换热器制造工艺指导流程.docx
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换热器制造工艺指导流程
换热器制造工艺指导流程
筒节Tube
section
1.材料确认:
在材料管理员的指导下,对材料的标记确认。
Confirmmaterial:
undertheguidanceofmaterialsadministrator,recognizedthemarkofthematerial。
2.根据工艺排版图将板料平铺于切割架上,号料划出切割线、刨边线、检查线。
Accordingtoprocessdiagram,layoutingthematerialboardontheshelves,cuttinganddrawthecuttingline,planeedge,checkingline.
3.坡口加工(见坡口工艺卡),完成后对坡口进行超声检测。
Grooveprocessing(seegrooveprocesscard),Ultrasonictesting
afterthecompletionofthegroove。
4.卷板:
将坡口加工完好的板料置于卷板机上、下辊轮间,板料周长方向与辊轮垂直,纵向与辊轮平行。
Coil:
placethegrooveprocessingintactsheetontherollingmachine,betweentheupperandlowerroller,thesheetperimeterdirectionisverticaltotheroller,andthelongitudinalisparalleltotherooler.
5.纵缝组对:
将纵缝口两端对齐,控制错边量,错边不大于1/4δ且不大于2mm,并点上引弧板。
Combinethelongitudinalseam:
Alignbothendsofthelongitudinalseam,controltheamountoftheStaggeredside,thestaggeredsideisnotgreaterthan1/4δandnotgreaterthan2mm,andpointthearcplate.
6.纵缝焊接,见焊接工艺卡。
Longitudinalseamwelding,seetheweldingprocesscard。
7.校园:
不园度控制在0.5%DN,且不大于5mm,DN≥1200,不大于7mm;棱角度,控制在δS/10+2,且不大于5mm。
Regulatetomakesureitcircle:
Park,controlthedegreeofof-roundnessat0.5%theDN,andnotmorethan5mm,theDN≥1200,notmorethan7mm;theangularity,shouldbecontrolledatδS/10+2,andnotmorethan5mm。
筒体Tube
Body
1.将各筒节按排版图要求组对,各缝分布于0~180°,互错180°,环缝组对间隙0~2mm。
Accordingtotherequirementsofeachtubesectionlayoutdiagram,combinethem,eachseamisdistributedinthe0to180°,Stagger180°,thecircumferentialseamcombinationgapis0~2mm.
2.组对完毕后,从0°、90°、180°、270°四个方位检测,直线度10%,且不大于4.5mm。
.Detectafterthecombinationofthe0°,90°,180°,270°fourorientation,10%straightness,andnolargerthan4.5mm.
3.环缝棱角度控制在δS/10+2,且不大于5mm错边量。
ControltheringslitangulardegreeatδS/10+2,nolargerthan5mmStaggerionofthevolume.
4.环缝组对时不可强行组装,可用加减丝扣调节间隙,间隙在0~1.5mm最佳。
WhencombinetheCircumferentialseam,wemustnotassembleforcibly,usetheavailablesubtractionthreadedtoadjustthegap,thegapisatbestinthe0~1.5mm.
5.确定错边值后,依次从最佳点入手,顺势而成,环缝错边量不得大于1/4δ板厚且不大于2mm。
DeterminingthevalueoftheStagger,startfromthebestpointbyturn,homeopathytobeit,thecircumferentialseamshouldnotbethan1/4δplatethicknessandnotmorethan2mm.
6.对组装后的筒体进行直线度检测,四点方位,其最大差值不得大于4.5mm。
Testthestraightnessafterassemblingthecylinder,fourpiontposition,themaximumdifferenceisnotgreaterthan4.5mm。
筒体
与
法兰
组对Tube
Body
And
Law
Orchid
Group
To
1.法兰必须是经过检验,贴有合格标签的,对应的流水号和产品编号的。
Theflangemustbetested,labelledwithaqualifiedlabel,thecorrespondingserialnumberandproductnumber.
2.用直尺划出法兰螺栓孔跨中线,与筒体纵缝线平行组装。
Drawtheflangeboltholesacrossthecenterlinewitharuler,assembleandmakesureitparalleltothecylinderlongitudinalsuture.
3.将装一端法兰的筒体,纵缝方向转至90°和270°方位(即水平方向左、右两侧),均分法兰孔,四等分。
Turntheoneendinstalledflangeofthecylinder,longitudinalseamdirectiontothe90°and270°azimuth(horizontalleftandrightsidesdirection),dividedequallyflangeholes,quartered。
4.用铅垂线或水平尺将有一端法兰的筒体调节好,要求0°~180°跨中线与铅垂线重合。
Adjusttheoneendflangeofthecylinderbytheplumblineorlevelruler,requirethe0°to180°crossingcenterlineandplumblinetocoincidewitheachother.
5.组对另一端法兰,即管箱法兰铅垂线与跨中等分线要求与上法兰相同条件(即螺栓孔跨中)。
Assembletheotherendoftheflange,thusthetubeboxflangeplumblinesharesthesameconditionwiththemiddle-pointline(thustheboltholeisatthemiddle).
6.装配间隙0~1.5mm,错边量0~2mm。
Theassemblygapis0~1.5mm,thestaggrmountis0~2mm.
7.检测两端法兰面水平度,用卷尺在0°、90°、180°、270°四个方位,测得壳体长,长度偏差2mm。
筒体总长控制在()±3mm。
Detectetheleveldegreesofbothendsoftheflange,usethetapemeasureat0°,90°,180°,270°fourcardinalposition,measuretheshelllength,thedeviationis2mm.Thebarrellengthiscontledat()±3mm。
8.检测、焊接完毕后,对筒体环缝内打磨平,送探伤检测,要求RT≥()%,Ⅲ级合格。
Afterdetectionandwelding,polishedflatwithintheseamofthecylinderring,sendingtheflawtodetect,requsttheRT≥()class,IIIqualified.
接管与法兰Nozzleandtheflange
将坡口加工好的接口与相对应法兰进行组装,要求:
间隙3~4mm,错边在1.5mm以下,氩弧焊打底,全熔透结构。
焊接完成后送无损检测,检验标准RT≥()%,Ⅲ级合格。
Assemblethegroovemachinednozzlewiththecorrespondingflange,requirements:
thegapis3~4mm,thestaggeredsideislessthan1.5mm,argonarcbottoming,fullpenetrationstructure.Afterwelding,havinganon-destructivetesting,theinspectionstandardsisRT≥()class,IIIqualified.
支座点焊Supports
welding
1.按图对支座的底板、筋板、立板进行组装前的检查。
Inaccordancewithdrawings,inspectthesupportsbackplane,ribs,riserbeforeassembling.
2.组装各部件,点固,加支撑件等,焊接。
Assembleeverycomponent,solidpoint,supportpieces,andwelding.
接管支座与壳体组装Nozzlesupportsandshellassembling
1.按先前标出的0°、90°、180°、270°方位点,延长在壳体上。
Baseonthepreviouslymarked0°,90°,180°,270compasspoints°,extendingtothehcase.
2.画出接管、支座,预开孔,安装位置,即坐标点。
Drawthenozzle,supports,pre-openings,theinstallationlocation,thatis,thecoordinatesofpoints
3.检验合格后,开孔,然后打上坡口,角度为外坡口30°AfterInspection,opening,thengrooving,theangleoftheoutergrooveis30°
4.组对接管与壳体,组装前,接管必须将补强圈带上固定好,一起装配。
Connectnozzletoshell,beforeassembling,thenozzlemustfixthereinforcementring,alongwiththeequipment.
5.接管与壳体组对间隙为2~3mm,且间隙均匀。
Thegapofthenozzleandshellis2~3mm,andthegapisuniform
6.焊接完毕后,内接管须清根封底,焊缝打磨与母材齐,并倒2×45°圆角。
Afterwelding,tonozzlerequirestocleartherootofthebackcover,weldandpolisetoensurethebasemetallevel,andthefilletis2×45°.
管箱
Tubebox
1.封头:
材质确认,标记移植,切割,外协模压,回厂检验,材质为(),δ()。
Head:
Materialconfirmation,markandtransplante,cutting,outsourcingmolding,backtothefactoryinspection,thematerialis(),δ().
2.短节:
材质确认a.按排版图尺寸划线下料坡口加工。
(见具体工艺文件)Shortsection:
materialconfirmationa.Drawing,crossedmaterialandgrooveprocessingbythesizeofthelayoutchart.(Seethespecificprocessdocuments).
b.卷板,纵缝焊接,校圆,纵缝RT≥()%,Ⅲ级合格,车加工削薄。
b.coil,longitudinalseamwelding,regulateround,longitudinalseamRT≥(),IIIclassqualified,vehicleprocessingthinning.
3.管箱法兰与短节组装:
a.管箱法兰与短节组焊,封头与短节组焊。
Flangeandshortsectionofthetubeboxassembly:
a.tubeboxflangeandashortsectionwelding,theheadandashortsectionwelding。
b.对环缝进行射线检测。
Ringsewn-raydetection.
c.与壳体联接,整体划线,开孔,接管组装,焊接,确保其整体一致性。
Connectionwiththeshell,theoveralldrawing,openings,nozzleassembly,welding,ensurethatitsoverallconsistency.
d.卸下管箱,对接管法兰清根封底,划出隔板安装线,再按封头实样放样切割,装配隔板和焊接,装配要求:
每层隔板端口尺寸必须与固定端管板()槽一致吻合。
(d)Removethetubebox,cleartherootofthenozzleoftheflange,drawthebulkheadinstallline,andthencuttingbaseontherealshapeofthehead,assemblingthebulkheadandwelding,assemblyrequirements:
eachpartitionportsizemustbeconsistentwiththefixedendofthetubeplate()notch.
e.做好热处理前支撑,防止热处理使隔板变形。
Dogoodsupportbeforeheattreatmenttopreventheattreatmentsothatbulkheaddeformation
f.热处理完毕冷却后,再加工密封面,保证法兰密封面与隔板端平面一致。
Aftertheheattreatmentandcooling,reprocessingthesealingsurfacetoensuretheflangesealingsurfaceandthebaffle-sideplaneconsistent.
外头盖theoutside
bonnet
1.封头:
材质确认划线,标记移植,切割,外协模压,回厂检验,贴合格标签。
Head:
Thematerialconfirmation,markandtransplante,cutting,outsourcingmolded,backtothefactoryinspection,pastequalifiedlabel.
2.短节:
材质确认按图尺寸划线,切割,坡口精加工,卷板,焊接,校园。
Shortsections:
materialsconfirmationdrawingbaseonthesizeofthechart,cuttingandfinishingofthegroove,platebending,welding,regulateround.
3.法兰与封头,短节组焊:
a.将合格封头和短节及对应法兰组焊,错边量控制在0~2mm之间。
Flangeandthehead,ashortsectionofwelding:
(a)weldingthequalifiedhead,ashortsectionandthecorrespondingflange,thestaggervolumeiscontrolledbetween0~2mm.
b.环缝焊接,无损检测。
(b).Thegirthwelding,nondestructivetesting.
c.划线开孔,安装管嘴和吊耳,焊接(c).Drawingandopening,installthenozzleandlug,welding.
d.与壳体、管箱、浮头盖,一并整体热处理。
(d).Theshell,tubebox,floatingcover,togetherwiththeoverallheattreatment.
浮头盖Floatingbonnet
1.拱盖:
材质确认划线下料,标记移植、切割,外协模压、回厂检验。
Ledge:
materialconfirmationDrawingandcutting,marktransplantation,cutting,outsourcingmolding,backtothefactoryinspection.
2.浮头法兰:
在材料检验员指定下领取贴有合格标签的法兰。
Floatingheadflange:
receivedesignatedqualifiedlabeloftheflangeundertheguidianceofthematerialsinspector.
3.将拱盖与浮头法兰组装,装配尺寸如图。
Assembleledgeandfloatingheadflange,theassemblysizeshowninFigure。
4.焊接完毕后,再按拱盖的实形放样、隔板、切割、组装、焊接,确保隔板装配尺寸与浮动管板槽尺寸一致。
Afterwelding,thethenloftbaseontherealshape,bulkhead,cutting,assembling,welding,ensuresizeofthebulkhead,assemblysizeandfloatingtubenotchgrooveconsistent.
5.与前壳体、外头盖及管箱一并进炉热处理。
Havingaheattreatmentfurnacetothefrontshell,theoutsidebonnetandthetubebox.
管束tubebundle
换热管
1.材质确认:
φ()×()规格()。
Materialconfirmation:
φ()×()Specification().
2.单管试压,试验压力为设计压力的2倍,即()MPa。
Single-tubetestingpressure,thepressureis2timesthedesignpressure,thatis()MPa.
管板
本锻件应按JB4726制造与验收,进行PT检测,依图数控放样、钻孔、隔板槽铣加工、倒坡口、拉丝孔攻丝。
TheforgingsshallbeJB4726manufactureandacceptance,PTdetection,accordingtoFigureNCloft,drilling,thebulkhead.slotmilling,chamferthegroove,wiredrawingholetapping.
折流板
1.材质确认,Q235B,δ16,数控放样切割,去渣,整形,打垛点固焊。
Materialconfirmation,Q235,δ16,CNCcuttingloft,removetheresidue,shaping,playingstackpointofsolidwelding.
2.数控划线,钻孔,折流板车园,做标记顺序号,单块剪切去毛刺。
NCdrawing,drilling,baffletocarround,marktheordernumber,asingleblockofsheardeburring.
3.顺序号移植,管孔倒角,折流板打磨,整形。
Sequencenumbertransplantation,porechamfer,bafflepolished,plastic
管束
其它
辅件
加工
定距管机加工,拉杆端点过丝,滑道旁路挡板剪切下料、整形。
Distancetubemachining,rodendpointwire,slidethebypassdampershearcutting,shaping.
管束
组装
1.立架:
先将固定管板直于工装平台架上,依次按图安装拉杆、距管、折流板,锁紧拉杆螺姆。
Stands:
firstfixedtubeplatestraighttothetoolingplatformrack,followedbytheplantoinstalltherod,thedistancetube,baffle,