Steel piping systems are widely used at coal-fired power plants for a variety of purposes, including the conveyance of coal ash slurry to nearby settling ponds, the transfer of limestone slurry to absorber spray towers for removal of sulfur dioxide (SO2) and hydrogen chloride (HCl) from flue gases and for transporting away the calcium sulfate by-product of the flue gas desulfurization process.

钢管系统广泛应用在火力发电厂出于各种目的,包括粉煤灰砂浆的输送到附近的池塘,石灰石泥浆的转移到吸收塔喷淋塔去除二氧化硫(SO2)和氯化氢(HCl)从烟道气体和运输的硫酸钙烟气脱硫过程的副产品。

However, when these abrasive, caustic slurries are transported through steel pipe, the effect on the inner surface can be devastating. Abrasive wear within these transportation systems is produced when hard particles are forced against or slide along the wall of the pipe. The loss of material is the result of the hard, sharp angular edges producing a cutting or shearing action on the pipe wall, which in more extreme cases can result in pipe leaks and even failure, or significant maintenance costs and downtime for pipe replacement.

然而，当这些磨料、腐蚀性泥浆通过钢管输送时，对内部表面的影响可能是毁灭性的。在这些运输系统内的磨料磨损是在硬颗粒被强迫或沿管道壁滑动时产生的。材料的损失是由于硬的、尖锐的角边产生的切割或剪切作用在管壁上，在更极端的情况下可能导致管道泄漏甚至故障，或重要的维护费用和更换管道的停机时间。

For these abrasive applications, mild steel pipe is not tough enough to stand up to the abuse for more than a year or two. As a result, maintenance engineers are seeking superior piping alternatives to reduce maintenance and prolong system life, at a price point that will not significantly impact the budget.

对于这些研磨性的应用，软钢管不够强硬，足以经受一年或两年的虐待。因此，维修工程师正在寻找更好的管道替代方案，以减少维护和延长系统寿命，在价格点上不会对预算造成重大影响。

“The slurry is so abrasive, that standard grade carbon steel pipe just wears out too quickly,” said John Pillard, a senior pipe technician with experience in high abrasion applications.

“砂浆非常粗糙，标准的碳钢管磨损得太快了，”资深管道技术员约翰·皮拉德(John Pillard)说。

Abrasive Applications

One-hundred-twenty-nine-million tons of coal ash—a byproduct of the coal burning process—is produced in the U.S. every year. Most power plants transport the coal ash in liquid form to large surface impoundments or in solid form at landfills near the facility through long lengths of steel piping, which can range in length from several thousand feet to miles. There are almost 900 such landfills and surface impoundments in the U.S. today.

美国每年生产的煤渣——煤炭燃烧过程的副产品——一亿九千九百万吨。大多数发电厂都将煤灰以液态形式输送到大型的地表蓄水层，或者在工厂附近的固体形式，通过长时间的钢管输送，这些管道的长度可以从几千英尺到英里不等。今天，美国大约有900个这样的垃圾填埋场和地表蓄水设施。

Limestone slurry is also commonly used by coal-fired plants for the effective removal of sulfur dioxide and hydrogen chloride from flue gases.

石灰石浆也常被燃煤发电厂用于有效去除烟气中的二氧化硫和氯化氢。

These wet scrubber flue gas desulfurization (FGD) systems utilizes a pumped in limestone slurry through which flue gas containing SO2 is passed in absorber spray towers.

这些湿式洗涤塔烟气脱硫系统利用了石灰石浆料的泵浦，其中含SO2的烟气通过吸收塔。

The limestone slurry reacts with the flue gas, removing the SO2.

石灰石浆与烟气发生反应，去除二氧化硫。

To deal with the extremely abrasive and caustic nature of these various slurries, plant maintenance managers are looking to a variety of “abrasion resistant” steel pipe products and accessories to replace standard mild steel pipe in these high wear areas.

为了处理这些不同泥浆的研磨性和腐蚀性，工厂的维修经理们正在寻找各种各样的“耐磨”钢管产品和配件来代替这些高磨损区域的标准的软钢管。

Pipe Options

Most abrasion resistant pipe options operate on the premise that when two objects meet, the harder object wins.

大多数耐磨管道的选择是在两个物体相遇时，较难的物体获胜。

As such, products are available in a variety of increasing hardness, measured on the Brinell Scale from A-R steel (200 BHN) through iron cast pipe (up to 800 BHN).

因此，产品可以用各种各样的硬度增加，从a - r钢(200 BHN)的Brinell Scale (200 BHN)通过铸铁管(高达800 BHN)来测量。

Unfortunately, any product that is very hard throughout the wall thickness is also brittle.

不幸的是，任何在整个壁厚都很硬的产品也是易碎的。

This brittleness is unacceptable as piping systems are constantly flexing and moving as a result of pressure surges and spikes and due to mechanical and physical contact at the facility.

这种脆性是不可接受的，因为管道系统不断地弯曲和移动，由于压力的激增和尖峰，以及由于机械和物理接触的设施。

However, one type of pipe delivers the best of both worlds: an induction hardened pipe with an abrasion resistant inner surface that tapers to a strong, yet ductile outer surface.

然而，有一种类型的管道输送的是两个世界最好的:一种感应淬火管，它具有耐磨的内表面，它可以逐渐变细到坚固的表面，但却可以延展到表面。

Manufactured by Port Washington, Wisc.

由华盛顿港口制造。

-based Ultra Tech, this pipe is produced under the Ultra 600 brand.

本公司生产的超技术，是在超600品牌下生产的。

Ultra Tech begins with a steel pipe manufactured to a proprietary chemistry, followed by induction heating and finally water-quenching the inner surface to create a single-wall pipe.

Ultra Tech开始使用的是一种制造成专有化学的钢管，然后是感应加热，最后是水淬，内部表面形成一个单壁管。

At 600 BHN, the inner surface of this induction hardened pipe can withstand most common abrasives and tapers to a 250 BHN outer surface that is ductile enough to accommodate normal handling during shipment, installation and maintenance.

在600 BHN，这个感应淬火管的内表面能够承受最常见的磨料和锥体，到250 BHN的外表面，在运输、安装和维护过程中足以容纳正常的处理。

With this process, pipe can be created in various diameters up to 40”, in varying lengths and wall thickness.

有了这个过程，管子就可以在不同的直径上形成40英寸，在不同的长度和壁厚。

Because the outer surface behaves like mild steel, the product can be cut and welded with proper procedure in the field, configured into a variety of fittings and can accept the standard end options of flanges, weld rings and couplings.

由于外表面的性能类似于低碳钢，因此可以在现场进行适当的切割和焊接，并将其配置成各种配件，并可接受法兰、焊缝和联轴器的标准端选项。

The company can also produce the pipe in long-radius bends to further reduce wear and eliminate the frequent replacement, repair, and associated expense accepted as the norm at the bends and elbows in high wear applications.

该公司还可以生产长半径弯管，以进一步减少磨损，消除频繁更换、维修和相关费用，作为在高磨损应用场合的弯头和手肘的规范。

Pillard estimated that in an extremely high wear area an A-R pipe could wear out in as little as a year and a half.

皮拉德估计，在一个极高的磨损区域内，a - r管道在一年半的时间内就会磨损。

He estimated the Ultra 600 could double that duration in the same location.

他估计，在同一地点，Ultra - 600的续航时间可能会增加一倍。

In a lower (yet still abrasive) wear application, Pillard has seen the induction hardened pipe last 6 to 8 years.

在较低的(但仍然是磨料)磨损应用程序中，Pillard已经看到了感应硬化管道6 - 8年。

A wide range of different materials with different characteristics can be chosen to protect against wear. Pipe linings made of mineral, metallic or ceramic materials have proven to work well.

To achieve both technical and economical wear protection, many factors have to be taken into account. The choice needs to be based on the application. The best solution for long life and economical abrasion protection depends upon the proper selection of the wear resistant pipe linings as well as a knowledge of expected cost.

Clear Advantages of Using Wear Resistant Pipe Linings:

• Long lifetime and maintenance free operation

•NO operation interruption or production losses

•NO contamination of the conveyed materials due to abrasion, mixture or oxidation

•Physiologically harmless, suitable for food products

•Smooth surface to achieve good flowability and to avoid plugs

•Reduced pressure losses and lower energy cost

•No spilled material to clean up