, випробування на твердість, і ударні випробування.

3. Сертифікація:

   • Compliance with relevant industry standards and certifications, such as ASME, API, or ASTM specifications.

Clad Pipe Chemical Composition

The chemical composition of both the base material and the cladding material is crucial for determining the overall performance of the cladded pipe. Here are typical compositions for some common materials used in cladded pipes:

Carbon Steel Base Material (наприклад, ASTM A106 Grade B)

Елемент	Склад (wt%)
ВУГЛЕЦЬ (C)	0.25 Макс
марганець (MN)	0.27–0.93
фосфор (P)	0.035 Макс
сірки (S)	0.035 Макс
кремній (Сі)	0.10–0,35

INCONEL 625 Матеріал обшивки

Елемент	Склад (wt%)
нікель (Н)	58.0 мені
хром (Кл)	20.0–23.0
молібден (МО)	8.0–10,0
Ніобій (NB)	3.15–4.15
залізо (Фе)	5.0 Макс
марганець (MN)	0.50 Макс
кремній (Сі)	0.50 Макс
ВУГЛЕЦЬ (C)	0.10 Макс

Stainless Steel 316L Cladding Material (Continued)

Елемент	Склад (wt%)
молібден (МО)	2.0–3.0
залізо (Фе)	Balance
марганець (MN)	2.0 Макс
кремній (Сі)	1.0 Макс
фосфор (P)	0.045 Макс
сірки (S)	0.030 Макс
ВУГЛЕЦЬ (C)	0.030 Макс

Hastelloy C-276 Cladding Material

Елемент	Склад (wt%)
нікель (Н)	Balance
молібден (МО)	15.0–17.0
хром (Кл)	14.5–16.5
залізо (Фе)	4.0–7.0
вольфрам (Вт)	3.0–4.5
кобальт (Ко)	2.5 Макс
марганець (MN)	1.0 Макс
кремній (Сі)	0.08 Макс
ВУГЛЕЦЬ (C)	0.01 Макс
ванадій (V)	0.35 Макс
фосфор (P)	0.04 Макс
сірки (S)	0.03 Макс

двухшпиндельная нержавіюча сталь (наприклад, 2205)

Елемент	Склад (wt%)
хром (Кл)	22.0–23.0
нікель (Н)	4.5–6.5
молібден (МО)	3.0–3.5
залізо (Фе)	Balance
марганець (MN)	2.0 Макс
кремній (Сі)	1.0 Макс
фосфор (P)	0.03 Макс
сірки (S)	0.02 Макс
ВУГЛЕЦЬ (C)	0.03 Макс
Азот (N)	0.14–0,20

резюме

Cladded pipes combine the mechanical strength of a carbon or alloy steel base with the superior corrosion resistance of a cladding layer, such as Inconel, Хастеллой, або з нержавіючої сталі. The manufacturing process, тестування, and inspection ensure high reliability and performance in demanding environments. By adhering to strict tolerances and specifications, cladded pipes effectively meet the rigorous requirements of industries like oil and gas, нафтохімічної, і хімічна обробка. Understanding the chemical composition and mechanical properties of both the base and cladding materials is essential for selecting the appropriate cladded pipe for specific applications.

API 5LD clad or lined steel pipes including longitudinal seam clad steel pipe, сталеві труби зі спіральним швом і безшовні сталеві труби з футеруванням відповідно до API SPEC 5LD, DNV-OS-F101, SY/T6623 ТА CJ/T192. Плакований матеріал поєднує корозійні та стійкі властивості CRA з високою міцністю вуглецевих марганцевих сталей. Результатом такого поєднання матеріалу CRA з тоншою стінкою та міцністю матеріалу з вуглецевої сталі з великою товщиною стінок є економічна ефективність.

Бек-труба ОД: NPS 6″ ~ NPS28″
Матеріал обшивки: LC1812, 2205, UNS S317030, S31803, S30400, S30403, S31600, S31603, S32100, N08904, N08825, N06600, N04400