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Codeofchina.com is in charge of this English translation. In case of any doubt about the English translation, the Chinese original shall be considered authoritative. This document is developed in accordance with the rules given in GB/T 1.1-2020 Directives for standardization - Part 1: Rules for the structure and drafting of standardizing documents. This document is Part 5 of GB/T 16507 Water-tube boilers. The following parts of GB/T 16507 have been published: ——Part 1: General requirement; ——Part 2: Materials; ——Part 3: Structure design; ——Part 4: Strength calculation of pressure parts; ——Part 5: Fabrication; ——Part 6: Inspection, testing and acceptance; ——Part 7: Safety appurtenances and instruments; ——Part 8: Installation and operation. This document replaces GB/T 16507.5-2013 Water-tube boilers - Part 5: Fabrication. In addition to structural adjustment and editorial changes, the following main technical changes have been made with respect to GB/T 16507.5-2013: ——The definitions of "cold forming" and "hot forming" are changed (see 3.1~3.2; 3.1~3.2 of Edition 2013); ——The definition of “nominal thickness of weld” is added (see 3.4); ——The qualification requirements of boiler fabrication units and personnel are deleted (see 4.1 of Edition 2013); ——The assembly requirements of water-tube boilers are added (see 4.6); ——The provision that “Boiler fabrication shall be under supervision and inspection” is added (see 4.7); ——The requirements for fabrication supervision and inspection of tubes and their assembled devices within the scope of utility boilers are added (see 4.8); ——The scope of marking materials with steel seals is changed, and the marking methods are detailed (see 5.1~5.4; 5.1~5.4 of Edition 2013); ——The preheating requirements for hot cutting of materials are added (see Table 1 of 6.2.2); ——The heat treatment requirements for austenitic steel drum after forming are deleted [see 6.3.3 a) of Edition 2013]; ——The expression of equation for tensile deformation rate is changed [see Equation (1) and Equation (2); Equation (1) and Equation (2) of Edition 2013]; ——The heat treatment requirements for tube after forming are changed (see 6.4.1.2 and 6.4.4; 6.4.4 of Edition 2013); ——The equations for thinning the outside of the bend and thickening the inside of the bend are changed, and the equations for the thickness reduction ratio of the bend are added [see Equation (3), Equation (4) and Equation (5); Equation (3) and Equation (4) of Edition 2013]; ——The scope of thickening requirements for the inside of bend is changed [see 6.4.2.5 b); 6.4.2.4.1 b) of Edition 2013]; ——Relevant provisions on heat treatment of 07Cr2MoW2VNbB material are deleted; the requirements for heat treatment after tube forming are changed and detailed; the requirements for heat treatment of Fe-5B-2 after cold bending are supplemented in the form of table notes; and the requirements for heat treatment of austenitic steel tubes after cold forming are added (see 6.4.4.1~6.4.4.4, Table 2 and Table 3; 6.4.4.1~6.4.4.2 and Table 1 of Edition 2013); ——The requirements for thickness deviation of seal head are improved [see 6.5.1.7 c); 6.5.1.7 c) of Edition 2013], and the schematic diagram for thickness deviation of seal head are added (see Figure 7); ——The fabrication and assembly tolerances of boiler drum and start-up (steam-water) separator are integrated, and the requirements for fabrication and assembly tolerances of water storage tank are added (see 6.5.1, Table 4 and Table 5; 6.5.1~6.5.2, Table 2, Table 3 and Table 4 of Edition 2013); ——The expressions given in Figure 8, Figure 11 and Figure 12 are corrected (see Figure 8, Figure 11 and Figure 12; Figure 7, Figure 10 and Figure 11 of Edition 2013); ——The fabrication and dimensional deviation control requirements of heated surface tube, tubing, header, start-up (steam-water) separator and water-cooled wall components are detailed (see 6.5.3 and 6.5.4; 6.5.4 and 6.5.5 of Edition 2013); ——The product specimen requirements during the production of membrane tube panel are added (see 6.5.4.1); ——Requirements for expansion record and hydrostatic test after expansion are added (see 7.7.4 and 7.7.5); ——Two specifications of nominal outside diameters of tube (i.e. 14~16 and 18~25) are deleted from the tube hole dimensional deviation (see Table 9 of Edition 2013); ——Other tests specified in the contract, such as joint hardness test and fracture test, are deleted from the test items of welding procedure qualification and product welded test pieces [see 8.2.3 c), 8.2.7 and 8.9.3 c) of Edition 2013]; ——The assessment requirements for test results of full-weld metal tensile specimen are changed (see 8.2.7; 8.2.5 of Edition 2013); ——The acceptance criteria of Charpy V-notch impact test of weld deposited metal and heat affected zone is added (see 8.2.8); ——The requirements for preservation of welding procedure qualification specimens are added (see 8.2.10); ——The requirements for welding records of welding operators and steel seal (or record) of welder code are added (see 8.4.2); ——The minimum preheating temperature before welding and expression of materials Fe-1, Fe-3, Fe-5A, Fe-5B-2, Fe-5C are changed (see 8.7.2.5 and Table 13; 8.7.2 of Edition 2013); ——The quality requirements for mechanical damages on the surface of straight tubes are included in the clause of "repair" (see 8.9.3; 6.4.2.4.4 of Edition 2013); ——The requirement that “No repair welding shall be allowed for iron casting used at pressure bearing parts.” is added (see 8.9.3.2); ——The specific contents of product welded test pieces are deleted, and the relevant requirements shall be implemented according to GB/T 16507.6 (see 8.10; 8.9 of Edition 2013); ——The heat treatment requirements are added if the welded tube hole must be opened on the weld and its heat affected zone due to structure design (see 9.1.5); ——The requirements for heating section length during post weld sectional heat treatment of tubing components are deleted (see 9.3.2.2 of Edition 2013); ——The limiting conditions of the temperature of furnace installed on the tubes on heating surface are changed (see 9.3.3.1; 9.3.3.2 of Edition 2013); ——The temperature rise and drop speed of post weld heat treatment is changed (see 9.3.3.2 and 9.3.3.3; 9.3.3.3 and 9.3.3.4 of Edition 2013); ——The requirements for post weld heat treatment temperature for Fe-5C materials are changed (see Table 14 of 9.3.3.2; Table 12 of 9.3.5.3 of Edition 2013); ——The note of Fe-5B-2 materials is deleted and its contents are included in footnote a of Table 14 (see Table 14 of 9.3.3.2; note of Fe-5B-2 materials in Table 12 of Edition 2013); ——The conditions for canceling post weld heat treatment of Fe-1, Fe-4 and Fe-5A materials are changed (see 9.3.6; notes of Fe-1, Fe-4 and Fe-5A materials in Table 12 of Edition 2013); ——The expression of holding time when the post weld heat treatment temperature is lower than the specified minimum holding temperature is changed (see Table 15 of 9.3.6.1; Table 13 of 9.3.5.3 of Edition 2013); ——The heat treatments not required in this document are added; the condition “When welding is required after heat treatment, no heat treatment is required after welding” is not changed (see 9.4.2); ——Requirements for painting and packing are added (see Clause 10); ——The qualification standards for depth of fusion when steel tube and steel flat are welded with gas-shielded arc welding and manual metal arc welding are changed (see Table B.1, Table B.1 of Edition 2013); ——Grouping and classification of 07Cr2MoW2VNbB material are deleted, and materials may be applied by enterprises according to their own experience (see Table C.1 of Edition 2013). Attention is drawn to the possibility that some of the parts of this document may be the subject of patent rights. The issuing body of this document shall not be held responsible for identifying any or all such patent rights. This document was proposed by and is under the jurisdiction of the National Technical Committee on Boilers and Pressure Vessels of Standardization Administration of China (SAC/TC 262). The previous editions of this document are as follows: ——This document was firstly issued as GB/T 16507-1996 in 1996; ——In its first revision in 2013, the contents of water-tube boilers and shell boilers are divided into eight parts respectively; the contents of water-tube boilers are specified in GB/T 16507.1-2013 ~ GB/T 16507.8-2013 under the general title Water-tube boilers; the contents of shell boilers are specified in GB/T 16508.1-2013 ~ GB/T 16508.8-2013 under the general title Shell boilers. This document is GB/T 16507.5-2013 Water-tube boilers - Part 5: Fabrication. ——This is the second revision. Introduction GB/T 16507 Water-tube boilers is one of the general boiler construction standards that shall be developed, revised and under the jurisdiction of the National Technical Committee on Boilers and Pressure Vessels of Standardization Administration of China (hereinafter referred to as "the Committee"). It was developed according to the basic safety requirements of the boiler safety regulations promulgated by the nation, and all the design criteria, material requirements, technical requirements for fabrication and inspection, acceptance criteria and installation requirements meet the relevant requirements of TSG 11 Regulation on safety technology for boiler. GB/T 16507 is a coordinative standard, which meets the basic requirements of Regulation on safety technology for boiler and the requirements of TSG 91 Regulation on energy conservation and environmental protection technology for boiler. GB/T 16507, which consists of the following eight parts, is designed to standardize the design, fabrication, inspection, acceptance and installation of boilers. ——Part 1: General requirements, designed to determine the general technical requirements related to water-tube boiler construction, such as the range, parameters, construction specifications, energy conservation and environmental protection of water-tube boilers. ——Part 2: Materials, designed to determine the material selection and use requirements for pressure and non-pressure elements, stressed members, steel structures and welding materials of water-tube boilers. ——Part 3: Structure design, designed to determine the basic requirements of structure design, welding connection requirements, openings and specific design requirements of various elements (components) of water-tube boilers. ——Part 4: Strength calculation of pressure parts, designed to determine the calculated wall temperature, calculation pressure, permissible design stress value and calculation method for strength design of pressure parts of water-tube boilers. ——Part 5: Fabrication, designed to determine the requirements for marking, cold and hot forming, expansion, welding and heat treatment in the fabrication process of water-tube boilers. ——Part 6: Inspection, testing and acceptance, designed to determine the inspection, test and acceptance requirements of the pressure elements of water-tube boilers and the load-bearing non-pressure elements directly connected with them. ——Part 7: Safety appurtenances and instruments, designed to determine the settings and selection requirements for safety appurtenances and instruments of water-tube boilers. ——Part 8: Installation and operation, designed to determine the requirements for installation, commissioning, quality acceptance and operation of water-tube boiler proper and tubing within the boiler range. It is unnecessary and impossible for GB/T 16507 to cover all the technical details for the construction and installation of boilers within the application scope, so under the premise of satisfying the basic safety requirements specified in TSG 11 Regulation on safety technology for boiler, the technical contents not specially mentioned in GB/T 16507 shall not be banned. GB/T 16507 does not restrict the adoption of advanced technical methods that meet safety requirements in actual engineering design and construction. For the comprehension ambiguities and the resulting consequences caused by the publicizing or interpretation of this standard by other organizations without written entitlement or approval of the Committee, the Committee will not undertake any responsibility. Water-tube boilers - Part 5: Fabrication 1 Scope This document specifies the requirements for marking, hot and cold forming, expansion, welding and heat treatment of water-tube boilers in the fabrication process. This document is applicable to the fabrication of water-tube boiler as defined in GB/T 16507.1. 2 Normative references The following documents contain provisions which, through reference in this text, constitute indispensable provisions of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. GB/T 5310 Seamless steel tubes and pipes for high pressure boiler GB/T 16507.1 Water-tube boilers - Part 1: General requirement GB/T 16507.2 Water-tube boilers - Part 2: Materials GB/T 16507.3 Water-tube boilers - Part 3: Structure design GB/T 16507.4 Water-tube boilers - Part 4: Strength calculation of pressure parts GB/T 16507.6 Water-tube boilers - Part 6: Inspection, testing and acceptance GB/T 30583-2014 Specification for post weld heat treatment of pressure equipment JB/T 3223 Welding material quality management specifications NB/T 47014 Welding procedure qualification for pressure equipment GB/T 47018 (All parts) Technical permission of welding materials for pressure equipment NB/T 47055 Painting and packing specification of boiler 3 Terms and definitions For the purposes of this document, the terms and definitions given in GB/T 16507.1 and the following apply. 3.1 cold forming plastic deformation processing conducted below the recrystallization temperature of the workpiece material Note: In engineering practice, the plastic deformation processing conducted at room temperature is usually referred to as cold forming; and that above the room temperature to the recrystallization temperature is referred to as warm forming. For ferritic steels with reinforced creep strength 10CAMo1VNbN, 10Cr9MoW2VNbBN, 10Cr11MoW2VNbCu1BN and 11Cr9Mo1W1VNbBN, the bend-forming temperature (t) of steel tube falls below 705℃; for 07Cr2MoW2VNbB steel, the bend-forming temperature (t) of steel tube falls below 605℃. 3.2 hot forming plastic deformation processing conducted above the recrystallization temperature of the workpiece material Note: For ferritic steels with reinforced creep strength 10Cr9Mo1VNbN, 10C9MoW2VNbBN, 10Cr11MoW2VNBCu1BN and 11Cr3Mo1W1VNbBN, the bend-forming temperature (t) of steel tube is not below 705℃; for 07Cr2MoW2VNbB steel, the bend-forming temperature (t) of steel tube is not below 605℃. 3.3 tube forming tube processing such as bending, upsetting, necking and flaring 3.4 nominal thickness of weld nominal thickness of the weld Note 1: For full-penetration butt welds, the nominal thickness means the thickness of the thinner welded part. Note 2: For full-penetration fillet welds, the nominal thickness means the depth of the weld. Note 3: For partial penetration groove weld and weld for material repairing, the nominal thickness means the depth of the weld. For partial or full penetration groove welds welded from both sides, the sum of the depths on both sides at a given position is taken as the total depth of the weld. Note 4: For fillet welds, the nominal thickness means the throat height of the weld. When fillet weld and groove weld are used together, the groove weld depth or throat dimension of fillet weld (whichever is greater) shall be taken as the nominal thickness. Note 5: If there are multiple holes on the drum to form a hole bridge, and their pitch is less than twice the average hole diameter, the nominal thickness means the sum of groove depth and the dimension of fillet weld throat. 4 Basic requirements 4.1 As for boiler pressure elements, their structure shall meet the requirements of GB/T 16507.3 and their strength calculation shall meet the requirements of GB/T 16507.4. 4.2 The design and fabrication process documents shall be consistent with the production conditions of the unit. 4.3 Appropriate process and method shall be adopted for the fabrication of pressure elements without introducing any additional stress and harmful defects that affect safety and use. 4.4 The equipment, instruments and apparatus involved in the fabrication of boiler pressure elements shall conform to the specified accuracy, and shall be verified or calibrated regularly. 4.5 The raw materials shall meet the requirements of GB/T 16507.2 and design drawings. 4.6 The water-tube boiler shall be fabricated and assembled according to the design drawings reviewed and approved by the appraisal organization approved by the nation, the process and technical requirements of the fabrication unit and the corresponding practical engineering experience. 4.7 Boiler fabrication shall be under the supervision and inspection of the supervision and inspection institutions. 4.8 As for element assembly devices such as tubing, temperature and pressure reduction device, flow meter (shell) and factory prefabricated tube section within the scope of utility boiler, fabrication supervision and inspection shall be conducted according to the requirements for boiler components or pressure tubing element assembly devices. Foreword i Introduction vi 1 Scope 2 Normative references 3 Terms and definitions 4 Basic requirements 5 Marking 6 Forming, processing and fabrication tolerances 7 Expansion 8 Welding 9 Heat treatment 10 Painting and packing Annex A (Informative) Tube bending process test Annex B (Nominative) Supplementary requirements for welding procedure qualification of boiler membrane tube panel Annex C (Nominative) Classification and grouping of materials for welding procedure qualification of boilers Bibliography 水管锅炉 第5部分：制造 1 范围 本文件规定了水管锅炉在制造过程中的标记、冷热加工成形、胀接、焊接和热处理等的各项要求。本文件适用于GB／T 16507.1界定的水管锅炉的制造。 2 规范性引用文件 下列文件中的内容通过文中的规范性引用而构成本文件必不可少的条款。其中，注日期的引用文件，仅该日期对应的版本适用于本文件；未注日期的引用文件，其最新版本(包括所有的修改单)适用于本文件。 GB／T 5310 高压锅炉用无缝钢管 GB／T 16507.1 水管锅炉 第1部分：总则 GB／T 16507.2 水管钢炉 第2部分：材料 GB／T 16507.3 水管锅炉 第3部分：结构设计 GB／T 16507.4 水管锅炉 第4部分：受压元件强度计算 GB／T 16507.6 水管锅炉 第6部分：检验、试验和验收 GB／T 30583-2014 承压设备焊后热处理规程 JB／T 3223 焊接材料质量管理规程 NB／T 47014 承压设备焊接工艺评定 NB／T 47018(所有部分) 承压设备用焊接材料订货技术条件 NB／T 47055 锅炉涂装和包装通用技术条件 3 术语和定义 GB／T 16507.1界定的以及下列术语和定义适用于本文件。 3.1 冷成形 cold forming 在工件材料再结晶温度以下进行的塑性变形加工。 注：在工程实践中，通常将室温下进行的塑性变形加工称为冷成形；高于室温至再结晶温度之间的塑性变形加工称为温成形(warm forming)。对蠕变强度增强型铁素体钢10CAMo1VNbN、10Cr9MoW2VNbBN、10C11MoW2VNbCulBN、11Cr9Mo1W1VNbBN，钢管弯曲成形温度(t)小于705℃；对07Cr2MoW2VNbB钢，钢管弯曲成形温度(t)小于605℃。 3.2 热成形 hot forming 在工件材料再结晶温度以上进行的塑性变形加工。 注：对蠕变强度增强型铁素体钢10Cr9Mo1VNbN、10C9MoW2VNbBN、10Cr11MoW2VNBCulBN，11Cr3Mo1W1VNbBN，钢管弯曲成形温度(t)不小于705℃；对07Cr2MoW2VNbB钢，钢管弯曲成形温度(t)不小于605℃。 3.3 管子成形 tube forming 管子的弯管、镦厚、缩颈、扩口等加工过程。 3.4 焊缝公称厚度 nominal thickness of weld 焊缝的名义厚度。 注1：对全焊透对接焊缝，为所连接较薄零件的厚度。 注2：对全焊透角接焊缝，为焊缝深度。 注3：对部分焊透坡口焊缝和材料修补时的焊缝，为焊缝的深度。从两侧施焊的部分焊透或全焊透坡口焊缝，把在给定位置上两侧焊缝深度之和作为该焊缝的总深度。 注4：对角焊缝，为角焊缝喉高。角焊缝与坡口焊缝组合在一起使用时，取坡口焊缝深度和角焊缝喉部尺寸两者中的较大值。 注5：如果筒体上有多个开孔形成孔桥，且其节距小于平均孔径的两倍，则为坡口深度与角焊缝喉部尺寸之和。 4 基本要求 4.1 锅炉受压元件的结构应符合GB／T 16507.3的规定，强度计算应符合GB／T 16507.4的要求。 4.2 设计和制造工艺文件应与本单位的生产条件相符合。 4.3 受压元件的制造应采用适宜的工艺和方法，不应产生影响安全和使用的附加应力、有害缺陷。 4.4 锅炉受压元件制造中所涉及的设备、仪器仪表应符合规定精度，并定期进行检定或校正。 4.5 原材料应符合GB／T 16507.2和设计图样的要求。 4.6 应根据经国家核准的鉴定机构审核通过的设计图样、制造单位的工艺及技术要求和相应的工程实际经验来制造和装配水管锅炉。 4.7 锅炉制造应由监督检验机构进行制造监督检验。 4.8 对于电站锅炉范围内管道，减温减压装置、流量计(壳体)、工厂化预制管段等元件组合装置，应按锅炉部件或压力管道元件组合装置的要求进行制造监督检验。 5 标记 5.1 材料标记 5.1.1 应制订受压元件和主要承载构件用材料的材料标识程序。 5.1.2 锅炉受压件(钢筒、启动(汽水)分离器、储水箱、集箱类部件、公称外径不小于219 mm的管子)的材料标记应能追溯到材料的质量证明书；其他受压件(公称外径小于219 mm的管子)和承受载荷的非受压件(锅筒、启动(汽水)分离器、储水箱、集箱类部件上的支吊件)的材料标记应便于识别，以防止材料混用。 5.2 材料标记移植 应在制造过程中保留材料标记。锅炉受压元件用的材料分割下料前，应作标记移植，并且便于识别。 5.3 制造过程中的标记 焊工标记，无损检测(RT检测)标记以及要求追溯的材料标记应作为永久性的标记保留，生产过程中标记被覆盖或因加工而丢失标记时应作标记移植。 5.4 标记方法 5.4.1 宜采用下列标记方法或下列方法的组合： a) 钢印(低应力钢印)； b) 震动蚀刻或其他蚀刻工具； c) 涂漆或用标记笔标记。 5.4.2 下列情况不应用钢印标记： a) 不锈钢管； b) 在管子弯头内外弧区域； c) 客户要求不准许用钢印标记的材料。 5.4.3 当无法用5.4.1的方法进行标记时，可用其他不损坏锅炉安全性的方法(如定位图、贴票签等)进行标记。 6 成形、加工和制造公差 6.1 一般要求 6.1.1 制造单位应确保受压元件加工或成形后的实际厚度不小于设计要求的最小需要厚度。 6.1.2 采用冷成形时，应考虑所用钢材的冷脆性。 6.1.3 采用温成形时，应避开钢材的回火脆性温度区。 6.1.4 材料成形工艺应考虑材料的应变量。冷成形所采用的制造方法不应使元件产生过大的变形率(或应变量)，否则应进行相应的成形后热处理。 6.1.5 用于制造端盖、法兰、管件等的材料应符合GB／T 16507.2和设计图样的规定。 6.2 材料的分割 6.2.1 根据材料特性和规格选择材料的分割方法。采用的分割方法应保证工艺要求的加工精度，还应减少或避免因下料而造成的变形。下料后如变形超出允许范围，应采用合适的方法予以矫正。 6.2.2 根据钢材的类别和厚度确定材料的热切割是否需要预热，推荐的预热要求见表1。 表1 热切割预热要求 钢材类别a 材料厚度 mm 最低预热温度 ℃ 备注 Fe-1-1 Fe-1-2 ≤150 不要求 最低预热温度也可按焊前预热温度执行 ＞150 80 Fe-1-3 ≤30 不要求 ＞30 80 Fe-3-1 ≤16 不要求 ＞16 80 Fe-3-2、Fe-3-3 任意厚度 100 Fe-4 ≤50 不要求 ＞50 150 Fe-5A ≤50 100 最低预热温度也可按焊前预热温度执行 ＞50 150 Fe-5B-1、Fe-5B-25C ≤13 150 ＞13 200 Fe-6 任意厚度 要求b Fe-7 任意厚度 要求b a 钢材类别应符合NB／T 47014。 b 预热温度应符合相应的材料标准的要求。 6.2.3 热切割表面应通过机械加工或打磨的方法去除所有过烧金属、割渣、有害刻痕及多余金属等。对于合金钢，热切割后应留有加工裕量，除非能表明材料的组织没有损坏。 6.3 锅筒、启动(汽水)分离器、储水箱、集箱类筒体和封头成形 6.3.1 用钢板制造筒体和封头，当采用锻制或冲压方式制造时，应根据锻造加热控制要求进行，并与锅炉制造单位的生产条件相符合。 6.3.2 封头的热成形或冷成形制造应采用连续成形工艺。 6.3.3 成形后热处理的要求按如下规定： ——钢板冷成形如图1，当变形率大于5%时，应于成形后进行相应热处理恢复材料的性能，热处理按第9章的规定进行； ——单向拉伸变形率(ε1)按公式(1)，双向拉伸变形率(ε2)按公式(2)进行计算： ε1=50δ[1－(Rf／Ro)]／Rf (1) ε2=75δ[1－(Rf／Ro)]／Rf (2) 式中： ε1——单向拉伸变形率，%； ε2——双向拉伸变形率，%； δ——板材名义厚度，单位为毫米(mm)； Rf——成形后中面半径，单位为毫米(mm)； Ro——成形前中面半径(对于平板为∞)，单位为毫米(mm)。 a) 单向拉伸 b) 双向拉伸 标引序号说明： δ——板材名义厚度； Rf——成形后中面半径。 图1 单向拉伸和双向拉伸成形 6.3.4 成形后外观质量的要求如下。 a) 卷制或压制后的筒体和压制后的封头应清除内外表面的氧化皮、凹陷和疤痕，当其深度不影响设计要求的最小需要厚度且呈圆滑过渡时，可不予修磨；若底部呈尖锐状态应修磨成圆滑过渡。深度影响设计要求的最小需要厚度时应按评定合格的焊补工艺进行焊补及修磨，并经无损检测合格。 b) 人孔扳边加工完后应经表面检查，不应有裂缝。 6.4 管子成形 6.4.1 一般要求 6.4.1.1 管子成形包括弯管和管端成形。若管子采用冷成形不能满足产品技术要求时应采用热成形。 6.4.1.2 管子成形后的热处理要求按6.4.4及第9章的规定进行。 6.4.2 弯管 6.4.2.1 应根据管子材料、规格、弯曲半径、弯管形状和弯管设备选用热成形(即热弯，包括内侧加热弯、热挤压成形及中频感应加热弯等)或冷成形(即冷弯)。 6.4.2.2 采用热弯时，应严格控制加热规范和加热范围。 6.4.2.3 弯管宜进行弯管工艺试验，以验证所采用的弯管工艺满足产品技术要求。弯管工艺试验可参照附录A。 6.4.2.4 管子弯管后应检测减薄率、弯头内外侧最小壁厚、弯头圆度、弯曲角度偏差及表面质量，并符合6.4.2.5～6.4.2.9的要求。 6.4.2.5 弯头减薄率、弯头内外侧壁厚应符合如下要求。 a) 弯头外侧减薄 管子弯后弯头外侧任何一点的厚度不应小于公式(3)的计算值： (3) 式中： δa——弯头外侧最小需要厚度，单位为毫米(mm)； δt——直管的计算厚度，单位为毫米(mm)，实际生产中可用“名义壁厚减去最大厚度负偏差再减去C1”代替δt进行计算，当不满足计算式时，再用δt进行校核，8。按GB／T 16507.4的规定； R——管子弯曲半径，单位为毫米(mm)； Do——管子公称外径，单位为毫米(mm)； C1——腐蚀裕量，单位为毫米(mm)，C1按GB／T 16507.4 的规定。 b) 弯头内侧增厚 公称外径大于219 mm的管子，弯后弯头内侧任何一点的厚度不应小于公式(4)的计算值： (4) 式中： δi——弯头内侧最小需要厚度，单位为毫米(mm)； δt——直管的计算厚度，单位为毫米(mm)，实际生产中可用“名义壁厚减去最大厚度负偏差再减去C1”代替δt进行计算，当不满足计算式时，再用δt进行校核，δt按GB／T 16507.4的规定； R——管子弯曲半径，单位为毫米(mm)； Do——管子公称外径，单位为毫米(mm)； C1——腐蚀裕量，单位为毫米(mm)，C1按GB／T 16507.4 的规定。 c) 弯头减薄率 弯头减薄率(b)按公式(5)计算： (5) 式中： b——弯头减薄率； δo——弯前管子的实际厚度，单位为毫米(mm)； δm——弯后弯头拉伸面管壁最薄处的实际厚度，单位为毫米(mm)。 弯头减薄率可作为弯管理论计算时弯管工艺附加厚度(C2)选取的依据。 6.4.2.6 弯头圆度(a)按公式(6)计算： (6) 式中： a——弯头圆度； Dmax——弯头顶点上测得的最大外径，单位为毫米(mm)； Dmin——在Dmax同一横截面上测得最小外径，单位为毫米(mm)。 考核标准如下： a) 成排弯管子弯头：圆度不应大于12%； b) 其他管子弯头： 1) 当弯头处应变量大于35%时，圆度不应大于14%； 2) 当弯头处应变量不小于20%～35%时，圆度不应大于12%； 3) 当弯头处应变量小于20%时，圆度不应大于10%。 弯管的应变量(εo)按公式(7)计算： εo=r／R×100% (7) 式中： εo——弯管的应变量； r——管子外半径(Do／2)，单位为毫米(mm)； R——管子弯曲半径，单位为毫米(mm)。 6.4.2.7 弯管角度偏差应符合如下要求： a) 公称外径(Do)不大于108 mm的管子，弯头平面弯曲角度的偏差不超过±1°； b) 公称外径(Do)大于108 mm 的管子，弯头平面弯曲角度的偏差不超过±30＇； c) 当管子公称外径(Do)不小于108 mm时，还应测两端间的距离，距离偏差不超过±4 mm。 6.4.2.8 弯头表面质量应符合如下要求。 a) 弯头表面不应有裂纹等尖锐性缺陷。 b) 管子弯后弯头内侧如有明显的波纹应按图2的方法测量，也可用模板测量。波纹应同时满足下列条件，若不能满足下列条件，应调换管子。 1) 波纹幅度：h=(d1＋d3)／2－d2≤3%×Do。 2) 波距：A＞12h。 标引序号说明： d1、d2、d3——测量处管子的实际外径； Do——管子公称外径； R——管子弯曲半径。 注：为清晰起见，波纹已被放大。 图2 弯管波纹示意图 c) 任何弯头沿管子中心线方向不应有宽度超过12 mm的平直区。 6.4.2.9 应对公称外径不大于60 mm的受热面弯管检测流通面积，进行通球检查，通球球径按GB／T 16507.6的规定。 6.4.3 管端成形 6.4.3.1 为满足不同壁厚管子或不同口径管子的拼接，可对管端进行镦厚、缩颈、扩口加工成形。 6.4.3.2 管端镦厚、缩颈、扩口加工成形后，管子的外表面及壁厚的过渡区应平滑、无裂纹。 6.4.3.3 管端镦厚、缩颈、扩口量的控制及成形后的热处理，应根据经验证过的工艺进行，并确保不会损害材料的使用性能。 |
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| GB/T 16507.5-2022, GB 16507.5-2022, GBT 16507.5-2022, GB/T16507.5-2022, GB/T 16507.5, GB/T16507.5, GB16507.5-2022, GB 16507.5, GB16507.5, GBT16507.5-2022, GBT 16507.5, GBT16507.5 |