Production process of butt welded elbow and tee

Guide for production work of elbow fittings ( 1)

Yaang Pipe Industry Co., Limited

Process name

Production process of seamless elbow

Product code

Yaang/YA-01

Process name

Production process of pushing (bending) elbow

Material

Austenitic, Duplex steel, super austenitic

Equipment

Pipe fitting production equipment

Indicate

Common for the production of conventional pipe elbow

Work step

Process

Content

Precautions

1

Blanking

1) Cut the material strictly according to the size chart, and measure the length to check the appearance.

a. During heat treatment, the holding time should not be less than20min , but it should not be too long. If the holding time is too long, it will cause coarse grains and reduce the mechanical properties and corrosion resistance of the product.

b. At step 7, if the appearance of the product is in good condition, you can directly roll the sand → finish turning → passivation No polishing or sandblasting process. But we must pay attention to grasp the degree of measurement, which needs to be confirmed by the technical department or relevant technical personnel.

c. When processing materials with thin wall thickness, special attention should be paid to the details such as the angle of placement, the rate of pushing, the furnace installation and holding time of heat treatment, and the depth of grinding.

d. Figure :

20200701040410 34434 - Production process of butt welded elbow and tee

The main parameters:

National standard

American Standard

Japanese Standard

German Standard

Wall thickness

22mm

a2

37.5 ±2.5

37.5 ±2.5

32.5 ±2.5

30+5-0

b2

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c2

1.5 ± 1

1.5 ± 1

1.0 ± 0.5

1.6 ± 0.8

Wall thickness

22mm

a

37.5 ±2.5

37.5 ±2.5

37.5 ±2.5

30+5-0

b

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c

1.5 ± 1

1.5 ± 1

1.6 ±0.8

1.6 ± 0.8

beta

10 °± 1

10 ± 2.5

10 °± 1

10 °± 1

R

3mm

3mm

3.2mm

3mm

t

19mm

19mm

19mm

19mm

When the German standard wall thickness ≤ , the flat mouth. When the wall thickness is less than 3American standard austenite adopts flat mouth or slight chamfer (as determined by the manufacturer).

5. After sandblasting, if passivation is necessary, passivation treatment can be done: use 30% nitric acid solution, soak for 1h at room temperature , do blue point test after passivation, no blue point appears within 35S is qualified.

2

Forming

1) First measure the incoming material and confirm that the wall thickness meets the processing requirements.

      2) The placement position should be accurate so as not to skew after pushing to cause insufficient length.

      3) Check the dimensions and surface conditions of the inner and outer molds to make sure that the surface of the product will not have quality problems such as silk paths and pits after molding.

3

Short hair

      1) When using tooling fixtures for flat heads, an extra 3-5 mm margin is required at each end .

2) When  no jig is used, a 10mmmargin is required at each end when cutting the head .

4

Heat

deal with

1) Austenitic materials are heat-treated at 1050 ℃ ± 10 ℃.

      2) Duplex steel and super austenitic materials are heat treated at 1080 ℃ ( +20 -0℃).

3) Incubation time for each . 1 th thickness promote 2min , and not less than 20 is minutes.

5

Pickling

      1) After pickling, the appearance must be clean without oxide scale, no overacid and underacid.

      2) After pickling, depending on the busyness of the specific process, first arrange the batch of products to flow into shaping (process step ) or polishing (process step ).The two-step process can be reversed.

6

Plastic surgery

        1)  Measure whether the size is up to standard, whether the surface is smooth, especially pay attention to the roundness of the end.

      2 ) If the wall thickness is thin, back arc is not easy to be rounded, or if the middle section of the product is not rounded during molding, the ball shaping process isadopted.

      3) The dimensions and radians of the end and back are measured to meet the requirements after shaping.

7

Surface treatment

      1) Depending on the surface condition of the product, if the surface condition is good, it can be directly processed by sanding and shot blasting without polishing.

      2) When polishing, pay attention to the product wall thickness requirements indicated on the process card. Random operations are strictly prohibited.

      3) During the grinding process, the product should not be rubbed or rubbed too much on the ground, resulting in excessive and deep surface scars after grinding.

8

Fine turning

1) Pay attention to protect the appearance of the product to avoid scratches and pinching.

2) Strictly enforce the standard requirements of the bevel angle, see Figure 1 on the right.

9

Rear

deal with

       1) According to customer requirements, produce and process the product surface.

       2) Products with a caliber above 355 are not sand-blasted, and are directly sandblasted. Products after sandblasting should pay attention to avoid bumps on the surface.

       3) After passivation treatment, gently handle it, and do not allow the product to scratch or bump against other materials.

       4) After passing the inspection, quickly pack the nylon film to prevent contamination and scratching.

Mark

Number of places

Change the file number

Signature

Date

Preparation (date)

Audit (date)

Approval (date)

01

 Guide for production work of elbow fittings ( 1b )

Yaang Pipe Industry Co., Limited

Process name

Production process of seamless elbow

product code

Yaang/YA-01

Process name

Production process of pushing (bending) elbow

Material

Austenitic, Duplex steel, super austenitic

Equipment

Pipe fitting production equipment

Indicate

For the production of thin-walled elbow fittings

Work step

Process

Content

Precautions

1

Blanking

1) Cut the material strictly according to the size chart, and measure the length to check the appearance.

a. This production process is for elbow pipe fittings with outer diameter 114 168 and wall thickness ≤ 3.5mm ; outer diameter 219and wall thickness ≤ 4.5mm ; outer diameter 273-355 and wall thickness ≤ 5mm .

b. During heat treatment, the holding time should not be less than20min , but it should not be too long. If the holding time is too long, it will cause coarse grains and reduce the mechanical properties and corrosion resistance of the product.

c. At step 7, if the appearance of the product is in good condition, you can directly roll sand → finish car → passivation No polishing or sandblasting process. But we must pay attention to grasp the degree of measurement, which needs to be confirmed by the technical department or relevant technical personnel.

d. When processing materials with thin wall thickness, special attention should be paid to the details such as the angle of placement, the rate of pushing, the furnace installation and holding time of heat treatment, and the depth of grinding.

e. Figure :

20200701041214 27619 - Production process of butt welded elbow and tee

The main parameters:

National standard

American Standard

Japanese Standard

German Standard

Wall thickness

22mm

a2

37.5 ±2.5

37.5 ±2.5

32.5 ±2.5

30+5-0

b2

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c2

1.5 ± 1

1.5 ± 1

1.0 ± 0.5

1.6 ± 0.8

The German standard is flat mouth when the wall thickness ≤ ; the American standard and the national standard adopt flat mouth or slight chamfering for the austenite when the wall thickness < 3(determined by the manufacturer).

f. After sandblasting, if passivation is necessary, passivation treatment can be done: use 30% nitric acid solution, soak for 1h at room temperature , do blue point test after passivation, no blue point appears within 35S is qualified.

2

Forming

1) First measure the incoming material and confirm that the wall thickness meets the processing requirements.

) The placement position should be accurate so as not to skew after pushing to cause insufficient length.

      3) Check the dimensions and surface conditions of the inner and outer molds to make sure that the surface of the product will not have quality problems such as silk paths and pits after molding.

3

Short hair

      1) When using tooling fixtures for flat heads, an extra 3-5mm margin is required at each end .

2) When  no jig is used, a 10mmmargin is required at each end when cutting the head .

4

Heat

deal with

1) Austenitic materials are heat-treated at 1050 ℃ ± 10 ℃.

      2) Duplex steel and super austenitic materials are heat treated at 1080 ℃ ( +20 -0℃).

3) Incubation time for each . 1 th thickness promote 2min , and not less than 20 is minutes.

5

Pickling

      1) After pickling, the appearance must be clean, free of scale, no over-acid and under-acid.

    2) After pickling, depending on the busyness of the specific process, the product can be arranged to flow into shaping (process step ) or polishing (process step ). The two-step process can be reversed.

6

Surface treatment

      1) Depending on the surface condition of the product, if the surface condition is good, it can be directly processed by sanding and shot blasting without polishing.

      2) When polishing, pay attention to the product wall thickness requirements indicated on the process card. Random operations are strictly prohibited.

      3) During the grinding process, the product should not be rubbed or rubbed too much with the ground, resulting in excessive and deep surface scars after grinding.

    4) For all specifications of products with wall thickness <1.5mm , no sanding or shot blasting is allowed.

7

Plastic surgery

        1) Measure whether the size is up to standard, whether the surface is smooth, especially pay attention to the roundness of the end.

      2) Over-ball shaping process is used for shaping.

      3) The dimensions and radians of the end and back are measured to meet the requirements after shaping.

8

Fine turning

1) Pay attention to protect the appearance of the product to avoid scratches and pinching.

2) Strictly enforce the standard requirements of the bevel angle, see Figure 1 on the right .

9

Rear

deal with

       1) According to customer requirements, produce and process the product surface.

       2) Products with a caliber greater than 355 mm and products with a wall thickness less than 1.5mm do not take sanding or shot blasting, and are directly shaped after pickling → fine turning → sandblasting. After sandblasting, the product should be careful to avoid knocking on the surface.

       3) After passivation treatment, gently handle it, and do not allow the product to scratch or bump against other materials.

       4) After passing the inspection, quickly pack the nylon film to prevent contamination and scratching.

Mark

Number of places

Change the file number

Signature

Date

Preparation (date)

Audit (date)

Approval (date)

02

Guide for production work of elbow fittings ( 1)

Yaang Pipe Industry Co., Limited

Process name

Production process of seam elbow

Product code

Yaang/CP-01

Process name

Production technology of seam elbow

Material

Austenitic, Duplex steel, super austenitic

Equipment

Pipe fitting production equipment

Indicate

Universal for plate welded elbow fittings

Work step

Process

Content

Precautions

1

Blanking

1) Strictly cut the materials according to the drawings and sample size, and check the measured arc length.

a. During heat treatment, the holding time should not be less than20min , but it should not be too long. If the holding time is too long, it will cause coarse grains and reduce the mechanical properties of the product.

b. Figure 1 :

20200701041548 17501 - Production process of butt welded elbow and tee

c. The main cause of undercut during welding is excessive current or excessive arc, so the current output during welding should be strictly controlled. When pairing together, the spot welding should be carried out carefully to prevent the occurrence of “wrong edges”. Do not start the arc on the base metal.

d. Figure 2:

20200701041902 82155 - Production process of butt welded elbow and tee

The main parameters:

National standard

American Standard

Japanese Standard

German Standard

Wall thickness

22mm

a2

37.5 ±2.5

37.5 ±2.5

32.5 ±2.5

30+5-0

b2

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c2

1.5 ± 1

1.5 ± 1

1.0 ± 0.5

1.6 ± 0.8

Wall thickness

22mm

a

37.5 ±2.5

37.5 ±2.5

37.5 ±2.5

30+5-0

b

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c

1.5 ± 0.8

1.5 ± 0.8

1.6 ± 0.8

1.6 ± 0.8

beta

10 °± 1

10 °± 2.5

10 °± 1

10 °± 1

R

3mm

3mm

3.2mm

3mm

t

19mm

19mm

19mm

19mm

The German standard is flat mouth when the wall thickness ≤ ; the American standard and the national standard adopt flat mouth or slight chamfering for the austenite when the wall thickness < (determined by the manufacturer).

e. If it is necessary to passivate after sandblasting, passivation treatment can be done: use 30% nitric acid solution, soak for 1h at room temperature , and no blue dot appears in 35S.

2

Forming

1) Measuring the sheet thicknessis determined to meet production needs.

2) Measure the size of the intima to ensure a tight fit and see if the edges are flat.

3

Whole side

    1) When cutting the edge, draw a line with a stylus on the material and measure the half circumference, see Figure 1 on the right Make sure the half circumference after cutting C = π ÷ 2+5~8mm is the outer diameter of the finished product, π takes 3.14 ) to ensure that the product can still meet the standard size requirements after welding shrinkage.

    2) The edging ensures that the welding groove is smooth and smooth, and the groove is not allowed to be saw-toothed.

    3) After the operator draws the line, the inspector measures half the circumference and writes the measured data on the product with a stone pen.Confirm the qualified flow into the welding process.

Cut edge

Edge

Edging

4

Welding

    1) The two sides must be matched during the alignment, and ensure that the perimeterO = π after welding isgreater than the diameter of the pipe, which is approximately equal to the upper limit of the outer diameter tolerance of the product.

    2) Weld surface inspection: undercutting is not allowed, pay attention to remove welding scars and welding knobs. Undercut depth limit, the weld residual height should be moderate (when 25 , the residual height ≯2.5mm , undercut ≯ 1mm 25∠ ≤ 50 , the residual height ≯3mm , undercut ≯ 2mm ), in principle The residual height of the product must be no more than 1.8mm , and undercut conditions are absolutely not allowed.

    3) The welding seam must be uniform, and the welding must be evenly covered, and the temperature between the control layers should not exceed the temperature required by the corresponding welding process evaluation.

5

Cutting head

1) When drawing and cutting by hand, 10-20mm extra margin is required at each end .

6

Heat treatment

1) Austenitic materials are heat-treated at 1050 ℃ ± 10 ℃.

      2) Duplex steel and super austenitic materials are heat treated at 1080 ℃ ( +20 -0℃).

    3) Incubation time for each . 1 th thickness promote 2min , and not less than 20 is minutes.

    4) After welding, because the workpiece is relatively large, heat treatment using a package furnace is adopted.

7

Pickling

      1) After pickling, the appearance must be clean, free of scale, no over-acid and under-acid.

9

Plastic surgery

    1) If there is no groove in the shaping mold, the welding seam needs to be ground first, and the residual height of the product welding seam should be ground to 0.1-0.2t is the wall thickness) before operation.

2) A thin wall thickness, the first scraping, grinding, tapping the weld, and then through the ball -shaping.

   3) After the shaping is completed, make sure that the ends are round and the size meets the requirements.

10

Surface treatment

    1) Pay attention to whether the internal and external seams are required in the order, and pay attention to the excess height of the weld seam and the excessive smoothness of the base material when grinding, not abrupt.

     2) Before polishing operation, check the thickness of the checked product and the requirements of the process card. Ensure that the repaired welds and products can meet product requirements.

    3) Pay special attention to the joint between the welding seam and the base metal, pay special attention to the thickness of the product when grinding, and the transition should be smooth and free of scale.

    4Products with Ф 273-355 and t≤ shall be shaped after rolling.

11

Fine turning

1) Pay attention to protect the appearance of the product to avoid scratches and pinching.

2) The bevel angle strictly implements the standard requirements, see figure 2 on theright .

13

Rear

deal with

      1) The product after sand blasting should pay attention to avoid bumps on the surface.

      2) After passivation treatment, gently handle it, and do not allow the products to scratch each other and bump with other materials.

3) Quickly pack the products after passing the inspection to prevent bumping and scratching.

Mark

Number of places

Change the file number

Signature

Date

Preparation (date)

Audit (date)

Approval (date)

03

 Guide for production work of elbow fittings ( 1d )

Yaang Pipe Industry Co., Limited

Process name

Production process of seam elbow

Product code

Yaang/CP-01

Process name

Production technology of seam elbow

Material

Austenitic, Duplex steel, super austenitic

Equipment

Pipe fitting production equipment

Indicate

Specially used for welding elbow fittings made of thin-walled plates

Work step

Process

Content

Precautions

1

Blanking

1) Strictly cut the materials according to the drawings and sample size, and check the measured arc length.

a. This production process is about the production process flow for butt-welded elbow fittings with wall thickness < 5.

b. During heat treatment, the holding time should not be less than20min , but it should not be too long. If the holding time is too long, it will cause coarse grains and reduce the mechanical properties and corrosion resistance of the product.

c. Figure 1:

20200701042514 81894 - Production process of butt welded elbow and tee

d. The main cause of undercut during welding is excessive current or excessive arc, so the current output during welding should be strictly controlled. When pairing together, the spot welding should be carried out carefully to prevent the occurrence of “wrong edges”. Do not start the arc on the base metal.

e. Figure 2:

20200701041214 27619 - Production process of butt welded elbow and tee

The main parameters:

National standard

American Standard

Japanese Standard

German Standard

Wall thickness

22mm

a2

37.5 ±2.5

37.5 ±2.5

32.5 ±2.5

30+5-0

b2

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c2

1.5 ± 1

1.5 ± 1

1.0 ± 0.5

1.6 ± 0.8

The German standard is flat mouth when the wall thickness ≤ ; the American standard and the national standard adopt flat mouth or slight chamfering for the austenite when the wall thickness < 3(determined by the manufacturer).

f. After sandblasting, if it is necessary to passivate, passivation treatment can be done: use 30% nitric acid solution, soak at room temperature for 1h no blue spot appears in 35S is qualified.

2

forming

1) Measuring the sheet thicknessis determined to meet production needs.

2) Measure the size of the intima to ensure a tight fit and see if the edges are flat.

3

Whole side

    1) When cutting the edge, draw a line with a stylus on the material and measure the half circumference, see Figure 1 on the right Make sure the half circumference after cutting C= π ÷ 2+5~8mm is the outer diameter of the finished product, π takes 3.14 ) to ensure that the product can still meet the standard size requirements after welding shrinkage.

    2) The edging ensures that the welding groove is smooth and smooth, and the groove is not allowed to be saw-toothed.

    3) After the operator draws the line, the inspector measures half the circumference and writes the measured data on the product with a stone pen.Confirm the qualified flow into the welding process.

Cut edge

Edge

Edging

4

Welding

    1) The two sides must be matched during the alignment, and ensure that the perimeterO = π after welding isgreater than the diameter of the pipe, which is approximately equal to the upper limit of the outer diameter tolerance of the product.

    2) Weld surface inspection: undercutting is not allowed, pay attention to remove welding scars and welding knobs. Undercut depth limit, the weld residual height should be moderate (when 25 , residual height ≯ 2.5mm , undercut ≯ 1mm ), in principle, the residual height of the company’s products must not be greater than 1.8mm , and undercut is absolutely not allowed Happening.

    3) The welding seam must be uniform, and the welding must be evenly covered, and the temperature between the control layers should not exceed the temperature required by the corresponding welding process evaluation.

5

Cutting head

1) When drawing and cutting by hand, 10-20mm extra margin is required at each end.

6

Heat treatment

1) Austenitic materials are heat-treated at 1050 ℃ ± 10 ℃.

      2) Duplex steel and super austenitic materials are heat treated at 1080 ℃ ( +20 -0℃).

    3) Incubation time for each . 1 th thickness incubated 2min , and not less than 20 isminutes.

    4) After welding, because the workpiece is relatively large, heat treatment using a package furnace is adopted.

7

Pickling

      2) After pickling, the appearance must be clean, free of scale, no acid, or lack of acid.

9

Plastic surgery

1) Spherical shaping process isadopted for shaping.

     2) If there is no groove in the shaping mold, the welding seam needs to be ground first, and the welding seam height of the product is grinded to0.1t-0.2t (t is the wall thickness. After the welding seam is flattened, the shaping operation is performed.

     3) After the shaping is completed, make sure that the ends are round and the size meets the requirements.

10

Surface treatment

     1) Pay attention to whether the internal and external seams are required in the order, and pay attention to the excess height of the weld seam and the excessive smoothness of the base material when grinding, not abrupt.

     2) Before polishing operation, check the thickness of the checked product and the requirements of the process card. Ensure that the repaired welds and products can meet product requirements.

     3Products with a caliber greater than 355mm and products with a wall thickness less than1.5mm do not take sanding or shot blasting, and are directly shaped after pickling → fine turning → sandblasting. The products after sandblasting should be careful to avoid bumps on the surface.

11

Fine turning

1) Pay attention to protect the appearance of the product to avoid scratches and pinching.

2) The bevel angle strictly implements the standard requirements, see figure 2 on theright .

13

Rear

deal with

       1) The product after sand blasting should pay attention to avoid bumps on the surface.

       2) After passivation treatment, gently handle it, and do not allow the products to scratch each other and bump with other materials.

3) Quickly pack the products after passing the inspection to prevent bumping and scratching.

Mark

Number of places

Change the file number

Signature

Date

Preparation (date)

Audit (date)

Approval (date)

04

Guide for production work of elbow fittings ( 1e )

Yaang Pipe Industry Co., Limited

Process name

Production process of seamless elbow

Product code

Yaang/CP-0 1

Process name

Production process of pushing (bending) elbow

Material

Low-alloy steel

Equipment

Pipe fitting production equipment

Indicate

Work step

Process

Content

Precautions

1

Blanking

1) Cut the material strictly according to the size chart, and measure the length to check the appearance.

a. heat treatment, the holding time should not be less than. 3 0minstrict according with the heat treatment process the file.

b. During thermoforming, the temperature of the heating pipe should be strictly monitored by infrared thermometer, suitable for 800-900 ℃.

c. When processing materials with thin wall thickness, special attention should be paid to the details such as the angle of placement, the rate of pushing, the furnace installation and holding time of heat treatment, and the depth of grinding.

d. Figure :

20200701041902 82155 - Production process of butt welded elbow and tee

The main parameters:

National standard

American Standard

Japanese Standard

German Standard

Wall thickness

22mm

a2

37.5 ±2.5

37.5 ±2.5

32.5 ±2.5

30+5-0

b2

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c2

1.5 ± 1

1.5 ± 1

1.0 ± 0.5

1.6 ± 0.8

Wall thickness

22mm

a

37.5 ±2.5

37.5 ±2.5

37.5 ±2.5

30+5-0

b

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c

1.5 ± 1

1.5 ± 1

1.6 ± 0.8

1.6 ± 0.8

beta

10 °± 1

10 ± 2.5

10 °± 1

10 °± 1

R

3mm

3mm

3.2mm

3mm

t

19mm

19mm

19mm

19mm

When the wall thickness is less than , use flat or slightly chamfered (as determined by the manufacturer).

eReasonable protective measures should be taken for painted products.

2

Forming

1) First measure the incoming material and confirm that the wall thickness meets the processing requirements.

2) Place the workpiece in a heating furnace and heat to 800-900  .

      3) Check the dimensions and surface conditions of the inner and outer molds to make sure that the surface of the product will not have quality problems such as silk paths and pits after molding.

      4) Put the heated workpiece into the forming mold, and use a reasonable advancement and pressing rate to perform the forming process.

      5) After the  molding, the product will be inspected for the first time, including the size and surface condition, and after being qualified, it will enter mass production.

3

Short hair

       1) When using tooling fixtures for flat heads, an extra 3-5mmmargin is required at each end .

 2) When  no jig is used, a 10mmmargin is required at each end when cutting the head .

4

Heat

deal with

1) Heat treatment refer to the heat treatment process document for a suitable heat treatment process. For example, 15CrMo steel adoptsnormalizing 950 ℃ tempering 690℃ air cooling .

2Incubation time for each oneholding a wall thickness of 2-3 minand less than 30 minutes , the tempering holding time for an appropriate extension of 50% . 

3) After heat treatment, hardness test is performed.

5

Pickling

1) After pickling, the appearance must be clean, free of scale and acid.

6

Plastic surgery

        1) Measure whether the size is up to standard, whether the surface is smooth, especially pay attention to the roundness of the end.

2) The dimensions and radians of the end and back are measured to meet the requirements after shaping.

7

Surface treatment

1) Depending on the surface condition of the product, if the surface condition is good, nogrinding is required.

2) When grinding , pay attention to the product wall thickness requirements indicated on the process card. Random operations are strictly prohibited.

3) During the grinding process, the product should not be rubbed or rubbed too much on the ground, resulting in excessive and deep surface scars after grinding.

8

Fine turning

1) Pay attention to protect the appearance of the product to avoid scratches and pinching.

2) Strictly enforce the standard requirements of the bevel angle, see Figure 1 on the right .

9

Rear

deal with

1) According to customer requirements, produce and process the product surface.

2) If there is a product that needs to be blackened blacken it.

3) No blackening or blackened products are required for spray painting, generally black anti-rust and anti-corrosion paints are used.

3) After the paint is handled, gently handle it, and do not allow the products to scratch each other and bump against objects of other materials.

4) Spray the logo on the products after passing the inspection toprevent contamination and scratching.

Mark

Number of places

Change the file number

Signature

Date

Preparation (date)

Audit (date)

Approval (date)

                                       05

Yaang Pipe Industry Co., Limited

Elbow production operation instruction (1f)

Process name

Production process of seamless elbow

product code

Yaang/CP-01

Process name

Production process of pushing (bending) elbow

Material

Low-alloy steel

Equipment

Pipe fitting production equipment

Indicate

Work step

Process

Content

Precautions

1

Blanking

1) Strictly cut the materials according to the drawings and sample size, and check the measured arc length.

aStrictly follow the heat treatment process during heat treatment

bFigure 1 :

20200701042514 81894 - Production process of butt welded elbow and tee

c. When welding, strictly follow the welding process When pairing together, the spot welding should be carried out carefully to prevent the occurrence of “wrong edges”. Do not start the arc on the base metal.

dFigure :

20200701041902 82155 - Production process of butt welded elbow and tee

The main parameters:

National standard

American Standard

Japanese Standard

German Standard

Wall thickness

22mm

a2

37.5 ±2.5

37.5 ±2.5

32.5 ±2.5

30+5-0

b2

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c2

1.5 ± 1

1.5 ± 1

1.0 ± 0.5

1.6 ± 0.8

Wall thickness

22mm

a

37.5 ±2.5

37.5 ±2.5

37.5 ±2.5

30+5-0

b

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c

1.5 ± 1

1.5 ± 1

1.6 ± 0.8

1.6 ± 0.8

beta

10 °±1

10 ± 2.5

10 °± 1

10 °± 1

R

3mm

3mm

3.2mm

3mm

t

19mm

19mm

19mm

19mm

When the wall thickness is less than 5, use flat or slightly chamfered (as determined by the manufacturer).

eReasonable protective measures should be taken for painted products.

2

Forming

1) measuring the sheet thicknessis determined to meet production needs.

2) Place the workpiece in a heating furnace and heat to 800-900  .

3) Measure the size of the innermold to ensure a tight fit and see if the edges are flat.

4) Put the heated workpiece into the forming mold, and use a reasonable pressing rate to perform the forming process.

5) After the molding, the product will be inspected for the first time, including the size and surface condition. After the product is qualified, it will enter mass production.

3

Whole side

     1) When cutting the edge, draw a line with a stylus on the material and measure the half circumference, see Figure 1 on the right Make sure the half circumference after cutting C = π ÷ 2+5~8mm (is the outer diameter of the finished product, π takes 3.14) to ensure that the product can still meet the standard size requirements after welding shrinkage.

    2) The edging ensures that the welding groove is smooth and smooth, and the groove is not allowed to be saw-toothed.

    3) After the operator draws the line, the inspector measures half the circumference and writes the measured data on the product with a stone pen.Confirm the qualified flow into the welding process.

Cut edge

Edge

Edging

4

welding

    1) The two sides must be matched during the alignment, and ensure that the perimeter O = π after welding isgreater than the diameter of the pipe, which is approximately equal to the upper limit of the outer diameter tolerance of the product.

     2) Weld surface inspection: undercutting is not allowed, pay attention to remove welding scars and welding knobs. Undercut depth limit, the weld residual height should be moderate (when 25 , residual height ≯ 2.5mm , undercut ≯ 1mm ), in principle, the residual height of the company’s products must not be greater than 1.8mm , and undercut is absolutely not allowed Happening.

     3) The welding seam must be uniform, and the welding must be evenly covered, and the temperature between the control layers should not exceed the temperature required by the corresponding welding process evaluation.

5

Cutting head

1) When drawing and cutting by hand, 10-20mm extra margin is required at each end .

6

Heat treatment

    1Holding time per heat a wall thickness of 2-3 min, not less than minutes.

    2) After welding, due to the relatively large workpiece, heat treatment using a package furnace.

7

Pickling

1) After pickling, the appearance must be clean, free of scale and acid.

9

Plastic surgery

1) Spherical shaping process isadopted for shaping.

     2) If there is no groove in the shaping mold, the welding seam needs to be ground first, and the welding seam height of the product is grinded to 0.1t-0.2t (t is the wall thickness. After the welding seam is flattened, the shaping operation is performed.

     3) After the shaping is completed, make sure that the ends are round and the size meets the requirements.

10

Surface treatment

    1) Pay attention to whether the internal and external seams are required in the order, and pay attention to the excess height of the weld seam and the excessive smoothness of the base material when grinding, not abrupt.

2) Before the grinding operation, check the thickness of the checked product and the requirements of the process card.Ensure that the repaired welds and products can meet product requirements.

11

Fine turning

1) Pay attention to protect the appearance of the product to avoid scratches and pinching.

2) The bevel angle strictly implements the standard requirements, see figure 2 on theright .

13

Rear

deal with

1) According to customer requirements, produce and process the product surface.

2) If there is a product that needs to be blackened blacken it.

3) No blackening or blackened products are required for spray painting, generally black anti-rust and anti-corrosion paints are used.

4) After the paint is handled, gently handle it, and do not allow the product to scratch each other and bump against other materials.

5After passing the inspection,mark the product to prevent contamination and scratching.

Mark

Number of places

Change the file number

Signature

Date

Preparation (date)

Audit (date)

Approval (date)

06

Yaang Pipe Industry Co., Limited

     Production operation instruction for tee fittings (2a)

Process name

Production process of tee

Product code

Yaang/CP-02

Process name

Production process of cold pressed tee

Material

Austenitic, Duplex steel, super austenitic

Equipment

Pipe fitting production equipment

Indicate

Cold forming

Work step

Process

Content

Precautions

1

Blanking

1) Cut the material strictly according to the size chart, and measure the length to check the appearance.

a. During heat treatment, the holding time should not be less than20min , but it should not be too long. If the holding time is too long, it will cause coarse grains and reduce the mechanical properties and corrosion resistance of the product.

B. Schematic diagram of hydroforming:

20200701045758 12266 - Production process of butt welded elbow and tee

c. When welding, strictly follow the welding process . When docking, the spot welding should be carefully combined to prevent the occurrence of “wrong edges”. Do not start the arc on the base metal.

dFigure :

20200701041902 82155 - Production process of butt welded elbow and tee

The main parameters:

National standard

American Standard

Japanese Standard

German Standard

Wall thickness

22mm

a2

37.5 ±2.5

37.5 ±2.5

32.5 ±2.5

30+5-0

b2

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c2

1.5 ± 1

1.5 ± 1

1.0 ± 0.5

1.6 ± 0.8

Wall thickness

22mm

a

37.5 ±2.5

37.5 ±2.5

37.5 ±2.5

30+5-0

b

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c

1.5 ± 1

1.5 ± 1

1.6 ± 0.8

1.6 ± 0.8

beta

10 °± 1

10 ± 2.5

10 °± 1

10 °± 1

R

3mm

3mm

3.2mm

3mm

t

19mm

19mm

19mm

19mm

When the German standard wall thickness ≤ , the flat mouth. When the wall thickness is less than American standard austenite adopts flat mouth or slight chamfer (as determined by the manufacturer).

. After sandblasting, if it is necessary to passivate, passivation treatment can be done: use 30% nitric acid solution, soak at room temperature for 1h , do blue point test after passivation, no blue point within 35S is qualified.

2

Forming

welding

1) First measure the incoming material and confirm that the wall thickness meets the processing requirements.

2) There is a seam tee, welded after rolling the plate, the weld should be left on the back of the main pipe (that is, the opposite side of the branch pipe) during molding, and formed. The welding seam must be evenly covered during welding, and the temperature between layers should not exceed the temperature required by the corresponding welding process qualification.

Weld surface inspection: Undercut is not allowed, pay attention to remove welding scars and welding knobs.

3) Ф≤325mm is formed by direct hydraulic tee machine. Ф>325 adopts the method of opening a hole in the stretched branch pipe and putting it into a die for compression molding.

      4) The product is inspected for the first time during the molding process, including the size and surface conditions. After the product is qualified, it will enter mass production. 

3

Short hair

      1) When using tooling fixtures for flat heads, an extra 3-5mm margin is required at each end.

2) If  no clamp is used, a 10mmmargin is required at each end when the head is flat.

4

Heat

deal with

1) Heat treatment refer to the heat treatment process document for a suitable heat treatment process. For example, austenite material adopts 1050 ℃ ± 10 ℃, heat treatment. Duplex steel and super austenitic materials are heat treated at 1080 ℃ ( +20-0 ℃).

2) Incubation time for each. 1 th thickness promote 2min, less than 20 is min.

5

Cutting head

1) The position of the middle head and branch pipe needs to be cut, fixed on the sawing machine, and measure the length, leaving enough height of the middle head to cut the head.After cutting the head, check whether the height of the measured tube conforms to the standard size.

6

Pickling

1) After pickling, the appearance must be clean without oxide scale, over-acid and under-acid.

2) After pickling, depending on the busyness of the specific process, first arrange the batch of products into plastic shaping (process step ) or polishing (process step 8 ). The two- step process can be reversed.

7

Plastic surgery

       1) Measure whether the size is up to standard, whether the surface is smooth, especially pay attention to the roundness of the end.

2) The dimensions of themeasuring end and the branch pipe are all in compliance with the requirements after shaping .

8

Surface treatment

1) Check the surface condition of the product. If the surface condition is good, you can use sanding and shot blasting directly without polishing.

2) When polishing, pay attention to the product wall thickness requirements indicated on the process card. Random operations are strictly prohibited.

3) During the grinding process, the product must not be rubbed or rubbed too much with the ground, which may cause excessive and deep surface scars after grinding.

9

Fine turning

1) Pay attention to protect the appearance of the product to avoid scratches and pinching.

2) Strictly enforce the standard requirements of the bevel angle, see Figure 1 on the right .

10

Rear

deal with

1) According to customer requirements, produce and process the product surface.

2Products with caliber Ф 355 and above are not sand-blasted, and are directly blasted. Products after blasting should pay attention to avoid bumps on the surface.

3) After passivation treatment, gently handle it, and do not allow the products to scratch each other and bump with other materials.

4) After passing the inspection, quickly pack the nylon film to prevent contamination and scratching.

Mark

Number of places

Change the file number

Signature

Date

Preparation (date)

Audit (date)

Approval (date)

07

Yaang Pipe Industry Co., Limited

     Production operation instruction for tee fittings (2b)

Process name

Production process of tee

Product code

Yaang/YA-01

Process name

Production process of hot pressing tee

Material

Low-alloy steel

Equipment

Pipe fitting production equipment

Indicate

Hot press forming

Work step

Process

Content

Precautions

1

Blanking

1) Cut the material strictly according to the size chart, and measure the length to check the appearance.

a. When heat treatment, strictly refer to the heat treatment process.

b. At step 7 , the appearance of the product is in good condition, but we must pay attention to the degree of measurement, which needs to be confirmed by the technical department or relevant technical personnel.

c. When welding, strictly follow the welding process . When docking, the spot welding should be carefully combined to prevent the occurrence of “wrong edges”. Do not start the arc on the base metal.

d. Figure 1:

20200701050555 47519 - Production process of butt welded elbow and tee

e. Figure 2 :

20200701041902 82155 - Production process of butt welded elbow and tee

The main parameters:

National standard

American Standard

Japanese Standard

German Standard

Wall thickness

22mm

a2

37.5 ±2.5

37.5 ±2.5

32.5 ±2.5

30+5-0

b2

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c2

1.5 ± 1

1.5 ± 1

1.0 ± 0.5

1.6 ± 0.8

Wall thickness

22mm

a

37.5 ±2.5

37.5 ±2.5

37.5 ±2.5

30+5-0

b

≤ 14 °

≤ 14 °

≤ 18 °

15-18

c

1.5 ± 1

1.5 ± 1

1.6 ± 0.8

1.6 ± 0.8

beta

10 °± 1

10 ± 2.5

10 °± 1

10 °± 1

R

3mm

3mm

3.2mm

3mm

t

19mm

19mm

19mm

19mm

When the wall thickness is less than 5, use flat or slightly chamfered (as determined by the manufacturer).

e. Reasonable protective measures should be taken for painted products.

2

Forming

welding

1) First measure the incoming material and confirm that the wall thickness meets the processing requirements.

2) There is a seam tee, welded after rolling the plate, the weld should be left on the back of the main pipe (that is, the opposite side of the branch pipe) during molding, and formed. The welding seam must be evenly covered during welding, and the temperature between layers should not exceed the temperature required by the corresponding welding process qualification.

Weld surface inspection: Undercut is not allowed, pay attention to remove welding scars and welding knobs.

3) Open a hole in the stretched branch pipe, place the workpiece in a heating furnace, heat to 800-900 ℃, put a die inside toperform compression molding.

      4) The product is inspected for the first time during the molding process, including the size and surface condition. After passing the confirmation, the product will be mass produced. Picture 1

3

Short hair


      1) When using tooling fixtures for flat heads, an extra 3-5mm margin is required at each end.

2) If  no clamp is used, a 10mmmargin is required at each end when the head is flat.

4

Heat

deal with

1) Heat treatment refer to the heat treatment process document for a suitable heat treatment process.

2) Incubation time for each oneholding a wall thickness of 2 -3min, and less than 20 is minutes.

5

Cutting head

1) The position of the branch pipe needs to be cut, fixed on the sawing machine, and measure the length, leaving enough middle head height for cutting. After cutting the head, check whether the height of the measured branch pipe conforms to the standard size.

6

Pickling

1) After pickling, the appearance must be clean, free of scales, and free of acidic sand .

2) After pickling, depending on the busyness of the specific process, first arrange the batch of products into plastic shaping (process step 7 ) or polishing (process step 8 ). The two-step process can be reversed.

7

Plastic surgery

        1) Measure whether the size is up to standard, whether the surface is smooth, especially pay attention to the roundness of the end.

2) The dimensions of themeasuring end and the branch pipe are all in compliance with the requirements after shaping.

8

Surface treatment

1) Check the surface condition of the product, if the surface condition is good.

2) When grinding, pay attention to the product wall thickness requirements indicated on the process card. Random operations are strictly prohibited.

3) During the grinding process, the product must not be rubbed or rubbed too much with the ground, which may cause excessive and deep surface scars after grinding.

9

Fine turning

1) Pay attention to protect the appearance of the product to avoid scratches and pinching.

2) Strictly enforce the standard requirements of the bevel angle, see the picture on the right 2.

10

Rear

deal with

1) According to customer requirements, produce and process the product surface.

2) There is a product that needs to be blackened that, blacken it.

3) No blackening or blackened products are required for spray painting, generally black anti-rust and anti-corrosion paints are used.

4) paint is handled, gently handle it, and do not allow the products to scratch each other and bump against objects of other materials.

5) Spray the logo on the products after passing the inspection to prevent contamination and scratching.







Mark

Number of places

Change the file number

Signature

Date

Preparation (date)

Audit (date)

Approval (date)

















08

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