Реконструкции трубоэлектросварочного цеха с ТЭСА-1020 с установкой оборудования участков термообработки

Содержание.

 

Аннотация.

Введение.

1.КРАТКАЯ ХАРАКТЕРИСТИКА ОАО ВМЗ.

1.1. Географическое размещение  предприятия в экономико-географическом  районе         страны.

1.2. Профиль предприятия, мощности  и сортамент по товарной продукции.

1.3.Сырьевые и топливные источники завода.

2.ОБОСНОВАНИЕ ПРОЕКТА РЕКОНСТРУКЦИИ  ЦЕХА №4 ОАО ВМЗ.

3. ТРЕБОВАНИЯ КАЧЕСТВА ТРУБ.

4. ТЕХНИКА ПРОИЗВОДСТВА.

4.1 Выбор марки стали и сортамент  труб для нефтепровода Сахалин-1.

4.2. Дефекты сварных труб большого  диаметра.

4.3. Перечень основных технологических операций.

4.4. Описание технологического процесса  и техническая характеристика  основного оборудования для производства  электросварных труб диаметром  610 мм из стали 14ГБ-Ш.

    4.4.1.      Складирование  листовой стали.

    4.4.2.       Задача металла в производство.

4.4.3.      Правка листа.

4.4.4.      Контроль размеров  листа.

4.4.5.      Строжка листа.

4.4.6.      Подгибка кромок.

7.      Пресс предварительной формовки труб.
8.      Пресс окончательной формовки труб.
9.      Клеймение трубных заготовок.
10. Сварочные операции.
11. Ремонт и контроль сварного шва.
12. Термическая обработка труб.
13. Калибровка, испытание, отделка и приемка труб.

5. СПЕЦИАЛЬНАЯ ЧАСТЬ.

    5.1. Описание  оборудования подготовки исходных  заготовок для формовки и сварки (листоправильная машина)

    5.1.1. Расчет усилий правки  листа толщиной 20 мм на девятивалковой  листоправильной машине.

    5.1.2. Расчет мощности  агрегата.

    5.1.3. Расчет рабочего  ролика на прочность и жесткость.

    5.2. Устройство и принцип  работы пресса предварительной формовки.

    5.2.1. Методика и расчет  калибровки рабочего инструмента.

    5.2.2. Методика и расчет  станины пресса предварительной  формовки на прочность.

    5.2.3. Методика и расчет  энергосиловых параметров пресса  предварительной формовки.

   5.3. Описание и принцип работы оборудования термической обработки.

6. ЭЛЕКТРООБОРУДОВАНИЕ И ЭЛЕКТРОСНАБЖЕНИЕ.

    6.1. Расчет мощности и  выбор типа двигателя привода  подводящего рольганга пресса  П – 9046.

    6.2. Разработка  схемы питания сварочного узла.

7. ОРГАНИЗАЦИЯ ПРОИЗВОДСТВА.

     7.1. Номенклатура  и сортамент труб.

     7.2. Годовой  объем производства труб.

           Баланс времени работы оборудования.

           Годовой объем производства в  физических единицах.

           Годовой объем производства в условных единицах.

           Годовой объем производства в  денежном выражении.

    7.3 Организация  труда рабочих.

          Режим работы цеха и график  выходов.

         Штаты рабочих.

          Заработная плата рабочих.

    7.4 Форма хозяйствования.

    7.5 Управление  качеством продукции.

    7.6. Система  обеспечения требуемого качества  сварных труб на базе ЭВМ.

8. БЕЗОПАСНОСТЬ ЖИЗНЕДЕЯТЕЛЬНОСТИ.

    8.1 Объемно-планировочные  решения зданий и сооружений  цеха.

    8.2 Технические  решения по производственной санитарии.

          Отопление и вентиляция.

          Производственное освещение.

          Естественное освещение.

          Искусственное освещение.

          Производственная санитария.

    8.3 Анализ потенциально  опасных и вредных производственных факторов при выполнении основных операций.

    8.4 Технические  меры защиты персонала от влияния  вредных и опасных производственных  факторов.

    8.5 Безопасность  жизнедеятельности в чрезвычайных  ситуациях.

    8.6 Инженерная  разработка мер защиты от повышенного уровня шума.

    8.7. Техника  безопасности участка ПШК. 

9. ОХРАНА ОКРУЖАЮЩЕЙ  СРЕДЫ.

    9.1 Проектные  решения по охране окружающей  среды и рациональному использованию  природных ресурсов.

          Расчет объемов отходящих газов  и сточных вод.

         Способы и средства очистки и нейтрализации отходящих газов и сточных вод.

10. ЭКОНОМИКА ПРОИЗВОДСТВА.

Заключение.

Список используемой литературы.

 

 

 

 

 

 

 

Аннотация.

 

 

    В данном дипломном проекте рассмотрен вопрос о реконструкции трубоэлектросварочного цеха с ТЭСА-1020 с установкой оборудования участков термообработки и нанесения внутреннего полиэтиленового покрытия в условиях ОАО ВМЗ ТЭСЦ-4 с целью получения труб для работы в агрессивных средах. Для достижения повышения качества происходит внедрение новой коррозионностойкой стали, также с внедрением нового сортамента расширяется рынок сбыта продукции.

 

    В разделе  обоснования проекта реконструкции  приведена краткая характеристика  ОАО ВМЗ, описана базовая схема производства электросварных прямошевных труб большого диаметра с приведением технических характеристик основного оборудования, профиль и сортамент выпускаемой продукции, описание и обоснование выбора марки стали, а также мероприятия по установки нового оборудования.

 

         В специальной  части проекта представлены: описание оборудования подготовки исходных заготовок для формовки и сварки (листоправильной машины), расчет усилий правки листа толщиной 20 мм на девятивалковой листоправильной машине, расчет мощности агрегата, расчет рабочего ролика на жесткость и прочность по методу Верещагина, устройство и принцип работы пресса предварительной формовки, методика и расчет калибровки рабочего инструмента, методика и расчет станины пресса предварительной формовки на прочность, методика и расчет энергосиловых параметров пресса, описание и принцип работы оборудования участка термической обработки труб.

 

В разделе «электрооборудование и  электроснабжение» приведены: расчет мощности и выбор типа двигателя  привода подводящего рольганга  пресса П 9046, выбор системы управления для регулировки скорости двигателя, разработка схемы питания сварочного узла.

 

В разделе по безопасности жизнедеятельности производятся расчеты  по внедрению мероприятий, снижающих  влияние вредных факторов производства на организм человека. В разделе экономика производства производятся расчеты переменных статей затрат в результате реконструкции цеха, а также расчет прибыли и срока окупаемости проекта.

 

 

 

 

 

 

 

 

 

Введение.

 

Одной из ведущих отраслей черной металлургии является трубная промышленность, развитие которой тесно связано с развитием важнейших отраслей народного хозяйства.

Анализ рынка показывает, что  доля бесшовных труб в общем, объеме мирового производства снижается с 40-45 % до 30-35 % и, следовательно, доля сварных  труб непрерывно растет, что объясняется технико-экономическими преимуществами данного метода производства. Однако на Российском рынке существует потребность в трубах с антикоррозионными свойствами и термической обработкой для работы в агрессивных средах.

Следовательно, главной задачей ОАО «ВМЗ» является повышение ее конкурентоспособности.

Вопрос о повышении  надежности эксплуатации трубопроводного  транспорта является для нефтяников и газовиков Западной Сибири не новым, но до сих пор очень злободневным и больным.  
Долговечность нефтегазопроводных труб в своей основной массе низка и составляет 18-24 месяца. Трубы выходят из строя либо из-за язвенной коррозии, либо из-за канавочной коррозии, характеризующейся мгновенным раскрытием трубы на большие расстояния и приводящей к наиболее значительным экологическим последствиям. Причины такого положения разные. Одной из них является изменение состава сред, перекачиваемых по трубопроводам. Эти среды сегодня обладают повышенной агрессивной способностью.  
Причем, состав сред нестабилен и не контролируемо меняется во времени, что затрудняет точное определение их химического состава. А именно химический состав, физические свойства, количество механических примесей, а также гидродинамические условия в первую очередь определяют те коррозионные повреждения, которые развиваются в трубопроводах. Тем не менее, исследования показали, что транспортируемые среды имеют высокую минерализацию, содержат значительную концентрацию ионов кальция, растворенных газов СО2 и Н2S природного или бактериального происхождения. Наличие большого количества сульфатвосстанавливающих бактерий интенсифицирует коррозионные процессы, и в первую очередь, язвенную коррозию.

Требования к качеству продукции со стороны потребителя  непрерывно растут. Следовательно, главной задачей трубных предприятий и металлургических комбинатов, для обеспечения устойчивых позиций на рынке сбыта отечественной трубной продукции, является повышение ее конкурентоспособности. Среди основных направлений развития производства сварных труб можно отметить следующие: освоение производства особо чистого металла; создание новых сталей и освоение производства труб в "северном" и сероводородостойком исполнениях; создание мощностей  по  выпуску труб  диаметром  610  мм  для  магистральных газонефтепроводов; строительство отделений покрытий                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     труб, термоотделений, участков неразрушающего контроля качества труб; модернизация оборудования отделки труб; сертификация оборудования по международным стандартам; освоение новых видов резьб; расширение сортамента; снижение издержек производства, а так же снижение импортируемых труб на территорию России.

 

Динамика производства труб нефтяного сортамента в России /тыс.т/.

 

Таблица№1

Вид труб	1991	1998	2000	2002	2003
Обсадные бесшовные	769,6	183,8	416,5	464,0	498
Обсадные электросварные	260,2	62,8	161,7	117,0	152,0
Насосно-компрессорные	219,4	149,0	274,0	232,0	261,0
Бурильные	102,9	10,3	30,5	23,6	25,2
Сварные Dт>480 мм	2032,2	327,6	617,8	735,0	1174,0
Нефтепроводные бесшовные	592,8	446,0	611,0	637,0	715,0
Нефтепроводные электросварные Dт<480 мм	1049,0	182,5	292,2	464,0	661,0

 

 

Задача разработки технологии производства нефтегазопроводных труб повышенной долговечности  в коррозионно-активных высоко минерализованных средах, содержащих CO2 и H2S природного бактериального происхождения имеет очень важное значение, тем более, что в последние годы отмечен рост агрессивной способности промысловых средств, связанных с их бактериальной заражённостью.

При не правильном выборе трубных  сталей для эксплуатации в сероводородсодержащих средах, разрушение стальных конструкций может происходить в очень короткий промежуток времени.

Мировой и отечественный  опыт производства труб нефтяного сортамента свидетельствует о необходимости  их термического улучшения кроме труб низкой категории прочности.

Для снижения уровня остаточных сварочных напряжений, а также  для повышения пластичности и  стабильности структуры металла  шва и околошовной зоны применяется  термическая обработка - закалка  с последующим отпуском.

 

 

 

 

 

 

 

1. Краткая характеристика ОАО ВМЗ.