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Wear-resistant pipe elbow for boiler powder feed
The wear resistance of the pulverized coal conveying pipeline of the boiler of the thermal power plant must be designed for leakproof, anti-corrosion, rain-proof, anti-freeze and other factors. The key points are anti-wear and anti-corrosion. It has always been the key part of power plant maintenance. The comprehensive performance of the pipeline system, especially the wear resistance, is directly related to the operating cost and the economic benefit of the entire power plant, and is a key issue that must be considered in the construction and maintenance of new power plants.
Please send your inquiry by sales@sunnysteel.com
Description
The wear resistance of the pulverized coal conveying pipeline of the boiler of the thermal power plant must be designed for leakproof, anti-corrosion, rain-proof, anti-freeze and other factors. The key points are anti-wear and anti-corrosion. It has always been the key part of power plant maintenance. The comprehensive performance of the pipeline system, especially the wear resistance, is directly related to the operating cost and the economic benefit of the entire power plant, and is a key issue that must be considered in the construction and maintenance of new power plants.
- Bimetal wear-resistant composite elbow material grade: KMTBCr26
- Working temperature: 150℃
- Working pressure: 0.4Mpa
- Working medium: pulverized coal, air two-phase flow
- Maximum flow velocity of gas-solid two-phase flow: 28m/s
Technical requirements
- The overall performance of the bimetal wear-resistant composite elbow must meet the following requirements; the flexural strength must be greater than 610MN/M2, the tensile strength must be greater than 415MN/M2, the impact toughness must be greater than 15J/CM2, and the hardness of the wear-resistant layer must be greater than 50.
- The inner and outer surfaces of the bimetal wear-resistant composite elbow should be smooth and clean, without burrs, burrs, cracks, porosity, pores or air bubbles, no cracks are allowed, the pipe has good compactness, and the flow direction of the medium should be marked in obvious parts. The inner lining of each elbow must be formed at one time, and it is strictly prohibited to weld the folded line after it is produced in sections.
- The dimensional deviation of pipe fittings shall comply with the provisions of GB3092, GB8162 and GB8163, and shall comply with the requirements of product drawings and order agreements. Thickness deviation of inner lining ≤+1.2mm. The weight of each elbow cannot exceed the design weight. And mark the weight in the obvious place.
- The steel pipe used in the composite pipe adopts seamless steel pipe, and its performance shall comply with the relevant agreement.
- The bimetal wear-resistant composite elbow is installed by direct welding, with good welding performance, and the outer welded pipe is made of 16MnR# steel.
- Each inlet and outlet of the bimetal wear-resistant composite elbow has a straight section of a certain length. The straight section (L1/L2) should be consistent with the material and wall thickness of the elbow body, and a 100mm transition section is added outside the straight section to be welded to the powder feeding pipeline. There should be no special requirements for on-site welding of products to ensure good welding performance when products are welded at room temperature on site.
- The life of the bimetal wear-resistant composite elbow is not less than 10 years (8000 hours of operation per year).
- During the service life of the bimetal wear-resistant composite elbow and under the abnormal conditions of spontaneous combustion of the powder feeding pipeline, the product should ensure that the lining wear-resistant layer does not crack or peel off; when the pipeline is partially blocked, it should ensure that it can knock , cutting, it should be convenient for unloading, installation and maintenance.
- The sealing performance test of the bimetal wear-resistant composite elbow shall be carried out before leaving the factory, and the test shall be carried out according to the relevant standards. When the quality and performance of the products provided by the supplier do not meet the specified standards, they shall not leave the factory.
- The product should meet the “DL/T 680-1999 Technical Conditions Standard for Wear-Resistant Pipelines”.
Technical requirements parameter table
Special Corundum ceramics made of rare metal oxides as solvents and sintered at high temperature by 1730 ℃ through bonding, welding, mosaic, riveting and socket technology, a variety of wear-resistant ceramic pieces, block brick materials in the pipe wear surface, so as to form a surface with excellent wear resistance, and the matrix is still using the composite pipe of ordinary metal.
Main technical parameters of bimetal composite wear-resistant elbow:
- Thickness of bimetal wear-resistant composite elbow: inner arc: 22 outer arc: 32
- Eccentricity: 5mm
- Thickness deviation of inner lining: ≤+1.2mm
- Design pressure: 1.6Mpa, hydraulic test pressure: 5.6-19MPa:
- Design temperature: 350℃
Mechanical properties of bimetal composite wear-resistant elbow
| Flexural strength | tensile strength | Elongation | rate of reduction in area | Impact toughness (requires greater than 50) | The hardness of the inner wall |
|---|---|---|---|---|---|
| Mpa | Mpa | % | % | J/cm2 | HRC |
| ≥610 | ≥145 | 4.8 | 5.1 | ≥15 | 50 |
Chemical composition of bimetal composite wear-resistant elbow
| Grade | C | Cr | Ni | Mn | Mo | Cu | P | Re |
|---|---|---|---|---|---|---|---|---|
| KmTBCr26 | 2.5-3.2 | 26-28 | 0.8-1.2 | 1.0-2.0 | 2.0-3.0 | 0.5-0.8 | ≤0.03 | ≤0.10 |
Advantages
- The hardness of a good wear resistance superhard wear alloy is greater than 56 (HRC), which has good wear resistance and thermal stability.
- Excellent impact resistance, metal binding and thermal shock resistance KMTBCr28 bimetal composite wear-resistant elbow. The joint surface of the two metals is completely metallurgical, safe and reliable. The coefficient of thermal expansion is equal to that of expansion, shrinkage and crack. The outer wall of the elbow is made of steel tube and the inner lining is made of super-hard wear-resistant alloy.
- Good resistance to heat and corrosion. The matrix of super hard alloy material has strong resistance to heat and corrosion. Under the action of wet state, corrosion medium and particle scour, it is more suitable to use the super hard wear-resistant alloy. Under the condition of dry state in which abrasive wear is the main failure mode, a kind of super hardness wear-resistant alloy material which can be obtained by heat treatment is selected.
- The bimetal wear-resistant pipe with low composite cost and good quality is manufactured by the internationally advanced epc casting process with high yield, good compactness, uniform thickness and stable quality.
- The bimetal wear-resistant pipe can be connected by flange, quick joint and direct welding.In addition, due to the high resistance and beating performance of the composite pipe, when partial blockage occurs in the pipe system maintenance, it can be knocked or hammered at will, and can be cut, unloaded, welded and installed at will.
Features of centrifugal casting for bimetal wear resistant pipe production process
(1) centrifugal casting technology enables the molten steel to solidify and form under the gravity condition, which is dozens of times higher than conventional casting. It solves the problem of loose inside the casting tube billet, has high metal density, and has good discharge and exhaust effect.
(2) the size accuracy of centrifugal cast pipe is high and the wall thickness is even, which provides a favorable guarantee for the size accuracy of subsequent processed products.
(3) centrifugal casting process has high flexibility for the production of steel pipes of small batch, multiple varieties and specifications, high quality and high value-added steel.
What is CRA Cladding?
CRA basically means corrosion resistant alloy.
It’s a material that is built for cladding because its main purpose is to enhance a pipe’s resistance to corrosion.
What is Elbow Cladding?
Pipe elbow cladding is the process of applying a cladding material to elbow pipes.
It’s done on a more careful manner than the usual.
This is because elbow pipes can change throughout the entirety of the process.
Where Can Pipe Cladding be Applied to?
Particularly, the process of pipe cladding benefits the oil and gas industry the most.
However, it can also be used by other industries such as:
- Mining Industry
- Aquamarine Industry
- Manufacturing Industry
- Fabrication Industry
- And Other Industries That Have High Temperature and High Impact
What is Pipe Lining?
Pipe lining is the process of prolonging the lifespan of pipes.
It can also be used, however, to restore a pipe from natural damages such as:
- Corrosion
- Abrasion
- Erosion
- Leaks
- And the Like
Lined Pipes vs. Clad Pipes
Pipe lining and pipe cladding are processes that are far from each other.
Lining is the process of mechanically bonding materials to pipes for restoration. Some of the uses of pipe lining include:
- To protect the pipes from damages
- To prolong lifespan of pipes
- To restore the original dimensions of pipes
Cladding is the procedure of metallurgical bonding of clad materials to pipes. Some of the major uses of pipe cladding include:
- To create abrasion resistant pipes
- To prevent corrosion and wear
- To be able to resist high temperatures and high stress and impact situations
Who Can Help You With Pipe Cladding?
There are a lot of companies that utilize state-of-the-art pipe cladding equipment.
We have cutting-edge technology that can complete projects ahead of time.
Some of the most notable features that our pipe cladding equipment have include:
- Simplicity of use and operations
- High automation
- Effective water cooling effect
- Multi welding torch swing integration
- All are of a high quality and original – best to produce the components your business needs!
Application
Because oil and natural gas contains a large amount of corrosive media such as hydrogen sulfide, carbon dioxide and chloride ions, especially the content of corrosive components in the oil and gas medium before pipeline purification in the seabed oil and gas field is high, and some even require heat transfer, and internal corrosion problems are very prominent. The use of stainless steel or corrosion-resistant alloys in large quantities is not economical. Double metal clad pipes are a good choice.
The bimetal clad pipe structure uses a corrosion-resistant alloy tube (stainless steel or corrosion-resistant alloy) as the inner liner (wall thickness 0.5-3mm) to contact the corrosive medium and carbon steel or low-alloy steel as the outer base pipe to withstand the pressure. low. Generally, the double-metal clad pipe contains 316L austenite stainless steel as the inner liner in the case of containing CO2 medium, and 2205 and 2505 duplex stainless steel can be used as the medium containing CO2 + small amount of chloride, when H2S+CO2 is contained. + Chloride, the inner liner should be 028, G3, INCONEL625 and Inconel825 nickel-base or iron-nickel alloy, in order to ensure the corrosion resistance of the pipeline, but also can choose the titanium alloy and other materials with excellent corrosion resistance as lining. The outer layer material is usually API 5L X42, X50, X60, X70, ASTM-A106GB and A335-P22 and other materials, so as to ensure the strength of the pipeline.
Casing pipe for oil and gas transportation
Choosing stainless steel such as Incoloy625 and Incoloy825 for inner tubes to ensure the corrosion resistance of the pipe. The outer pipe are usually X42, X50, X60, X70, A335-P22 and other materials to ensure the strength of the pipeline. The American Petroleum Association (API) has developed the standard for composite pipes for pipelines, with the serial number API 5LD:Cr-Mo steel, super 13Cr, G3, C028 and other oil well tubes and the nickel-base alloy cladding tubes such as 825, 028.
Waste incinerator
Cladding steel tube for waste incinerator.The outer tube can be made of Sanicro65 alloy, and the inner pipe may be carbon steel or chromium, molybdenum steel with resistance to stress corrosion cracking.Europe and the United States have used 2 million meter composite steel pipe since the first installation cladding pipe incinerator superheater and water wall tubes in the 1971.
Heat exchanger
Cladding steel pipe used for heat exchanger should also have good thermal conductivity and a certain strength and corrosion resistance. We manufactured cladding pipe with high alloy, nickel chromium alloy 800 as the inner tube and the low-alloy steel ASTM A213 Ti2 as the outer pipe.
Used for wear-resistant steel
A Japan company have made cladding steel pipe with SUS316L corrosion resistant steel for outer pipe, Stellite No12 alloy for inner pipe,after 4 years is still new. They has also been well applied in the pneumatic conveying pipe of other micro powder particles, and the demand is increasing.
Marine environment
- Inner pipe: Nickel, Titanium stainless steel or Copper alloy.
- Outer pipe: Carbon steel or low alloy corrosion resistant steel.
Cladding pipe used for marine environment made by Japan’s Kawasaki is widely used as marine heat exchanger tube and seawater desalination of seawater intake pipe.
Civil areas
Cold, hot water pipes, direct drinking water pipes, heating, solar energy, ground source heat pump; civil construction water supply pipes, water distribution trunk; air conditioning circulation pipe, fine decoration high-grade commercial housing water pipes.
Industry
Oil and gas pipeline, oil and gas wells casing, sewage return pipe; chemical heat exchanger tube bundle; power desalination water, desulfurization pipeline and other metallurgy, desalination, medicine and chemical industry, sewage treatment, new energy, food processing and other industries.
Technology
High chromium cast iron is the third generation of white cast iron developed from ordinary white cast iron and hard nickel cast iron.
Process requirement
- Wear-resistant elbow is made of bimetal wear-resistant composite.
- The general manufacturing method is made by the combination of the vacuum absorption casting process of the vanishing mould, and the manufacturing process of the commodity shall be indicated in other processes.
- Adopt composite alloy steel wear-resistant layer, each elbow shall be eccentric compound, and the outside of the elbow shall be thickened according to the working condition to achieve the life design of the outside and inside. In order to reduce the resistance of coal powder transportation, the elbow should be smooth and excessive, and the shrimp waist welding method should not be adopted, so as to ensure that the inner diameter of the throughflow at all parts is 510mm, and no convex platform can be found.
- Wear-resistant lining is made of high chromium alloy (not lower than KMTBCr28), with service life over 2 years and annual wear less than 5mm.The outer wear resistant lining thickness is 28mm, the inner wear resistant lining thickness is 22mm, and the hardness of HRC is greater than 55. Outer pipe of lining part 558*10, connecting pipe 508*10, outer ring 558*22, material is 10 steel. Seamless pipes (or welded pipes) can be used, and their performance should meet the requirements of GB2087, GB8163.
The bimetal wear-resistant tube inner wall KMTBCr28 has stable quality and good comprehensive performance. Adding a certain amount of rare earth elements can improve the alloy quality of steel, refine the grain and form a protective film on the surface.A certain amount of Mo was added to make the alloy have certain antioxidant effect and increase service life at high temperature.A certain amount of boron carbide can be added to control the hardness in the range of HRC45 ~ 65, and solve the contradiction between the hardness and weldability of wear-resistant steel.
Quality requirements
The inner and outer surface of bimetal wear-resistant elbow should be smooth and clean, without burrs, burrs, cracks, loose, pores or bubbles;The inner wall of the wear-resisting elbow should be smooth without accumulated powder.The bend should have good thermal shock resistance. When there is a sharp change in temperature or welding connection, the inner layer of the wear-resistant pipe will not break and spalling due to the expansion or contraction of the inner layer.The dimensional deviation shall meet the requirements of product drawings and order, agreement, and shall meet the provisions of GB3092, GB8162 and GB8163 without special requirements.The thickness deviation of lining is + / – 1.2mm.
Grade and chemical composition of high chromium cast iron (%)
| Grade | C | Mn | Si | Ni | Cr | Mo | Cu | P | S |
|---|---|---|---|---|---|---|---|---|---|
| KmTBCr12 | 2.0-3.3 | ≤2.0 | ≤1.5 | ≤2.5 | 11.0-14.0 | ≤3.0 | ≤1.2 | ≤0.10 | ≤0.06 |
| KmTBCr15Mo | 2.0-3.3 | ≤2.0 | ≤1.2 | ≤2.5 | 11.0-18.0 | ≤3.0 | ≤1.2 | ≤0.10 | ≤0.06 |
| KmTBCr20Mo | 2.0-3.3 | ≤2.0 | ≤1.2 | ≤2.5 | 18.0-23.0 | ≤3.0 | ≤1.2 | ≤0.10 | ≤0.06 |
| KmTBCr26 | 2.0-3.3 | ≤2.0 | ≤1.2 | ≤2.5 | 23.0-30.0 | ≤3.0 | ≤1.2 | ≤0.10 | ≤0.06 |
Inquiry
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FAQ
Q: How long is your delivery time?
A: The delivery time of customized products is generally 25 35 days, and non customized products are generally shipped within 24 hours after payment.
Q: Do you provide samples? Is it free?
A: If the value of the sample is low, we will provide it for free, but the freight needs to be paid by the customer. But for some high value samples, we need to charge a fee.
Q: What are your payment terms?
A: T/T 30% as the deposit,The balance payment is paid in full before shipment
Q: What is the packaging and transportation form?
A: Non steaming wooden box and iron frame packaging. Special packaging is available according to customer needs. The transportation is mainly by sea.
Q: What is your minimum order quantity?
A: There is no minimum order quantity requirement. Customized products are tailor made according to the drawings provided by the customer.
