复合板压力容器制造工艺规程修改.docx

1、复合板压力容器制造工艺规程修改SMS3128-2011第1版复合板压力容器制造工艺规程THE FABRICATION PROCEDURE SPECIFICATION OF CLAD PLATE PRESURE VESSEL 上海森松压力容器有限公司地址：中国上海浦东新区金闻路29号邮编：201323 传真：0086-21-电话：0086-21-E-mail 2011年03月20日发布 2011年03月20日实施1目的 Purpose为保证复合板制压力容器制造质量，正确指导施工、检验等，特制订本规程。This procedure is prepared for ensuring the fabr

2、ication quality of clad plate pressure vessel and guiding the construction, inspection and so on. 2适用范围Scope of application.本规程适用于不锈钢、镍及镍基合金与碳钢、低合金钢,镍及镍基合金与不锈钢具有良好可焊性的复合板设备的制造。This procedure is applied to the equipment that fabrication with clad plates which have good weldability and are composed of

3、 stainless steel, nickel and nickel alloy with carbon steel or low alloy steel, nickel and nickel alloy with stainless steel.本规程不适用于钛、锆及其合金与钢或不锈钢的复合板设备的制造。This procedure is not applied to the equipment that fabrication with clad plates which are composed of titanium, zirconium or their alloy with st

4、eel or stainless steel.本规程为制造过程中必须遵循的工艺原则。工艺编制、施工制作、工序检验等各环节必须遵守。This procedure shall be complied as process principle during fabrication. Process compiled, construction, inspection and other processes shall comply with it.3. 原材料的管理The administration of material 原材料管理除遵守公司压力容器采购与材料管理规程外，还应遵守以下规定：The

5、 administration of material shall comply with and conform to the following regulations: 原材料的采购除遵照用户技术文件外，还应遵照压力容器爆炸复合板（不锈钢-钢复合板）、压力容器爆炸复合板（镍-钢复合板）The purchase of material shall comply with the documents submitted by buyer and conform to and .材料验收合格后应做好标记，标记应采用无氯无硫记号笔书写，不得在复层打钢印。并对特材（不包括普通不锈钢）复层贴膜保护，

6、复层为特材的应按特材设备材料保护及加工的重要注意事项要求进行保护。The materials shall be marked with ink that doesnt contain chlorine and sulfur after they have been checked and accepted, and the steel markings shall not be made on the cladding surface. The special materials (not including normal stainless steel) shall be protected

7、 with film. If the cladding is special materials, it shall be protected according to .材料堆放时复层应朝上，每层间应垫木板或橡胶板。The cladding shall be up when the plates are stacked, wood plate or rubber plate shall be put on between them. 吊运和摆料时，应避免复层表面划伤，不允许钢丝绳和其它碳钢夹具与复层直接接触，禁止在复层上走动，不得让复层沾染油污、铁离子或其它污物。吊运转序按设备内件零部件储存

8、运输管理规程。During swing and putting, the scratch of the cladding surface shall be avoided, steel rope and other carbon steel clamp shall not be directly contacted with cladding surface, walking on the cladding surface shall be forbidden, and the cladding surface shall be free of oil, iron and other cont

9、amination. Swing and transferring shall be performed according to 4切割下料Cutting 下料前，应检查材料表面质量，包括局部凹陷和划伤情况，表面质量合格才能下料，如复层表面有局部伤痕、刻槽等，则应修磨，修磨深度不应超过复层厚度的30%，且不大于1mm，修磨范围的斜度至少为1：3，且应有良好的圆滑过渡。Before cutting, the surface quality of materials shall be checked, including portion sag and scratch conditions, c

10、utting should be done only after the acceptance of the quality, if the cladding surface have portion sag, scratch and so on, grind shall be carried out and the depth of the grind shall not exceed 30% of the clad layer thickness and not more than 1mm, the pitch of grind shall be 1:3 at least and have

11、 good smooth transition.下料时，复层面应朝上，对于复合板总厚度不大于60mm，采用等离子直接切割；对于复合板总厚度大于60mm，应将割缝处的复层剥掉，然后用氧-乙炔切割，割口两边应涂保护涂料，如白垩粉等，以免飞溅物影响复层表面质量。切割前，应进行标记移植（先在复层用记号笔移植，待工件翻身后再在碳钢基层上移植并打钢印）。During cutting, the cladding surface shall be put up. For the total thickness of the clad plates not more than 60mm, the plasma

12、cutting shall be used; for the total thickness of the clad plates more than 60mm, the cladding that on the cutting seams shall be peeled off firstly and then use the oxy-acetylene to cut them, the area adjacent to the cutting area shall be protected by painting chalkiness powder to avoid the spatter

13、 dropping on the cladding surface. Before cutting, the markings shall be transferred (firstly, transfer the markings on the cladding surface, secondly, transfer the markings on the carbon steel after the plate is overturned.)刨边机加工坡口时，严防刨边机机油污染复层表面，刨边机夹具处应用不锈钢垫板隔开。When use planer machine to process t

14、he groove, the oil from the machine shall be strictly controlled to avoid it to drop on the cladding surface, the clamp of the planer machine shall be separated by stainless steel pad.用等离子或氧-乙炔切割的坡口，需用砂轮或风铲打掉熔渣，并去除1的切割影响区，打磨过碳钢的砂轮片不得用来打磨复层（打磨碳钢的砂轮片应该用油漆做好标记，如用红色油漆）。The grooves which are cut by plasm

15、a or oxy-acetylene shall be ground with grinding wheel or wind shovel to remove the slag. And the 1 of cutting HAZ shall be removed. The piece of the grinding wheel which grinds the carbon steel shall not be used for grinding the cladding (The piece of the grinding wheel which grinds the carbon stee

16、l shall be marked by paint, such as red paint).筒体下料尺寸要求：为了保证环缝组对错边量，对筒体展开长度应严格控制，相邻两筒节长度偏差不大于5mm；筒体展开长度应按封头实测外周长换算成内径，以内经为基准计算展开长度。对于厚壁容器要考虑卷制伸长量，具体按厚壁容器制造工艺规程确定。The requirements for the cutting dimension of the shell: In order to ensure the misalignment of the circumferential welds during assembly,

17、 the length of the open up shell shall be strictly controlled, and the deviation of two adjacent shell length shall be not more than 5mm; the length of the open up shell shall be conversed to inner diameter according to the true measurement and calculate the true open up length shall base on the inn

18、er diameter of end. For the thick wall vessel which shall regard the elongation, the specific requirement shall be performed according to .锥体下料尺寸要求：按有关文件规定及具体产品工艺文件要求放余量下料。The requirements of the cutting dimension for cone: it shall be performed according to the requirements of the corresponding doc

19、ument and specified process document of equipment.坡口加工后，基层表面弱酸试验，具体按复合板坡口表面酸蚀试验流程。After the groove processed, the backing shall be tested by weak acid and the specific requirements according to .5冷作成形 Cold forming 筒体一般采取冷卷成形；锥体宜采取冷压成形。Shell is usually formed with cold rolling; cone is usually formed

20、 with cold pressing. 卷板前必须将卷板机上辊表面的铁屑、毛刺、锈斑、油污等杂物清除干净，并用砂纸打磨光滑。Before rolling the plate, the iron, fragments, rust, oil and other contaminations on the surface of roller shall be removed cleanly and ground smoothly by sand paper.卷板机上辊应用塑料薄膜或不锈钢薄板包住，以保护复层表面。The roller of the rolling machine shall be

21、covered by plastic film or thinner stainless steel to protect the surface of the cladding. 卷制前应先压头，压头应在油压机或卷板机上进行。如用油压机压头，在模具与复板之间应衬垫810mm厚不锈钢板。对于厚壁容器是否加放压头量以及成形前的准备，按厚壁容器制造工艺守则规定执行。压头曲率用样板控制，样板弦长不小于300mm，并符合相关标准要求。The head shall be pressed before rolling, and pressing head shall be done on the oil

22、pressing machine or rolling machine. If using the oil pressing machine, 810mm thickness stainless steel shall be put on between the mould and clad plate. For the thick wall vessel, whether the measure of the head shall be set or not and the preparation before formation shall be according to .The cur

23、vature of the pressing head shall be controlled by former, and the string length of the former shall be not less than 300mm and shall comply with the requirement of corresponding regulation.卷制时应控制上辊的下压量，在同一段区域不宜多次反复碾压。The down pressing measurement of up roller shall be controlled during rolling, and

24、 too many times on the same area is forbidden.锥体冷压成形一般分2到3片压制，对于厚度大于60mm的锥体，应分成3片压制。压制前，在扇形板片上复层面画等分素线。压制时，复层与上模间应用810mm厚不锈钢板条垫好，然后沿素线压制。大、小口曲率用样板控制。The cone shall be divided to two or three pieces for cold pressing forming. For the thickness more than 60mm, the cone shall be divided to three pieces

25、. Before forming, cladding surface of the sector shall be drawn with line. During forming, the cladding and upper mould shall be filled up with 810mm thickness stainless steel, and the cladding shall be pressed along the line. The former shall be used to control the big and small vent curvature.6热成形

26、或温成形Hot forming or warm forming 凸形封头整体宜采取热成形或温成形。不得采用旋压成形。成形过程中，主要保证基层的力学性能和复层的耐腐蚀性能。如采取整体冷压成形应经工艺责任工程师批准。The gibbose head should be adopted hot forming or warm forming and the spin pressure forming is forbidden. During the forming, the mechanical properties of the backing and the corrosion resistan

27、ce of the cladding shall be mainly ensured. In case of adopting cold forming, the procedure shall be approved by process responsibility engineer.对于奥氏体不锈钢复合板宜采取热成形，热成形时，升温速度应较同等厚度的碳钢或合金钢慢。冲压时，为了避免温差应力过大而影响了两种不同金属间的结合强度，还应使模具有一定的预热温度。具体应按封头数据表要求执行。热成形一般采取控制温度成形，不另外热处理。对于特殊材料需要单独热处理的应制定具体工艺。For the aus

28、tenitic stainless steel clad plate, hot forming should be used. The speed of the temperature raising shall be slower than the carbon steel and alloy steel which are with same thickness during hot forming. During punching, in order to avoid the big temperature difference stress to affect the coalesce

29、nt strength between two different metals, the mould shall be with definite preheat temperature. The specific requirements shall be performed according to . Hot forming usually adopts temperature controlled to shape and other heat treatment is not need. For the special materials which need single hea

30、t treatment, the specific procedure shall be prepared.对于其它材料的复合板成形，应根据材料的性能，包括相变特性，制订成形工艺。For other materials clad plate forming, the forming procedure shall be prepared according to the properties of the material, including the photograph change character.检验要求Inspection requirements形状及尺寸检验按相应标准要求及具体工艺要求。The inspection of the shape and dimension shall be performed according to the requirements of the corresponding standards and the specific procedure.成形后的封头应进行100%UT检测，检查复层与基层结合情况。The head after forming s