Rau sab hauv corrosive flow applications - uas suav txog ntau dua 80% ntawm tag nrho cov kev pabcuam corrosive piping hauv cov roj & roj, tshuaj, thiab hluav taws xob tsim kev lag luam - metallurgically clad yeeb nkab (carbon steel backing + 2-3mm nickel alloy cladding) muab cov khoom zoo tib yam corrosion tsis kam rau cov khoom npib tsib xee%. Cov khoom siv nickel alloy yeeb nkab yog tsim nyog tsuas yog thaum lub cheeb tsam sab nraud kuj corrosive, thaum cov yeeb nkab txoj kab uas hla me me (hauv qab NPS 2), los yog thaum qhov kev pab cuam kub tshaj 450C.
Scope Daim ntawv qhia no suav nrog: metallurgical clad yeeb nkab kev tsim cov txheej txheem (kub yob daim ntawv cog lus, explosive bond, weld overlay); tus nqi sib piv nrog cov khoom nickel alloy yeeb nkab thoob plaws qhov ntau thiab tsawg thiab alloys; Cov qauv siv tau (ASTM A264, A265; API 5LD; DNV ST F101); Kev txheeb xyuas tus nqi ntawm lub neej suav nrog CAPEX, kev teeb tsa, kev tshuaj xyuas, thiab kev saib xyuas; xaiv cov kev txwv thiab kev txiav txim siab matrix; thiab FAQ rau pawg neeg yuav khoom.
Clad Pipe yog dab tsi?
Clad pipe has a metallurgical bond between the corrosion-resistant alloy (CRA) layer and the carbon steel backing - the two metals are fused at the atomic level. Lined pipe has only a mechanical interference fit. This single difference determines temperature capability (clad: >400C; kab:<150C), resistance to disbonding under thermal cycling, and pressure rating - clad pipe is always the choice for safety-critical, high-temperature, or high-pressure corrosive service.
Cov yeeb nkab clad muaj ob txheej sib txuas ua ke ntawm qhov sib txuas los ntawm cov txheej txheem metallurgical: txheej txheej txheej txheej ntawm cov pa roj carbon steel los yog qis-alloy steel ("rov qab" lossis "pem hlau") uas muab cov txheej txheem muaj zog thiab siab ntim, thiab txheej txheej sab hauv ("cladding" lossis "clad hlau") ntawm cov nickel alloy, stainless steel, {1} corrosion resistant, stainless steel 1. kua dej. Lub cladding txheej feem ntau yog 2.0-4.0mm tuab, suav txog 10-25% ntawm tag nrho cov phab ntsa tuab. Qhov sib txawv ntawm engineering tseem ceeb yog cov hlau nplaum: cov txheej txheej cladding thiab cov hlau thim rov qab tau koom nrog atomic diffusion ntawm qhov sib cuam tshuam thaum kub kub tsim, tsim kom muaj cov qauv nplej tas mus li thoob plaws ciam teb. Daim ntawv cog lus no muaj lub zog shear tshaj 140 MPa (20,000 psi) rau ASTM A264 / A265 qhov yuav tsum tau - siab dua lub zog shear ntawm ntau carbon steels lawv tus kheej.
Ib txoj kab yeeb nkab, los ntawm qhov sib txawv, muaj nyias - lub tes tsho CRA tso rau hauv cov yeeb nkab carbon steel thiab mechanically nthuav dav (hydrauulically lossis nrog npua) kom nias - haum rau sab hauv phab ntsa. Tsis muaj atomic bond ntawm lub liner thiab lub nraub qaum. Nyob rau hauv thermal cycling, lub liner thiab thaub qab nthuav dav thiab kev cog lus ntawm cov nqi sib txawv vim tias carbon steel (CTE ~ 12 x 10 K) thiab npib tsib xee alloys (CTE ~ 13-14 x 10 K) muaj qhov sib txawv thermal expansion coefficients, tsim qhov sib txawv ntawm cov liner thiab cov thaub qab. Nyob rau ntau lub voj voog thermal, cov khoob no loj tuaj, uas ua rau cov kab tawg hauv qab sab nraud overpressure los ntawm lub annulus. Qhov no yog vim li cas cov yeeb nkab kab yog txwv rau nruab nrab qhov kub thiab txias (feem ntau hauv qab 150C) thiab tsis pom zoo rau cov ntawv thov uas nquag siv thermal cycling.
|
Feature |
Clad Pipe (Metallurgical Bond) |
Kab Yeeb (Mechanical Fit) |
|
Hom Bond |
Metallurgical (atomic diffusion daim ntawv cog lus) |
Mechanical cuam tshuam (nias - haum) |
|
Interfacial Shear Strength |
>140 MPa rau ASTM A265 |
Tsawg kawg nkaus (kev sib txhuam nkaus xwb) |
|
Qhov Kev Pab Cuam Siab Tshaj Plaws |
Txog li 450C |
Feem ntau<150C |
|
Thermal Cycling Resistance |
Zoo heev - tsis muaj kev cuam tshuam |
Tsis zoo - kev pheej hmoo ntawm cov kab tawg |
|
Sab nraud Pressure Resistance |
Tag Nrho (Integral Structure) |
Limited (liner yooj yim rau vau) |
|
Cladding Thickness |
1.5-4.0mm typical |
1.5-3.0mm typical |
|
Kev kho |
Weldable (PWHT tus qauv) |
Limited (yuav tsum tau hloov lub tes tsho hlau) |
|
Lub Sijhawm Ua Haujlwm Ua Haujlwm |
14-24 lub lis piam typical |
8-16 lub lis piam typical |
|
Nqi vs Khoom Alloy |
50-65% kev txuag nyiaj |
60-70% kev txuag nyiaj |
|
Txheem Specification |
API 5LD, ASTM A264/A265, API 5LD |
API 5LD (Liab hom) |
[Source] ASTM A265-12: Txheem Specification rau Nickel thiab Nickel-Base Alloy-Clad Steel Phaj; API 5LD-2015: CRA Clad lossis Lined Steel Pipe.
Peb txoj kev tsim khoom rau Clad Pipe
Clad yeeb nkab yog tsim los ntawm peb txoj kev - Kub Roll Bonding (zoo tshaj plaws rau qhov loj - txoj kab uas hla, siab- ntim ntau lawm), Kev sib tsoo tawg (zoo tshaj plaws rau cov tuab cladding lossis me me), thiab Weld Overlay Cladding (zoo tshaj plaws rau fittings, me diameters, thiab post- kev tsim kho). Txoj kev xaiv nyob ntawm cov yeeb nkab txoj kab uas hla, ntau lawm ntim, thiab cladding thickness yuav tsum tau.
Kub Roll Bonding (HRB) - Kev Lag Luam Standard rau Cov Yeeb Nkab Loj
Kub Roll Bonding yog txoj kev siv dav tshaj plaws los tsim cov phaj clad uas tau tsim los rau hauv welded clad yeeb nkab (UOE lossis JCOE txheej txheem). Cov txheej txheem pib nrog ob lub slabs sib cais: cov pa roj carbon steel slab (feem ntau ASTM A516 Gr.70 los yog API 5L X65) thiab nickel alloy slab (xws li Inconel 625, Alloy 825, lossis 316L stainless hlau). Cov mating nto raug ntxuav kom tshem tawm tag nrho cov oxides, tom qab ntawd ob lub slabs tau sib sau ua ke nrog cov mating nto nyob rau hauv kev sib cuag thiab kaw nyob ib ncig ntawm cov npoo los ntawm vuam los tiv thaiv oxidation thaum cua sov.
Lub rooj sib txoos yog rhuab mus rau 1,100-1,250C thiab tom qab ntawd kub- dov mus rau qhov kawg clad phaj thickness. Nyob rau ntawm qhov kub thiab txias no, atomic diffusion tshwm sim thoob plaws hauv lub interface, tsim kom muaj ib daim ntawv cog lus txuas ntxiv mus. Tom qab dov, lub phaj clad yog txiav mus rau qhov loj me, cua sov- kho ib qho tshwj xeeb, thiab tom qab ntawd tsim cov yeeb nkab los ntawm UOE (U-nias, O-nias, Nthuav) lossis JCOE txheej txheem. Lub longitudinal weld yog ua los ntawm cov hlau sib txuam - lub nraub qaum yog welded nrog carbon steel electrode, thiab sab cladding yog welded nrog npib tsib xee alloy electrode.
- Bond mechanism: atomic diffusion ntawm 1,100-1,250C - nruam grain qauv thoob plaws interface
- Hom cladding thickness: 2.0-4.0mm (tswj los ntawm slab thickness piv)
- Pipe txoj kab uas hla: NPS 16 txog NPS 84 (406mm txog 2,134mm) ntawm UOE / JCOE
- Lub sij hawm xa tuaj: 14-20 lub lis piam los ntawm kev txiav txim mus rau tus me nyuam rau qhov ntau thiab tsawg
- Ntau lawm ntim: siab (ntau txhiab tons ntawm ib qho kev txiav txim)
- Kev pov thawj zoo: kuaj ultrasonic ib ASTM A578; shear xeem rau ASTM A265; khoov xeem
Explosive Bonding - rau Thick Cladding lossis Me me
Kev sib txuas sib txuas siv cov khoom siv hluav taws xob tswj tau tawg tawm saum lub phaj cladding, uas tau muab tso rau ntawm qhov chaw ruaj khov- tawm ntawm qhov deb ntawm lub hauv paus phaj. Lub detonation nthwv dej taug kev hla cov phiajcim ntawm qhov nrawm ntawm 2,000-3,000 m/s, tsim kom muaj kev sib tsoo siab -kev sib tsoo uas ua rau muaj kev kub ntxhov ntau tshaj 10 GPa (100,000 cua) ntawm lub interface. Qhov siab tshaj plaws no tshem tawm tag nrho cov oxides saum npoo thiab ua rau ob lub hlau ua ke sai heev uas cov atomic-theem metallurgical daim ntawv cog lus tsis melting ob hlau.
Daim ntawv cog lus interface muaj tus yam ntxwv wavy qauv nyob rau hauv kev tshuaj xyuas microscopic - qhov sib cuam tshuam wavy ua rau thaj chaw sib koom ua ke los ntawm 30-50% piv rau lub tiaj tus interface, muab cov nyiaj sib npaug piv rau kev sib tw kub. Kev sib tsoo tawg yog qhov zoo tagnrho rau cov tuab cladding (3-10mm), cov khoom sib txawv ntawm cov khoom sib xyaw ua ke, thiab cov khoom siv me me uas teeb tsa kev sib tw kub-dov yog qhov tsis zoo.
- Bond mechanism: siab- nrawm oblique kev sib tsoo (2,000-3,000 m/s) - wavy interface qauv
- Hom cladding thickness: 2.0-10.0mm (tuaj yeem mus thicker dua kub yob sib txuas)
- Phaj loj: txwv rau qhov muaj peev xwm tawg tau (feem ntau txog 4m dav x 12m ntev)
- Lub sij hawm xa tuaj: 8-14 lub lis piam
- Ntau lawm ntim: me me mus rau nruab nrab (ib daim hlau rau 500 tons)
Weld Overlay Cladding (GTAW los yog PTA) - rau Fittings thiab Me Diameters
Weld overlay cladding tso ib txheej ntawm nickel alloy ncaj qha mus rau sab hauv ntawm cov pa roj carbon steel yeeb nkab lossis haum siv Gas Tungsten Arc Vuam (GTAW / TIG) lossis Plasma Transferred Arc (PTA) vuam. Cov nickel alloy muab tub lim hlau lossis hmoov yog melted thiab fused mus rau cov pa roj carbon steel substrate, tsim kom muaj txheej txheej metallurgically bonded clad. Qhov kev sib tw tseem ceeb hauv weld overlay yog dilution: cov molten npib tsib xee alloy sib xyaw nrog qee cov pa roj carbon steel ntawm qhov sib cuam tshuam, uas tuaj yeem txo qhov corrosion tsis kam ntawm thaj chaw diluted.
Kev tswj cov txheej txheem zoo ua kom dilution qis dua 5-10%, thiab thawj qhov hla dhau los ntawm qhov thib ob uas muaj qhov tsis zoo. Weld overlay yog txoj kev xaiv rau: (1) clad fittings (lub luj tshib, tees, reducers) uas tsis tuaj yeem ua los ntawm clad phaj; (2) me me-inch clad yeeb nkab (NPS 2-14) qhov kub dov kev sib raug zoo yog uneconomical; (3) kev kho thaj chaw ntawm cov yeeb nkab puas uas cov txheej cladding tau khawb los yog hnav los ntawm.
- Bond mechanism: fusion vuam - npib tsib xee alloy melted thiab fused rau steel substrate
- Hom clad thickness: 2.0-5.0mm (ob-dhau yam tsawg kawg nkaus rau cov txheej uas tsis muaj dilution)
- Txoj kab uas hla: NPS 2 txog NPS 48; zoo tagnrho rau fittings thiab me me yeeb nkab
- Lub sij hawm xa tuaj: 10-16 lub lis piam
- Ntau lawm ntim: txhua qhov ntim (ib thooj rau ntau txhiab)
- Key QA parameter: Fe cov ntsiab lus<5% in the top cladding pass (prevents dilution-induced corrosion)
Tus nqi sib piv
Thoob plaws tag nrho cov nickel alloy qib thiab qhov ntau thiab tsawg ntawm cov yeeb nkab, clad yeeb nkab (3mm cladding ntawm carbon steel) raug nqi 40-65% tsawg dua cov khoom nickel alloy yeeb nkab. Kev txuag nyiaj nce nrog cov yeeb nkab txoj kab uas hla: rau 12-nti NPS yeeb nkab, clad Inconel 625 yog kwv yees li $ 290 / kg sib npaug vs ~ $ 55 / kg sib npaug rau clad - cov khoom siv txo qis dua 60%. Tus nqi kom zoo dua yog tus tsav tsheb tseem ceeb rau kev siv cov yeeb nkab clad hauv kev lag luam roj & roj.
|
Pipe Description |
Alloy Tus Nqi ($ / m) |
Clad Pipe Nqi ($ / m) |
Txuag ($/m) |
Txuag (%) |
Txuag ib xyoos twg (10,000m) |
|
8" SCH 40 Inconel 625 (UNS N06625) |
$2,100 |
$840 |
$1,260 |
60% |
$12,600,000 |
|
10" SCH 40 Inconel 625 |
$3,150 |
$1,260 |
$1,890 |
60% |
$18,900,000 |
|
12" SCH 40 Inconel 625 |
$4,100 |
$1,640 |
$2,460 |
60% |
$24,600,000 |
|
16" SCH 30 Inconel 625 |
$6,200 |
$2,480 |
$3,720 |
60% |
$37,200,000 |
|
10" SCH 40 Alloy 825 (UNS N08825) |
$2,800 |
$1,120 |
$1,680 |
60% |
$16,800,000 |
|
12" SCH 40 Alloy 825 |
$3,700 |
$1,480 |
$2,220 |
60% |
$22,200,000 |
|
10" SCH 40 316L Stainless hlau |
$580 |
$290 |
$290 |
50% |
$2,900,000 |
|
12" SCH 40 316L Stainless hlau |
$720 |
$360 |
$360 |
50% |
$3,600,000 |
|
6" SCH 80 Monel 400 (UNS N04400) |
$1,800 |
$720 |
$1,080 |
60% |
$10,800,000 |
[Tau qhov twg los] Tus nqi kwv yees raws li 2024-2025 npib tsib xee alloy ua lag luam tus nqi rau zeb ntau. Clad nqi suav nrog 3 hli cladding thickness, carbon steel thaub qab (API 5L X65), kev tsim khoom, thiab NDE rau ASTM A265. Tus nqi tiag tiag txawv nrog tus nqi nickel qhov chaw, xaj kom muaj nuj nqis, thiab qhov chaw. Kev txuag nyiaj ib xyoos ib zaug raws li 10,000 linear meters - ib txwm rau qhov project loj nyob sab nraud.
Vim li cas cov khoom siv nickel alloy yog kim heev?
Cov khoom nickel alloy yeeb nkab yog kim vim tias nws yog ntau tshaj 60% npib tsib xee los ntawm qhov hnyav - thiab npib tsib xee yog cov khoom siv hlau tus nqi ntawm $ 16,000 -25,000 ib metric ton. Clad yeeb nkab hloov 80-90% ntawm cov khoom kim heev no nrog carbon steel nqi ntawm $ 600-900 ib tuj - 25x raw khoom tus nqi sib txawv - thaum tuav zoo tib yam sab hauv corrosion kuj. Tus nqi ntawm kev ntxiv 3 hli ntawm nickel alloy cladding rau carbon steel yog kwv yees li 10-15% ntawm tus nqi ntawm kev ua tag nrho cov phab ntsa los ntawm npib tsib xee alloy.
Tus nqi qauv ntawm cov khoom Inconel 625 yeeb nkab yog cov khoom siv raw: Inconel 625 yog kwv yees li 61% npib tsib xee, 22% chromium, 9% molybdenum, thiab 3.5% niobium los ntawm qhov hnyav. Ntawm tus nqi npib tsib xee $18,000/ton, chromium ntawm $12,000/ton, thiab molybdenum ntawm $45,000/ton - tus nqi raw khoom ib leeg rau Inconel 625 yog kwv yees li $18-22/kg. Ntxiv melting, kub ua hauj lwm, kev kho cua sov, thiab NDE, cov yeeb nkab tiav cov nqi yog kwv yees li $45-65/kg rau cov qauv ntau thiab tsawg.
A 12-inch SCH 40 yeeb nkab hnyav kwv yees li 73 kg / m, muab cov khoom siv nqi kwv yees li ntawm $ 3,300-4,100 / m rau cov khoom Inconel 625. Cov pa roj carbon steel rov qab rau cov yeeb nkab clad ntawm tib txoj kab uas hla thiab lub sij hawm hnyav kwv yees li 65 kg / m ntawm tus nqi kwv yees li $ 0.70 / kg 8 condding. kg/m ntawm tus nqi kwv yees li $50/kg. Cov khoom siv clad tag nrho yog $ 45 / m (carbon steel) + $ 400 / m (cladding) + $ 200 / m (bonding / forming)=kwv yees li $ 650 / m - piv rau $ 3,300 / m rau cov khoom sib npaug. Qhov ntawd yog 5x tus nqi sib txawv ib 'meter' ntawm cov yeeb nkab.
Kev Tshawb Fawb Txog Kev Ua Neej: CAPEX + OPEX Tshaj 30 Xyoo
Tshaj li 30-xyoo offshore platform lifecycle, clad yeeb nkab xa tag nrho cov nqi ntawm cov tswv cuab (TCO) kwv yees li 45-55% qis dua cov khoom nickel alloy yeeb nkab. CAPEX cov nyiaj khaws cia (40-60%) yog qhov tseem ceeb tshaj plaws. OPEX yog qhov tseem ceeb zoo ib yam vim tias cov txheej txheej cladding muab tib yam corrosion kuj zoo li cov khoom alloy. Tus nqi tsim khoom rau clad yeeb nkab ( txheej txheem cladding + NDE ntxiv) sawv cev tsuas yog 5-10% ntawm tag nrho cov nqi, uas yog negligible piv rau cov khoom siv raw khoom txuag.
|
Nqi Element |
Khoom Inconel 625 Pipe (12 "SCH 40, 1,000m) |
Clad Inconel 625 Pipe (12 "SCH 40, 1,000m) |
Clad Savings |
|
Kev yuav khoom |
$4,100,000 |
$1,640,000 |
$2,460,000 (60%) |
|
Tsheb thauj mus los & Logistics |
$82,000 (2% ntawm cov khoom siv) |
$49,200 (3% ntawm cov khoom siv) |
$32,800 |
|
Installation (welding + NDE) |
$250,000 |
$280,000 ({2}}% rau clad weld) |
-$30,000 |
|
Ua ntej -commissioning |
$45,000 |
$45,000 |
$0 |
|
CAPEX Subtotal |
$4,477,000 |
$2,014,200 |
$2,462,800 (55%) |
|
Kev tshuaj xyuas txhua xyoo (30 xyoo) |
$300,000 ($ 10k / xyoo) |
$300,000 ($ 10k / xyoo) |
$0 |
|
Kev tu txhua xyoo (30 xyoo) |
$450,000 ($ 15k / xyoo) |
$450,000 ($ 15k / xyoo) |
$0 |
|
Hloov Tus Nqi (xyoo 20) |
$0 (tsim lub neej 30 xyoo) |
$0 (tsim lub neej 30 xyoo) |
$0 |
|
OPEX Subtotal (30 xyoo) |
$750,000 |
$750,000 |
$0 |
|
TAG NRHO 30-YEAR TCO |
$5,227,000 |
$2,764,200 |
$2,462,800 (47%) |
[Tau qhov twg los] TCO kwv yees rau kev piav qhia ntawm ntug dej hiav txwv sab saum toj project. Kev teeb tsa tus nqi sib txawv qhia txog kev sib txuas ntxiv rau cov yeeb nkab clad (rov qab weld + cladding pass). TCO tiag tiag sib txawv nrog qhov project qhov chaw, tus nqi zog, thiab tus nqi npib tsib xee thaum lub sijhawm yuav khoom.
Standards thiab Specifications
Tsib tus qauv tswj hwm clad yeeb nkab yuav thiab tshuaj xyuas. ASTM A264 (stainless steel clad) thiab ASTM A265 (nickel alloy clad) qhia cov txheej txheem clad. API 5LD npog clad / lined steel yeeb nkab rau kev siv kav dej. DNV ST F101 tswj hwm submarine pipeline systems nrog rau clad yeeb nkab. NACE MR0175 / ISO 15156 npog cov kev pabcuam qaub qaub hydrogen sulfide ib puag ncig - qhov twg clad yeeb nkab yuav tsum ua kom pom cov cladding alloy ua tau raws li cov kev pabcuam qaub uas tsim nyog raws li cov khoom siv hlau.
|
Txuj |
Title |
Scope |
Cov Lus Qhia Tseem Ceeb |
|
ASTM A 264 2 |
Stainless Chromium-Nickel Steel-Clad Phaj |
Clad phaj nrog 304L / 316L / 317L stainless cladding ntawm carbon / qis- alloy steel |
Shear strength >140 MPa; UT rau A578; khoov kuaj; cladding thickness kam rau ua |
|
ASTM A265, ASTM A265 |
Nickel thiab Nickel-Base Alloy-Clad Steel Phaj |
Clad phaj nrog Inconel, Hastelloy, Monel, Alloy 20 cladding ntawm carbon / qis- alloy steel |
Shear strength >140 MPa; UT rau A578; khoov kuaj; tshuaj muaj pes tsawg leeg ntawm clad txheej |
|
API 5LD |
CRA Clad lossis Lined Steel Pipe |
Ua kom tiav cov khoom siv yeeb nkab (phaj tsim + welded) rau kev pabcuam kav dej |
Base yeeb nkab rau API 5L (X42-X80); clad daim ntawv cog lus rau A264 / A265; NDE suav nrog tag nrho-lub cev UT; hydrotest; kev npaj kawg |
|
DNV ST F101 |
Submarine Pipeline Systems |
Offshore rigid pipeline systems nrog rau clad yeeb nkab |
Combined loading tsim; kev soj ntsuam qaug zog; tswj kev puas tsuaj; installation kev ntxhov siab; Ntxiv rau API 5LD rau offshore |
|
NACE MR0175 / ISO 15156 |
Cov ntaub ntawv rau H2S-Containing Environments |
Sour kev pabcuam tsim nyog ntawm CRA cov ntaub ntawv |
Cladding alloy yuav tsum ua tau raws li cov kev txwv kev ua haujlwm nyuaj thiab SSC / SCC tsis kam ua cov khoom alloy |
Kev Tshuaj Xyuas thiab Kev Ntsuas - Kev Tshawb Fawb Kev Ncaj Ncees
Clad yeeb nkab tau dhau NDE ntau dua li cov yeeb nkab steel hlau - ntxiv rau kev ntsuas cov yeeb nkab txheem (tshuaj lom neeg, tshuab, hydrotest), cov yeeb nkab clad yuav tsum tau 100% ultrasonic tshuaj xyuas rau daim ntawv cog lus ncaj ncees rau ASTM A578 (Level S2 lossis S3), shear lub zog kuaj ntawm daim ntawv cog lus (yam tsawg kawg 140 MPa), khoov PO ntawm cov ntaub ntawv pov thawj, thiab cov ntaub ntawv pov thawj. Identification) ntawm cladding alloy los xyuas cov qib conformance.
- Ultrasonic Testing (UT): 100% clad daim ntawv tshuaj ntsuam xyuas ib ASTM A578 Qib S2 (50mm daim phiaj) los yog S3 (25mm daim phiaj). Txhua qhov chaw tsis muaj kev cuam tshuam ntau tshaj qhov kev lees paub yuav tsum tau kho lossis txiav tawm.
- Shear Test: Ib qho piv txwv cylindrical yog machined nrog daim ntawv cog lus ntawm nruab nrab - qhov siab thiab sheared. Yam tsawg kawg nkaus shear zog: 140 MPa (20,000 psi) rau ASTM A264 / A265.
- Khoov Test: Ib daim ntawv qhia tag nrho -phab ntsa- tuab tuab yog khoov 180 degrees hla lub mandrel nrog cladding nyob rau hauv nro. Tsis muaj kev sib cais lossis tawg ntawm daim ntawv cog lus raug tso cai tom qab khoov.
- Tshuaj Ntsuam Xyuas: Cov cladding alloy yog soj ntsuam raws li cov qauv siv ASTM (xws li ASTM B443 rau Inconel 625). Cov hlau thaub qab tau txheeb xyuas raws li ASTM A20 / A20M.
- PMI (Positive Material Identification): 100% ntawm clad yeeb nkab thiab fittings ib ASTM E2148. XRF los yog OES tsom xam xyuas tias cov cladding alloy muaj pes tsawg leeg yog qhov yuav khoom specification.
- Hydrostatic Test: Raws li API 5LD Tshooj 9.3, txhua qhov clad yeeb nkab sib koom ua ke yog hydrotested ntawm 1.5x tsim siab rau tsawg kawg yog 10 vib nas this tuav lub sijhawm.
Thaum Clad Pipe ua haujlwm - thiab Thaum Tsis Muaj
Clad yeeb nkab yog qhov kev xaiv pom zoo rau txhua daim ntawv thov sab hauv corrosive nrog cov yeeb nkab txoj kab uas hla saum NPS 2 thiab kev pabcuam kub hauv qab 450C. Cov khoom siv nickel alloy yeeb nkab yuav tsum tau tsuas yog thaum qhov chaw sab nraud kuj yog corrosive, cov yeeb nkab txoj kab uas hla yog me me heev rau kev lag luam cladding, los yog qhov kev pab kub siab tshaj 450C qhov thermal expansion mismatch ua qhov tseem ceeb.
|
Daim ntawv thov |
Corrosive nruab nrab |
Temp Range |
Siab |
Khoom siv pom zoo |
Vim li cas ho tsis Khoom? |
Vim li cas ho tsis Clad? |
|
Offshore tsim cov dej ntws |
Seawater + CO2 + H2S |
4-90C |
Mus txog 345 bar |
Clad Inconel 625 (3mm) ntawm API 5L X65 |
Khoom yog 60% kim dua rau qhov zoo tib yam nrog kev tiv thaiv corrosion |
- |
|
Offshore gas export riser (cov roj qhuav) |
Cov roj qab zib (CH4 + CO2) |
Ambient rau 120C |
Txog li 250 bar |
Khoom API 5L X70 (tsis xav tau CRA) |
- |
- |
|
Sab saum toj txheej txheem piping (3-theem cais qhov hluav taws xob) |
Ua dej + roj + roj |
40-120C |
Txog li 100 bar |
Clad 316L (3mm) ntawm API 5L X52 |
Khoom 316L yog 50% kim dua |
- |
|
Tshuaj nroj tsuag sulfuric acid kab |
H2SO4 (10-40%,<60C) |
20-60C |
Mus txog 16 bar |
Khoom Alloy 20 (UNS N08020) - NPS 2 |
- |
NPS<2: clad uneconomical |
|
Geothermal zoo casing |
Brine + H2S + CO2 |
150-350C |
Txog li 200 bar |
Khoom Inconel 625 lossis Alloy 825 |
- |
Temp >450C hauv zos: thermal mismatch txaus ntshai |
|
Subsea flowline (sab nraud faus) |
Ua kua dej (sab hauv) + cov av ntub dej (sab nraud) |
4-80C |
Txog li 500 bar |
Clad Inconel 625 (3mm) + sab nraud FBE txheej ntawm API 5L X70 |
Khoom: Sab hauv CRA yog khib nyiab vim kev tiv thaiv sab nraud yog txheej |
Sab nrauv txheej tuav sab nraud corrosion |
|
HF alkylation chav tsev (refinery) |
Hydrofluoric acid (tsis muaj roj) |
20-80C |
Txog li 30 bar |
Solid Monel 400 - NPS 4 |
- |
HF yuav tsum muaj tag nrho Monel phab ntsa rau kev nyab xeeb; clad NB- txwv rau me me txoj kab uas hla |
|
Flue gas desulfurization (FGD) absorber |
SO2 + H2SO4 mist |
50-100C |
Huab cua |
Khoom Hastelloy C276 los yog clad Hastelloy C276 ntawm cov hlau |
Khoom yog 60% kim dua |
Clad yog tus qauv xaiv |
|
Me - tho qhov ntsuas tubing |
Txheej txheem kua dej qauv |
Ambient rau 150C |
Txog li 100 bar |
Khoom 316L (6mm lossis 12mm OD) |
- |
Tubing me me heev rau cladding |
|
Refinery qaub dej stripper overhead |
H2S + NH3 + H2O |
80-130C |
Txog li 10 bar |
Clad Alloy 825 (3mm) ntawm carbon steel |
Khoom Alloy 825 yog 55% kim dua |
- |
Peb Cov Ntaub Ntawv Qhov twg yuav tsum muaj cov yeeb nkab Nickel Alloy
Txoj cai 1Sab nraud corrosive ib puag ncig. Thaum sab nraud ntawm cov yeeb nkab raug corrosive media - faus cov yeeb nkab hauv cov av qaub nrog H2S, cov yeeb nkab hauv dej hauv cov kua qaub, lossis cov yeeb nkab hauv cov cua corrosive - cov yeeb nkab CRA yog qhov yuav tsum tau ua vim cov pa roj carbon steel rov qab yuav corrode los ntawm sab nraud. Clad yeeb nkab tsuas yog tiv thaiv sab hauv.
Txoj cai 2Txoj kab uas hla hauv qab NPS 2 (DN 50). Hauv qab 2-inch nominal txoj kab uas hla, lub cladding-rau-phab ntsa-thickness ratio yuav uneconomical. 1.5-nti SCH 40 yeeb nkab muaj phab ntsa tuab ntawm 3.68mm. Yog tias 3 hli yog cladding, tsawg dua 0.68mm yog carbon steel - lub nraub qaum yog nyias uas nws tsis tuaj yeem muab cov qauv tsim. Lub sijhawm no, cov yeeb nkab CRA khoom raug nqi tib yam lossis tsawg dua li cov yeeb nkab clad.
Txoj cai 3Kev pabcuam kub siab tshaj 450C. Tshaj 450C, qhov sib txawv ntawm thermal expansion coefficients ntawm npib tsib xee alloys (CTE ~ 14 x 10 K) thiab carbon hlau (CTE ~ 12 x 10 K) ua rau siab shear stress ntawm clad interface thaum thermal cycling. Tshaj li 450C, lub zog tawm ntawm qhov cuam tshuam kuj txo qis, ua rau muaj kev pheej hmoo ntawm clad disbonding nyob rau hauv kev sib koom ua ke siab + thermal stress. Khoom alloy yeeb nkab tshem tawm hom kev ua tsis tiav no.
Clad Yeeb Nkab Vuam
Vuam cov yeeb nkab txuas txuas yog ob- cov txheej txheem - cov pa roj carbon steel rov qab yog welded ua ntej nrog cov pa roj carbon steel muab tub lim, tom qab ntawd cov alloy cladding rov qab hla cov vuam nrog cov nickel alloy muab tub lim. Yog hais tias lub backing weld nkag mus rau hauv lub cladding, los yog yog hais tias lub cladding pass muaj ntau dilution, lub corrosion kuj ntawm weld cheeb tsam yog compromised. Cov txheej txheem vuam kom tsim nyog raws li ASME Tshooj IX thiab API 5LD yog qhov yuav tsum tau ua rau txhua qhov txheej txheem vuam txheej txheem txheej txheem (WPS).
Lub vuam sib txuas rau clad yeeb nkab yuav tsum tau ua tib zoo tsim groove geometry. Cov txheej txheem zawj rau clad yeeb nkab taub qab vuam yog ib qho kev sib xyaw ua ke: cov pa roj carbon steel rov qab sab muaj ib qho qauv -V bevel (60℃suav nrog lub kaum sab xis) welded los ntawm sab nraud nrog carbon steel electrode (xws li E7018 rau API 5L X65). Tom qab cov txheej txheem rov qab ua tiav thiab kuaj xyuas (VT thiab RT / UT), ib daim kab xev -rov qab yog npaj rau sab hauv ntawm cov yeeb nkab - txheej txheej cladding raug tshem tawm kwv yees li 5-8 hli ntawm txhua sab ntawm lub vuam sib txuas kom nthuav tawm cov pa roj carbon zoo.
Lub cladding restoration pass yog muab tso rau siv ib tug npib tsib xee alloy muab tub lim hlau (xws li, ERNiCrMo-3 rau Inconel 625 cladding) nrog tsawg kawg nkaus dilution (<5% Fe). After the cladding pass, the weld is inspected by VT and PT (penetrant testing), and PMI verifies that the cladding composition meets the alloy specification. A post-weld cladding pass ferrite check (<5% Fe) is required for sour service per ISO 15156.
Txoj cai 4Lub cladding weld pass yuav tsum tau muab tso rau nrog ib tug npib tsib xee alloy muab tub lim hlau txuam rau cladding qib - tsis txhob siv ib tug carbon steel muab tub lim rau ntawm clad sab. Txawm tias ib qho carbon steel weld dhau los ntawm kev sib cuag nrog cov kua dej corrosive tuaj yeem pib pitting corrosion hauv lub hlis ntawm kev ua haujlwm.
Txoj cai 5Tom qab-weld kho cua sov (PWHT) rau carbon steel thaub qab - feem ntau 600-650C rau 1 teev ib 25 hli ntawm phab ntsa thickness - yuav tsum tau ua ua ntej lub cladding rov kho dua yog hais tias lub cladding alloy yog raug rau rhiab heev ntawm PWHT kub (xws li, stainless hlau 16). Rau npib tsib xee alloy cladding (Inconel 625, Alloy 825), PWHT tuaj yeem ua tau tom qab cladding yog tias saib xyuas kom tsis txhob chromium carbide nag lossis daus.
Welding Cost Differential - Clad vs Khoom
|
Vuam Parameter |
Khoom Inconel 625 Pipe |
Clad Inconel 625 Yeeb Nkab |
Clad vs Khoom Muag Khoom Impact |
|
Filler Hlau Tus Nqi |
$ 80-120 / kg (ERNiCrMo-3 tag nrho sib koom) |
$ 30 / kg (E7018 rov qab) + $ 100 / kg (ERNiCrMo-3 clad pass) |
Clad: +10-15% (ob qhov muab tub lim, ob qhov hla) |
|
Yuav tsum muaj kev txawj ntse |
Nickel alloy ntawv pov thawj welder |
Carbon steel + nickel alloy certified welder (ob daim ntawv pov thawj) |
Clad: kev xav tau ntau dua |
|
NDE Nqi |
Txheem (RT + PT) |
RT + PT + PMI + Fe- kuaj xyuas daim ntawv hla tebchaws |
Clad: +20-30% NDE nqi |
|
Tag nrho Weld Joint Tus Nqi (12 "SCH 40) |
$400-500 / sib koom |
$500-650 / sib koom |
Clad: +20-30% ib leeg |
[Source] Vuam tus nqi kwv yees rau lub khw fabrication. Field welding nqi feem ntau yog 1.5-2x tus nqi khw. Clad yeeb nkab vuam yog kim dua rau ib qho kev sib koom ua ke, tab sis qhov no yog ib feem me me ntawm tag nrho cov nqi tsim khoom - cov khoom txuag (60%) deb tshaj qhov nqi ntawm vuam (20-30% ib leeg).
Cov lus nug nquag
Q: Ntau npaum li cas cov nyiaj clad yeeb nkab txuag piv rau cov khoom nickel alloy yeeb nkab?
A: Clad yeeb nkab txuag kwv yees li 40-60% ntawm cov khoom siv nqi piv rau cov khoom siv nickel alloy yeeb nkab. Rau ib tug raug 12-inch Inconel 625 yeeb nkab, clad yeeb nkab nqi kwv yees li $1,640/m vs $4,100/m rau khoom - txuag ntawm $2,460 ib 'meter'. Rau ib qhov project nrog 1,000 meters ntawm 12-nti yeeb nkab, qhov no yog $ 2.46 lab hauv cov khoom txuag. Tshaj li 30-xyoo lub neej, clad yeeb nkab xa tawm kwv yees li 47% qis dua tus nqi ntawm cov tswv cuab vim tias cov txheej txheem corrosion-resistant cladding muab cov kev pabcuam zoo ib yam rau cov yeeb nkab steel hlau thaum tshem tawm 80-90% ntawm cov khoom kim nickel alloy.
Q: Puas yog clad yeeb nkab muaj zog li cov khoom nickel alloy yeeb nkab?
A: Yog - thiab qee zaum, nws muaj zog dua. Lub zog ntawm cov yeeb nkab yog txiav txim siab los ntawm nws cov pa roj carbon steel rov qab (piv txwv li, API 5L X65 nrog 450 MPa yield zog), tsis yog los ntawm txheej nyias nyias. Inconel 625 muaj lub zog tawm los ntawm ~ 414 MPa nyob rau hauv cov xwm txheej annealed, thaum API 5L X65 muaj lub zog tawm los ntawm 450 MPa - cov yeeb nkab clad yog tiag tiag 8% muaj zog nyob rau hauv cov nqe lus ntawm kev cia siab. Cov txheej txheej cladding ua rau lub zog tsis txaus ntseeg vim tias nws tsuas yog 3 hli ntawm 9.53 hli tag nrho phab ntsa (12 "SCH 40). Qhov ntsuas siab yog xam raws li tag nrho cov phab ntsa tuab ntawm ASME B31.3 lossis DNV ST F 101 - txheej cladding suav tag nrho rau ntawm phab ntsa tuab rau kev tsim kho tshuab.
Q: Cov yeeb nkab clad puas tuaj yeem siv rau hauv kev pabcuam qaub (H2S- muaj ib puag ncig)?
A: Yog, muab cov cladding alloy yog tsim nyog rau qhov tshwj xeeb H2S ib nrab siab, kub, thiab chloride concentration ib NACE MR0175 / ISO 15156. Cov yeeb nkab clad yuav tsum ua tau raws li peb qhov kev xav tau ntxiv: (1) cladding alloy hardness yuav tsum yog 22 HRC (248 HV10) siab tshaj plaws rau wrought nickel alloys; (2) weld zone dilution yuav tsum yog<5% Fe in the top cladding pass to maintain the alloy chemistry in the corrosion-resistant range; (3) the carbon steel backing must also meet NACE hardness requirements for the backing material grade (primarily relevant for the weld HAZ). Clad Inconel 625 and Alloy 825 pipes are widely used in sour gas production facilities worldwide - they are NACE MR0175 / ISO 15156 listed materials when the cladding alloy meets the qualification requirements.
Q: Dab tsi yog qhov txawv ntawm clad yeeb nkab thiab weld overlay yeeb nkab?
A: Clad yeeb nkab (kub yob sib koom ua ke los yog explosive bonded) muaj cov txheej txheem cladding tsim nrog lub hauv paus hlau thaum lub sij hawm tsim phaj, ua ntej cov yeeb nkab tsim. Weld overlay yeeb nkab muaj txheej txheej cladding tso los ntawm vuam mus rau sab hauv ntawm ib qho uas twb tau ua lawm - carbon steel yeeb nkab. Qhov sib txawv tseem ceeb: (1) Clad yeeb nkab muaj xoom dilution ntawm cladding txheej (lub alloy chemistry yog zoo tib yam rau thawj phaj), thaum weld overlay muaj 5-10% dilution nyob rau hauv thawj pass (Fe los ntawm cov hlau thaub qab sib tov rau hauv cladding); (2) Clad yeeb nkab muaj qhov sib txawv cladding thickness los ntawm kev tsim, thaum weld overlay thickness txawv los ntawm 10-20% vim qhov xwm ntawm cov txheej txheem vuam; (3) Weld overlay yog hloov tau yooj yim dua - nws tuaj yeem siv rau fittings, me me diameters, thiab kho - tab sis feem ntau kim dua ib chav tsev ntau dua li kub dov bonded cladding. Rau qhov loj-inch ncaj yeeb nkab (NPS 16+), kub dov bonded clad yeeb nkab yog tus qauv; rau fittings thiab me me diameters, weld overlay yog tus qauv.
Q: Yuav ua li cas yog hais tias lub cladding txheej puas thaum lub sij hawm installation los yog kev pab cuam?
A: Ib txheej txheej cladding puas tuaj yeem kho tau los ntawm kev sib tsoo hauv qhov chaw - qhov no yog ib qho zoo ntawm clad yeeb nkab hla cov yeeb nkab, uas tsis tuaj yeem kho. Cov txheej txheem kho yog: zom tawm cov txheej puas cladding mus rau qhov tob uas nthuav tawm huv si, tsis muaj pa roj carbon steel; sau nrog sib txuam nickel alloy muab tub lim hlau los ntawm GTAW (TIG) vuam; grind flush nrog qhov sib txuas cladding nto; PT soj ntsuam; thiab PMI txheeb xyuas tias cov khoom siv kho tau zoo sib xws nrog cov txheej txheem cladding qub. Yog tias qhov kev puas tsuaj txuas ntxiv los ntawm cov pa roj carbon steel rov qab (piv txwv li, kev cuam tshuam sab nraud ua rau lub qhov txhab), qhov cuam tshuam yuav tsum raug txiav tawm thiab hloov nrog ib qho tshiab clad yeeb nkab pup piece welded rau hauv qhov chaw raws li tsim nyog clad yeeb nkab vuam txheej txheem.
Q: Ntev npaum li cas clad yeeb nkab nyob rau hauv kev pab cuam offshore?
A: Clad Inconel 625 yeeb nkab nyob rau hauv offshore tsim dej kev pab cuam muaj ib tug tsim lub neej ntawm 25-30 xyoo nrog xoom sab hauv corrosion pub - tib yam li khoom Inconel 625 yeeb nkab. Lub cladding txheej corrodes ntawm tus nqi tsawg dua 0.01 hli / xyoo nyob rau hauv ib txwm offshore ua kua (seawater + CO2 + trace H2S ntawm 4-90C). Nyob rau ntawm tus nqi no, 3 hli cladding txheej yuav siv sij hawm ntau tshaj 300 xyoo los corrode los ntawm - deb tshaj txhua qhov project tsim lub neej. Cov pa roj carbon steel sab nraud yog tiv thaiv los ntawm 3-txheej polypropylene (3LPP) los yog fusion-bonded epoxy (FBE) txheej, uas muaj 25-30 xyoo tsim lub neej rau faus lossis submerged kev pab cuam ib DNV RP F106. Yog tias cov txheej txheem sab nraud tsis ua haujlwm, cov pa roj carbon steel rov qab yuav corrode ntawm 0.1-0.3 hli / xyoo hauv dej hiav txwv, uas suav nrog cov nyiaj pub dawb sab nraud (feem ntau 3-6 hli). Nrog rau ob qho tib si sab hauv thiab sab nraud tiv thaiv corrosion, tsim kom zoo clad yeeb nkab ua tiav 25-30 xyoo lub neej.
