What are the differences in the anticorrosion workshop of Huayang steel pipe
In the service life of steel pipe, corrosion resistance is the key factor to determine its "service time". Hebei Huayang Steel Pipe Co., Ltd. is well aware of this, and has made the anti-corrosion workshop an important line of defense for product quality. This is not only the place where steel pipes "put on protective clothing", but also the vivid practice of Huayang's concept that "what customers want is not' good looking' but' useful'". There are too many unknown ingenuity and technology hidden in the anti-corrosion workshop built independently and managed by special personnel.
Exclusive production line: to create a full range of anti-corrosion solutions
Walking into the anticorrosion workshop of Huayang steel pipe, the first thing you see is an orderly exclusive production line. Different from the ordinary workshop, according to the difference of anti-corrosion technology, there are many independent working areas, such as 3PE, 2PE, FBE, 2PP, 3PP, etc. Each area is equipped with suitable professional equipment to ensure that the anti-corrosion treatment of different technologies does not interfere with each other.
The 3PE anticorrosion production line is the "star equipment" in the workshop, which can sequentially complete three processes of epoxy powder coating, adhesive winding and polyethylene coating on the steel pipe surface to form a three-layer composite protective structure. This production line imported from Germany adopts a closed-loop control system, which can adjust the coating temperature and pressure in real time. For oil pipelines customized by customers in the Middle East, technicians accurately control the curing temperature of epoxy powder at 230℃ 5℃, so that the adhesion between coating and steel pipe reaches 120N/cm, far exceeding the industry standard of 80N/cm.
FBE (sintered epoxy powder) production line shows adaptability to high temperature environment. The process adopts electrostatic spraying technology, powder particles are uniformly adsorbed on the surface of steel pipe under the action of high voltage electric field, and a dense coating is formed after curing at 200℃. In order to meet the needs of the project in the desert area of Australia, the workshop carried out technical transformation on this production line, and added an infrared thermometer to monitor the curing temperature of the coating in real time to ensure that the coating can still maintain its stable performance under extreme temperature difference. After testing, its salt spray resistance can reach more than 10,000 hours.
Whether it is 2PE anticorrosive steel pipe used for municipal water conveyance or 3PP anticorrosive steel pipe commonly used in chemical field, Huayang's anticorrosive workshop can provide customized solutions. This ability to cover all categories allows customers in different industries and different environments to find suitable anti-corrosion products.
Precision technology: make every inch of coating stand the test
The core of anti-corrosion treatment is "precision", and the process details of Huayang anti-corrosion workshop show the ultimate pursuit of quality. From the moment the steel pipe enters the workshop, every step of operation has strict parameter standards to ensure that the key indexes such as coating thickness, uniformity and adhesion reach the standard.
Pretreatment is the basis of anticorrosion quality. Steel pipes need to go through three processes: shot blasting and derusting, degreasing and cleaning, preheating and drying to remove scale, oil stain and moisture on the surface. The equipment imported from Finland is used for shot blasting and derusting, and the diameter of steel shot is controlled at 0.8-1.2 mm. The steel shot is evenly sprayed on the surface of steel pipe through a high-speed rotating impeller, so that the surface roughness reaches Sa2.5 level. Technicians will randomly test each steel pipe with a roughness meter, and at least 5 points will be tested to ensure that the derusting effect meets the requirements.
The precision control of the coating process is even more amazing. The laser thickness gauge equipped with imported equipment can measure the coating thickness in real time during the operation of steel pipe, and the accuracy can reach 0.01 mm. For the 2PE anticorrosive steel pipe produced for an irrigation project in Africa, the customer required the coating thickness to be 2.5mm. The workshop controlled the actual thickness within the range of 2.5mm±0.05mm by adjusting the speed of extruder and the speed of steel pipe, and the error was far less than the international standard of 0.15 mm..
The cooling link can't be ignored. Three-stage water cooling system is adopted to gradually cool the coating in different temperature ranges to avoid cracks caused by excessive temperature difference. Through numerous experiments, technicians determined the gradient cooling scheme of "80℃→50℃→30℃", which improved the crystallinity of the coating by 15% and significantly enhanced the impact resistance.
Rigorous inspection: from "superficial qualification" to "intrinsic reliability"
In Huayang anti-corrosion workshop, "inspection" is not the last process, but the quality monitoring throughout the whole process. An independent testing laboratory is set up in the workshop, equipped with professional equipment such as pinhole detector, adhesion tester, impact tester, etc. Each steel pipe has to go through several rounds of "physical examination" before leaving the factory.
Pinhole detection is the most basic and key item. Using high-voltage EDM detector, the coating was fully scanned at a voltage of 5000V V. Once pinholes with a diameter greater than 0.3mm were found, the steel pipe would immediately return for reprocessing. Last year, a batch of FBE anticorrosive steel pipes produced for a wind power project in Europe were found to have tiny pinholes in three pipes. The technicians traced back to the powder particle size deviation in the spraying process and adjusted the screening equipment in time to ensure zero pinholes in the subsequent products.
Adhesion test directly verifies the "firmness" of the coating. Testers cut a 10mm×10mm square on the coating with a special tool, and then quickly tear it off after pasting it with tape to observe the peeling off of the coating. Huayang's standard is "zero shedding", which puts high demands on the process. In the detection of a seawater transportation project in Southeast Asia, even after 1000 hours of immersion test, the coating adhesion remained above 90N/cm to ensure that the steel pipe was not corroded in high salt environment.
The impact test simulates the collision scene in the process of steel pipe transportation and installation. After falling from a height of 1m with a 1kg impact hammer and impacting the coating surface, observe whether there are cracks or spalling through a magnifying glass. In this test, Huayang's anticorrosive steel pipe can withstand more than three impacts without damage, which is far higher than the customer's requirement of one standard.
Special person in charge: constructing the whole process quality traceability system
The uniqueness of anti-corrosion workshop lies in its operation mode of "special person management". The workshop is equipped with 20 experienced technicians, 8 of whom have more than 10 years experience in anti-corrosion technology, and everyone has a clear division of responsibilities, from raw material inspection to finished product delivery, forming a closed-loop management.
The special person is responsible for the management of raw materials, and all anti-corrosion materials must undergo strict inspection. The composition test report of epoxy powder shall be provided to ensure that the epoxy content is ≥ 95%; The melting index of polyethylene particles should be tested, and the numerical value should be controlled within the range of 0.8-1.2g/10min. Last year, a batch of imported adhesives were rejected by quality inspectors on the spot because their melting index exceeded the standard, thus avoiding the subsequent quality hazards.
During the production process, operators record key parameters every hour, including coating temperature, coating thickness, curing time, etc. These data are uploaded to MES system in real time to form traceable electronic files. The unique code is sprayed on the pipe body of each steel pipe, and the whole process data of anti-corrosion treatment can be viewed by scanning the code. This transparent management allows customers to clearly understand the details of the anti-corrosion process of products.
After-sales tracking is also an important link that special personnel are responsible for. Technicians will pay regular visits to customers to learn about the use of steel pipes and collect data on anti-corrosion performance in different environments. Aiming at the problem that the toughness of the coating decreased in winter, which was fed back by a Nordic customer, the workshop team developed a formula to improve the toughness at low temperature, so that the coating could still maintain good impact resistance at-40℃ and won high recognition from customers.
The anticorrosion workshop of Huayang steel pipe has no gorgeous decoration, but there is awe of quality everywhere. Every production line, every process and every test here are interpreting the deep meaning of "useful". It is this attitude that regards the anti-corrosion link as the life support of products that makes Huayang steel pipes stand the test of time in projects all over the world and become synonymous with "reliability" in customers' minds. Under the protection of the anti-corrosion workshop, Huayang steel pipe is taking root in every corner of the global market with longer vitality.
