1. Purpose
The purpose & scope of this document is for Hydrostatic Test Procedure.
2. Scope
The procedure is suitable for hydrostatic test of seamless steel pipe with outer diameter between Φ114.3mm and Φ920mm.
3. Test Equipment
3.1 Test capacity of hydraulic testing machine: 0 to 70 Mpa for Φ114.3mm to Φ323.8mm, and 0 to 25MPa for Φ350mm to Φ920mm.
3.2 Pressure gauge: 0 to 100Mpa. Calibration frequency is once per 6 months.
3.3 Pressure transmitter: 0 to 100Mpa. Calibration frequency is once per year.
4. Job Responsibilities
4.1 Responsible for replacing the corresponding tooling according to the operation plan and operation card requirements.
4.2 Hydrostatic Test shall be conducted in accordance with the requirements of the contract to ensure the conformity of the pressure and the holding time of the Hydrostatic Test.
4.3 Responsible for the spot check of the straightness of the tube body after the pressure to ensure the straightness of the tube body.
4.4 Report any abnormal water pressure in time.
4.5 Responsible for the cleaning and maintenance of the post area.1
4.6 Create a record.
4.7 Safe production.
5. General rules for safe
5.1 Obey the traffic rules, pay attention to the traffic when walking, and avoid the way in advance.
5.2 Abide by the labor discipline, do not drink alcohol before work, do not go to other posts, do not sleep, do not do private work, do not read books, newspapers, publications unrelated to work, do not smoke in the factory, do not smoke in the non-smoking points in the plant, do not bring food into the operation room.
5.3 Wear standard protective products, take good care of protective products, use protective products correctly, and do not use safety hats as benches.
5.4 Take the safe passage and pedestrian bridge, do not put your hand in your pants bag to get on and off the bridge, do not walk between the loading vehicle and the material frame, and do not stay and pass under the lifting objects (including the driving cab and the hook and the lifting beam).
5.5 Pay attention to all kinds of safety signs and warnings, and do self-protection according to the requirements, do not enter the dangerous area or stay in the warehouse, do not cross the roller table.
5.6 Consciously and conscientiously study the post procedures, know the safety management requirements and hazard sources and control measures, carefully observe the equipment movement and transmission area before starting the equipment, and make safety confirmation.
5.7 Do not start the electric, gas and liquid switches and pipeline valves that are not within the scope of their own work, and do not start the electric, gas and liquid switches, buttons and valves that have been listed (maintenance plates, self-propelled project plates).
5.8 Use a pry bar to move the steel pipe, and do not directly block the rolling and transmitting steel pipe by hand.
5.9 Strictly implement the listing regulations of self-reliant projects, hang up the license plate and enter the equipment area.
5.10 Protect and correctly use electrical equipment, do not wear dirty gloves to switch electrical equipment, do not use physical goods to operate electrical equipment, do not disassemble or damage electrical equipment.
5.11 Take good care of safety protection facilities and firefighting equipment facilities, strictly manage dangerous chemicals, and accurately use firefighting equipment.
6. Hazard identification
6.1 In case of equipment failure, when the pressure is not completely discharged during shutdown, personnel may enter the test area, and other actions may injure personnel by mistake Post hazard prevention and control measures do not rush to the equipment working area to check the causes or overhaul. Wait until the pressure is completely discharged.
6.2 When the pipe material deflects on the bench or the walking beam turns over two pipes Post hazard prevention and control measures: stop the machine immediately; It is forbidden to move pipes by hand, and crowbar shall be used for operation; If one person cannot solve the problem, it shall be reported to the operation director in time to coordinate and solve it.
6.3 When replacing the mold, the mold will shake when lifted with a small crane, which may cause casualties Post hazard prevention and control measures: people should stay away from the lifted mold during operation. The operator shall fasten the safety belt when replacing the exhaust head. Improve safety awareness and prevent personal injury and equipment damage accidents.
6.4 Post hazard prevention and control measures: pay attention to the gap and hydraulic pipeline between girders to prevent slipping or tripping; During the hydrostatic test, the operator shall not walk in the moving area of the transmission device, and shall not walk directly on the maintenance bench outside the operation room.
6.5 environmental pollution: Post hazard prevention and control measures: the water-soluble emulsion used in the test shall be replaced regularly without omission on site.
7. Environmental protection
7.1 The hydrostatic test medium shall be clean, fresh, potable water. Water used for hydrostatic testing of carbon steel and low alloy steel shall have a chloride content less than 50 ppm.
7.2 The water-soluble emulsion used shall be replaced regularly without omission on site.
7.3 When environmental pollution is found, the pollution trace shall be removed in time.
7.4 Waste statements, masks, cleaning cloths, files, wooden crowbars, etc. Shall be thrown into the "industrial waste bucket".
7.5 Waste duster clothes and gloves shall be thrown into the "special bucket for waste duster clothes and gloves".
7.6 Empty containers of hazardous chemicals, waste batteries and fluorescent tubes shall be "old for new" and recycled to the “waste material recycling point”.
8. Production preparation
8.1 Confirm that no one stays around the hydraulic compressor.
8.2 The pipe material on the feeding platform of the hydraulic press is not skewed.
8.3 The pressure shall be set according to the parameters specified in the technical notice, and the pressure shall be adjusted normally without overpressure.
8.4 The operator must be in the operating room to prevent injury when the pipe bursts and bends.
If someone is found to enter the working area of the hydraulic press from the channel of the hydraulic press operation room, the production can be continued only after the emergency shutdown is ordered to leave.
8.5 Wear labor protection articles when changing specifications.
8.6 Note that the ground must be free of oil stain to prevent slipping and falling.
8.7 Pay attention to the neutral and hydraulic pipeline between girders to prevent slipping or tripping. When replacing the exhaust head and flushing head, do not tighten the screws too hard to prevent falling injury.
8.8 Check whether there are steel pipes in the machine and their status. Check that each lifting, movable sealing head, movable clamping and fixed clamping should be in the initial position. The tested steel pipes in the machine should be in the non-clamped state. Both ends of the steel pipes are outside the sealing head. There should be two steel pipes on the test tube rack of the rack for simultaneous intervention. Otherwise, perform the reset procedure.
8.9 Check whether the tools and technical notices on the post are complete to ensure the orderly production.
8.10 Check whether the tape-recording paper is enough for the shift. The operator shall indicate the shift, shift, production specification, steel grade, test pressure, operator's name, date and paper change time on the recording paper before, after and after the specification change of the shift.
8.11 The operator of this post shall learn the production plan and other relevant information from the team leader and the operation leader. At the same time, it shall refer to the specific process requirements in the contract technical notice.
8.12 The operator is responsible for the release of qualified oil and casing hydrostatic test, and the identification and isolation of nonconforming products.
8.13 The pipe material information shall be passed down from the previous process, and the first three of different furnace batch numbers shall be marked by the shift on duty.
8.14 Record the pipe material information truthfully on the post record book according to the raw material pipe bundle label.
8.15 Make on duty records of the hydrostatic test results and keep on duty records.
9. Preparation
9.1 Start the machine only after confirming that there is no one in the hydraulic working area.
9.2 The passage of hydraulic press shall be kept unblocked and free of oil stain.
9.3 Hydraulic press tools and molds shall be placed neatly.
9.4 Confirm whether the tools and molds are installed correctly during each shift handover.
9.5 Before starting the machine at work, check whether there is a maintenance board on the machine tool; It is strictly prohibited to start any button and switch on the equipment without delisting. After the equipment is overhauled, the equipment can only be started up after being confirmed and delisted by both parties of maintenance and operation.
9.6 Check whether there are tools and dies in the hydraulic press. If any, clean it and start it after cleaning.
9.7 Before starting up, wipe the oil stain and emulsion on the operating platform. If hydraulic oil leakage is found, report for repair; And dry it with return wire. When the circuit fails, do not use other tools to forcibly connect the button. After periodical repair and before startup, check whether the emergency stop button functions normally. If the function is lost, report for repair, and start the machine until the function returns to normal.
9.8 Press the emergency button immediately in case of abnormal conditions. The tools and instruments shall be placed neatly and shall not be placed on the aisle and net plate of the hydraulic press. Before adjusting the pressure valve of the hydraulic press, the sealing ring must be checked to prevent emulsion overflow.
10. Operation
10.1 Step mode - press the "cycle start" button once, and the hydraulic press performs one step action as follows: the pipe body is sent to the waiting inclined arm of the hydraulic press after passing the diameter, the working cycle starts, and the feeding mechanism sends a steel pipe to the water flushing station. Move the water flushing trolley to clean the steel pipe and align the steel pipe at the same time → the feeding mechanism sends the aligned steel pipe to the lifting beam bench of the hydraulic press, and sends another steel pipe to be inspected on the inclined arm bar to the water flushing station → send the second steel pipe to the lifting bench, and then the lifting bench falls down, Two steel pipes are in the 1# and 2# tester clamps → the sealing head trolley moves forward and sends the two steel pipes into the fixed end and the trolley sealing head → the oil cylinder rod of the movable clamp trolley extends → the three fixed clamps and the movable clamp hold the pipe body at the same time → start pre sealing and upward pressure → the fixed end starts to fill and exhaust water in the pipe body → the fixed end starts to apply high pressure, and the pipe body maintains pressure for not less than 5 seconds → the trolley end releases high pressure, And drain water → return of the trolley → loosening of the fixed bag collet → retraction of the oil cylinder rod of the movable bag collet trolley, pull out the steel pipe from the sealing head at the fixed end → loosening of the movable bag collet → lifting the lifting bench, send out the inspected steel pipe and complete a working cycle.
10.2 Automatic mode
Press the "cycle start" button, and the hydraulic press will automatically execute the test cycle.
10.3 After the cycle is started, when the sealing head moves forward, pay attention to whether both ends of the steel pipe have entered the appropriate depth of the sealing head. If not, first execute the reset procedure to find out the cause.
10.4 During the pouring process, pay attention to whether there is drainage sound at the two rows of pressure relief ports in the later stage of pouring (a large amount of water is discharged at this port in the later stage of pouring).
10.5 After startup, confirm that the oil pressure is not lower than 9.5Mpa and whether there is leakage at each joint; Oil temperature condition, whether the cooler works normally and whether the lead screw is in lubrication state.
Check whether the oil level in the oil tank drops significantly before going off duty. If so, find out the cause.
11. Single acting operation
The operation mode switch is placed on the single acting switch.
Ensure that the pipe of the loading platform is not skewed.
Monitor each beat action.
When the pressure test frame is in the lower position under the inching state, it is not allowed to clamp the steel pipe; If the filling head and exhaust head are not in place into the steel pipe, it is not allowed to pressurize the seal, which will knock the pre seal out of the mold; The pre seal does not enter the pressure maintaining state, and it is not allowed to fill water and pressurize the supercharger; If the steel pipe is not clamped, it is not allowed to pressurize the supercharger.
The single acting works as follows:
Flushing length measuring station
Lifting and jacking of flushing frame - forward movement of length measuring trolley - falling of flushing frame - backward movement of length measuring trolley - flushing rotation - flushing stop - rotation stop - lifting and jacking of flushing frame - forward movement of length measuring trolley - falling of flushing frame - backward movement of length measuring trolley
Pressure test station
Selection of exhaust trolley hole position - selection of pressurization ratio - selection of number of material racks - lifting of material racks (lifting in place) - material clamping - charging head inlet (charging head inlet in place) - exhaust head inlet (exhaust head inlet in place) - pre sealing inlet (pre sealing pressure maintaining lamp on) - water filling - exhaust stop - water filling stop - pressurization - exhaust inlet - pressure maintaining lamp on(the pressure holding time is up) - Supercharger pressure relief - Supercharger retraction - pre sealing pressure relief - pre sealing retraction - charging head retraction (retraction position) - exhaust head retraction (retraction position) - material clamping loosening - pressure test frame lowering (lowering in place).
Air water station
Air water rising (in place) - blowing - air water falling (in place)
Step conveyor
Step up (raise to position) - step forward (step to position) - step down (lower to position) - step backward (retreat to position)
12. Automatic operation
It must be confirmed that the conditions for automatic operation are met
Starting conditions: The water is clean and free of impurities the air water rack is lowered in place and the light is on; Step down in place light is on; The step in and step out in place light is on; The charging head back to position light is on; The exhaust head retraction light is on; The pressure test rack is lowered in place, and the light is on; The pre sealing retraction light is on; The booster retraction light is on; The extension light of trolley latch is on; Pressure test clamping and loosening; Flush trolley back in place; Press the step "up" button to stop automatically: press the step "down" button to pause in case of failure: press the step "forward" button to pause and resume after troubleshooting: press the step "back" button.
Automatic operation
Turn the switch to < auto >, press the stepping beam < rise >, and start automatically; Press stepping beam < descending >, and automatic emergency stop; Press the step beam < forward >, and one cycle will end automatically; Press stepping beam < back >, and start automatically.
It is necessary to closely monitor whether each action is reasonable, and shut down in time in case of abnormality.
During automatic pressure test, ensure the normal transportation of pipe materials and improve the processing speed.
Test pressure holding time according to applicable specification and there shall be no leakage.
Only when the hydrostatic test pressure reaches the set pressure, the pressure fluctuation is
≤ + 0.5MPa of the set pressure. Only when the voltage stabilization time meets the requirements can it be judged as qualified.
Produce the contract of corresponding specifications and steel grades according to the technical notice.
During shift handover, understand the production of the previous shift and what should be paid attention to during the operation of this shift.
Check whether the electrical signal of each station is intact.
13. Test pressure setting
Set and adjust the pressure according to applicable product standard.
The water pressure record shall indicate: date, shift, operator, specification, steel grade, pipe end form and set pressure.
The pressure gauge and sensor used are qualified products within the validity period.
14. Finishing of the test
When changing the specification, replace the tool head and align the pin groove during installation.
Note that the ground must be free of oil stain to prevent slipping and falling.
Pay attention to the neutral and hydraulic pipeline between girders.
Do not tighten the screws too hard.
Use small cars correctly and cooperate tacitly.
Wear gloves during operation.
Confirm that there is no one near the trolley to stay or repair.
Pay attention to the operation of the trolley.
Install lifting lugs on the coupling clamp plate.
Loosen the screw on the chuck slot with a wrench.
Lift the coupling clamp plate with a small crane and gently put it into the clamp seat groove.
Tighten the screws on the chuck slot with a wrench.
Adjustment of the stop block of the loading platform.
Select to adjust the supercharger ratio.
When replacing the mold, the removed mold shall be directly placed in the mold warehouse, not on the sidewalk in the hood.
The drift diameter gauge shall be replaced according to the contract specifications.
The water pressure is reset according to the pipe specification.
Ensure the normal pressure test of the equipment, and the quality requirements of the pipes of various specifications meet the relevant regulations. The replacement specifications must be clearly seen and matched with the processed pipes. They must be accurately in place during assembly. The removed molds must be wiped and maintained in time. The specifications of the coupling clamp plate, flushing head, exhaust head and sealing ring must be consistent with the outer diameter of the pipe. Confirm the size of the required drift rod according to the pipe specifications.