Global Excellent One Stop Pipeline Solution
characteristic
Reliable connection
The flange of the tube sheet is tightly connected to the two flanges by bolts, and a gasket is used at the sealing surface to achieve sealing. This connection method can withstand external forces such as pressure, temperature changes, and pipeline vibration inside the pipeline under normal installation and use conditions, ensuring the sealing and stability of the pipeline system and reducing the risk of leakage.
Easy to install and disassemble
Compared to some welding connection methods, pipe plate flanges do not require complex welding equipment and techniques during installation. Simply place the gasket between the sealing surfaces and tighten the bolts to complete the connection. When the pipeline system needs maintenance or replacement of components, flange connections can also be easily disassembled, improving maintenance efficiency.
Strong adaptability
For pipes of different materials (such as carbon steel, stainless steel, alloy steel, etc.), suitable material tube sheet flanges can be found to match them. And under different working conditions, including temperature (from low to high temperature, such as -20 ℃ -500 ℃ or even higher), pressure (from low to high pressure), medium (such as gas, liquid, corrosive medium, etc.), suitable flange parameters and sealing materials can be selected to meet the usage requirements.
Adjustable sealing performance
By selecting different types of sealing gaskets (such as rubber gaskets, asbestos gaskets, PTFE gaskets, etc.) and adjusting the tightening torque of bolts, the sealing performance of the pipe plate flange can be adjusted within a certain range. This allows for optimizing the sealing effect according to actual needs in different application scenarios.
Forging process
Free forging: After heating the raw materials to the appropriate forging temperature, they are placed on the lower anvil of forging equipment such as air hammers and friction presses. Through multiple strikes from the upper anvil, the metal billet is gradually deformed to obtain the desired shape and size. The free forging process has high flexibility and can forge pipe flange blanks with relatively simple shapes, but the production efficiency is relatively low. It is suitable for single piece, small batch production or occasions with high requirements for flange performance.
Forging: Using a mold to deform the blank under pressure in the mold cavity, thereby obtaining a flange blank that matches the shape of the mold cavity. The forging process has high production efficiency, high product size accuracy, good surface quality, and relatively uniform mechanical properties. But the mold cost is relatively high, suitable for the manufacturing of large quantities of pipe flanges.
Mechanical processing technology
Turning machining: It is one of the most commonly used machining processes in the manufacturing of pipe flanges, used for machining the outer circle, inner hole, sealing surface, bolt hole and other parts of flanges. By utilizing the rotational motion of the lathe and the linear feed motion of the cutting tool, excess metal material is removed to achieve the required dimensions and precision in the design. Turning machining can ensure the dimensional accuracy and surface roughness of the flange, improve the sealing performance and connection reliability of the flange.
Milling machining: mainly used for machining flat surfaces, grooves, and other parts of flanges. By utilizing the rotational motion of milling cutters and the feed motion of workpieces, various shapes of planes and grooves can be machined on the surface of flanges. Milling processing can improve the flatness and surface quality of flanges, ensure good contact between flanges and gaskets, and enhance the sealing effect.
Drilling processing: used for machining bolt holes on pipe flanges. Drill the required bolt holes on the flange through the rotation and feed motion of the drill bit on the drilling machine or machining center. During drilling, it is necessary to ensure the positional and dimensional accuracy of bolt holes to ensure the correct installation of bolts and the connection strength of flanges.
.
welding technology
Manual arc welding: a method of welding using manually operated welding rods, with simple equipment and flexible operation, suitable for welding joints of various positions and shapes. But the welding efficiency is low and requires high operational skills from welders. In the manufacturing of pipe flange, it is commonly used for welding operations in small batches, irregular shapes, or on-site installation.
Submerged arc welding: a method of welding by burying the arc under a granular flux layer, with high welding current, deep penetration, high welding efficiency, good and stable weld quality. Suitable for large-scale and thick plate pipe flange welding production, but the equipment cost is high and the assembly accuracy requirements for welded joints are also high.
Gas shielded welding: a welding method that uses gas as a protective medium to isolate the arc, molten pool, and air, such as argon arc welding, carbon dioxide gas shielded welding, etc. Gas shielded welding has the advantages of fast welding speed, high weld quality, and small deformation. It is commonly used for bottom welding of pipe flanges, thin plate welding, and occasions with high requirements for welding quality.
Heat treatment process
Normalization: A heat treatment process in which the flange of the tube plate is heated above the critical temperature, held for an appropriate period of time, and then cooled in air. Normalization can refine grain size, improve the strength and toughness of flanges, enhance cutting performance, and provide a good organizational and performance foundation for subsequent processing and use.
Quenching+Tempering: Quenching is a heat treatment process that heats the flange above the critical temperature, maintains insulation, and rapidly cools it, which can obtain martensitic structure and improve the hardness and strength of the flange. But the flange after quenching is brittle and needs to be tempered in a timely manner. Tempering is a process of heating the quenched flange to a temperature range below the critical temperature, holding it for heat, and then cooling it. It can eliminate quenching stress, improve the toughness and plasticity of the flange, and achieve good comprehensive mechanical properties.
Stress relief annealing: During the manufacturing process of tube sheet flanges, residual stresses may occur due to welding, cold working, and other reasons, which may lead to defects such as flange deformation and cracking. Stress relief annealing can heat the flange to a certain temperature, keep it warm, and then slowly cool it to eliminate residual stress, stabilize the size and shape of the flange, and improve its reliability in use.
