復(fù)合板壓力容器制造工藝設(shè)計(jì)規(guī)程修改

1、.PAGE . . 1 . . . w d . SMS3128-2011第1版復(fù)合板壓力容器制造工藝規(guī)程THE FABRICATION PROCEDURE SPECIFICATION OF CLAD PLATE PRESURE VESSEL 森松壓力容器地址：中國浦東新區(qū)金聞路29號(hào) ：201323 ：0086-21-33756881：0086-21-38112058：morimorimatsu.2011年03月20日發(fā)布2011年03月20日實(shí)施目 錄1目的 Purpose為保證復(fù)合板制壓力容器制造質(zhì)量，正確指導(dǎo)施工、檢驗(yàn)等，特制訂本規(guī)程。This procedure is prepared

2、 for ensuring the fabrication quality of clad plate pressure vessel and guiding the construction, inspection and so on.2適用圍Scope of application2.1.本規(guī)程適用于不銹鋼、鎳及鎳基合金與碳鋼、低合金鋼,鎳及鎳基合金與不銹鋼具有良好可焊性的復(fù)合板設(shè)備的制造。This procedure is applied to the equipment that fabrication with clad plates which have good weldabil

3、ity and are posed of stainless steel, nickel and nickel alloy with carbon steelor low alloy steel,nickel and nickel alloy with stainless steel.2.2.本規(guī)程不適用于鈦、鋯及其合金與鋼或不銹鋼的復(fù)合板設(shè)備的制造。This procedure is not applied to the equipment that fabrication with clad plates which are posed of titanium, zirconium or

4、their alloy with steelor stainless steel.2.3.本規(guī)程為制造過程中必須遵循的工藝原則。工藝編制、施工制作、工序檢驗(yàn)等各環(huán)節(jié)必須遵守。This procedure shall be plied as process principle during fabrication. Process piled, construction, inspection and other processes shall ply with it.3. 原材料的管理The administration of material 原材料管理除遵守公司壓力容器采購與材料管理規(guī)程外

5、，還應(yīng)遵守以下規(guī)定：The administration of material shall ply with and conform to the following regulations: 3.1原材料的采購除遵照用戶技術(shù)文件外，還應(yīng)遵照NBT47002.1-2009壓力容器爆炸復(fù)合板不銹鋼-鋼復(fù)合板、NBT47002.2-2009壓力容器爆炸復(fù)合板鎳-鋼復(fù)合板The purchase of material shall ply with the documents submitted by buyer and conform to NBT47002.1-2009 and NBT4700

6、2.2-2009.3.2材料驗(yàn)收合格后應(yīng)做好標(biāo)記，標(biāo)記應(yīng)采用無氯無硫記號(hào)筆書寫，不得在復(fù)層打鋼印。并對(duì)特材不包括普通不銹鋼復(fù)層貼膜保護(hù)，復(fù)層為特材的應(yīng)按特材設(shè)備材料保護(hù)及加工的重要考前須知要求進(jìn)展保護(hù)。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

7、 materials (not including normal stainless steel) shall be protected with film. If the cladding is special materials, it shall be protected according to .3.3材料堆放時(shí)復(fù)層應(yīng)朝上，每層間應(yīng)墊木板或橡膠板。The cladding shall be up when the plates are stacked, wood plate or rubber plate shall be put on between them.3.4 吊運(yùn)和擺料時(shí)

8、，應(yīng)防止復(fù)層外表劃傷，不允許鋼絲繩和其它碳鋼夾具與復(fù)層直接接觸，制止在復(fù)層上走動(dòng)，不得讓復(fù)層沾染油污、鐵離子或其它污物。吊運(yùn)轉(zhuǎn)序按設(shè)備件零部件儲(chǔ)存運(yùn)輸管理規(guī)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 forb

9、idden, and the cladding surface shall be free of oil, iron and other contamination. Swing and transferring shall be performed according to 4切割下料Cutting 4.1 下料前，應(yīng)檢查材料外表質(zhì)量，包括局部凹陷和劃傷情況，外表質(zhì)量合格才能下料，如復(fù)層外表有局部傷痕、刻槽等，則應(yīng)修磨，修磨深度不應(yīng)超過復(fù)層厚度的30%，且不大于1mm，修磨圍的斜度至少為1：3，且應(yīng)有良好的圓滑過渡。Before cutting, the surface quality of

10、 materials shall be checked, including portion sag and scratch conditions, cutting 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 e*ceed 30% of the clad layer thickn

11、ess and not more than 1mm, the pitch of grind shall be 1:3 at least and have good smooth transition.4.2下料時(shí)，復(fù)層面應(yīng)朝上，對(duì)于復(fù)合板總厚度不大于60mm，采用等離子直接切割；對(duì)于復(fù)合板總厚度大于60mm，應(yīng)將割縫處的復(fù)層剝掉，然后用氧-乙炔切割，割口兩邊應(yīng)涂保護(hù)涂料，如白堊粉等，以免飛濺物影響復(fù)層外表質(zhì)量。切割前，應(yīng)進(jìn)展標(biāo)記移植先在復(fù)層用記號(hào)筆移植，待工件翻身后再在碳鋼基層上移植并打鋼印。During cutting, the cladding surface shall be put u

12、p. For the total thickness of the clad plates not more than 60mm, the plasma 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 o*y-acetylene to cut them, the area adjacent to the cutti

13、ng area shall be protected by painting chalkiness powder to avoid the spatter 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

14、.)4.3刨邊機(jī)加工坡口時(shí)，嚴(yán)防刨邊機(jī)機(jī)油污染復(fù)層外表，刨邊機(jī)夾具處應(yīng)用不銹鋼墊板隔開。When use planer machine to process the 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.4.4用等離子或氧-乙炔切割的坡口，需用砂輪或風(fēng)鏟打掉熔渣，并去除11.

15、5mm的切割影響區(qū)，打磨過碳鋼的砂輪片不得用來打磨復(fù)層打磨碳鋼的砂輪片應(yīng)該用油漆做好標(biāo)記，如用紅色油漆。The grooves which are cut by plasma or o*y-acetylene shall be ground with grinding wheel or wind shovel to remove the slag. And the 11.5mm of cutting HAZ shall be removed. The piece of the grinding wheel which grinds the carbon steel shall not be u

16、sed for grinding the cladding (The piece of the grinding wheel which grinds the carbon steel shall be marked by paint, such as red paint).4.5筒體下料尺寸要求：為了保證環(huán)縫組對(duì)錯(cuò)邊量，對(duì)筒體展開長度應(yīng)嚴(yán)格控制，相鄰兩筒節(jié)長度偏差不大于5mm；筒體展開長度應(yīng)按封頭實(shí)測外周長換算成徑，以經(jīng)為基準(zhǔn)計(jì)算展開長度。對(duì)于厚壁容器要考慮卷制伸長量，具體按厚壁容器制造工藝規(guī)程確定。The requirements for the cutting dimension of

17、the shell: In order to ensure the misalignment of the circumferential welds during assembly, 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 a

18、ccording to the true measurement and calculate the true open up length shall base on the inner diameter of end. For the thick wall vessel which shall regard the elongation, the specific requirement shall be performed according to .4.6錐體下料尺寸要求：按有關(guān)文件規(guī)定及具體產(chǎn)品工藝文件要求放余量下料。The requirements of the cutting d

19、imension for cone: it shall be performed according to the requirements of the corresponding document and specified process document of equipment.坡口加工后，基層外表弱酸試驗(yàn)，具體按復(fù)合板坡口外表酸蝕試驗(yàn)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

20、 forming 筒體一般采取冷卷成形；錐體宜采取冷壓成形。Shell is usually formed with cold rolling; cone is usually formed with cold pressing.5.1 卷板前必須將卷板機(jī)上輥外表的鐵屑、毛刺、銹斑、油污等雜物去除干凈，并用砂紙打磨光滑。Before rolling the plate, the iron, fragments, rust, oil and other contaminations on the surface of roller shall be removed cleanly and gro

21、und smoothly by sand paper.5.2卷板機(jī)上輥應(yīng)用塑料薄膜或不銹鋼薄板包住，以保護(hù)復(fù)層外表。The roller of the rolling machine shall be covered by plastic film or thinner stainless steel to protect the surface of the cladding.5.3 卷制前應(yīng)先壓頭，壓頭應(yīng)在油壓機(jī)或卷板機(jī)上進(jìn)展。如用油壓機(jī)壓頭，在模具與復(fù)板之間應(yīng)襯墊810mm厚不銹鋼板。對(duì)于厚壁容器是否加放壓頭量以及成形前的準(zhǔn)備，按厚壁容器制造工藝守則規(guī)定執(zhí)行。壓頭曲率用樣板控制，樣板弦長

22、不小于300mm，并符合相關(guān)標(biāo)準(zhǔn)要求。The head shall be pressed before rolling, and pressing head shall be done on the oil 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 mea

23、sure of the head shall be set or not and the preparation before formation shall be according to .The curvature of the pressing head shall be controlled by former, and the string length of the former shall be not less than 300mm and shall ply with the requirement of corresponding regulation.5.4卷制時(shí)應(yīng)控制

24、上輥的下壓量，在同一段區(qū)域不宜屢次反復(fù)碾壓。The down pressing measurement of up roller shall be controlled during rolling, and too many times on the same area is forbidden.5.5錐體冷壓成形一般分2到3片壓制，對(duì)于厚度大于60mm的錐體，應(yīng)分成3片壓制。壓制前，在扇形板片上復(fù)層面畫等分素線。壓制時(shí)，復(fù)層與上模間應(yīng)用810mm厚不銹鋼板條墊好，然后沿素線壓制。大、小口曲率用樣板控制。The cone shall be divided to two or three pi

25、eces for cold pressing forming. For the thickness more than 60mm, the cone shall be divided to three pieces. 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

26、 shall be pressed along the line. The former shall be used to control the big and small vent curvature.6熱成形或溫成形Hot forming or warm forming 凸形封頭整體宜采取熱成形或溫成形。不得采用旋壓成形。成形過程中，主要保證基層的力學(xué)性能和復(fù)層的耐腐蝕性能。如采取整體冷壓成形應(yīng)經(jīng)工藝責(zé)任工程師批準(zhǔn)。The gibbose head should be adopted hot forming or warm forming and the spin pressure fo

27、rming is forbidden. During the forming, the mechanical properties of the backing and the corrosion resistance of the cladding shall be mainly ensured. In case of adopting cold forming, the procedure shall be approved by process responsibility engineer.6.1對(duì)于奧氏體不銹鋼復(fù)合板宜采取熱成形，熱成形時(shí)，升溫速度應(yīng)較同等厚度的碳鋼或合金鋼慢。沖壓時(shí)

28、，為了防止溫差應(yīng)力過大而影響了兩種不同金屬間的結(jié)合強(qiáng)度，還應(yīng)使模具有一定的預(yù)熱溫度。具體應(yīng)按封頭數(shù)據(jù)表要求執(zhí)行。熱成形一般采取控制溫度成形，不另外熱處理。對(duì)于特殊材料需要單獨(dú)熱處理的應(yīng)制定具體工藝。For the austenitic 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 durin

29、g hot forming. During punching, in order to avoid the big temperature difference stress to affect the coalescent 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 tempera

30、ture controlled to shape and other heat treatment is not need. For the special materials which need single heat treatment, the specific procedure shall be prepared.6.2對(duì)于其它材料的復(fù)合板成形，應(yīng)根據(jù)材料的性能，包括相變特性，制訂成形工藝。For other materials clad plate forming, the forming procedure shall be prepared according to the

31、properties of the material, including the photograph change character.6.3檢驗(yàn)要求Inspection requirements6.3.1形狀及尺寸檢驗(yàn)按相應(yīng)標(biāo)準(zhǔn)要求及具體工藝要求。The inspection of the shape and dimension shall be performed according to the requirements of the corresponding standards and the specific procedure.6.3.2成形后的封頭應(yīng)進(jìn)展100%UT檢測，檢

32、查復(fù)層與基層結(jié)合情況。The head after forming shall be inspected by 100% UT to check the coalescent conditions between cladding and backing.7組裝和焊接Assembly and welding7.1 筒體組對(duì)時(shí)，應(yīng)保證錯(cuò)邊量不大于復(fù)層厚度的50%，且不大于2mm。對(duì)于具體設(shè)備有特殊要求時(shí)，按工程要求執(zhí)行。對(duì)于接頭錯(cuò)邊處的焊縫應(yīng)平滑過渡。During the shell assembly, the misalignment shall be ensured to not more

33、than 50% of the cladding thickness and not more than 2mm. For the specific equipments which have special requirements shall be performed according to the request of the project. The welds on the misalignment of joints shall be transition smoothly.7.2 組裝時(shí)，盡量防止在復(fù)層上焊工裝卡具，如必須焊時(shí)，工裝、卡具與復(fù)層接觸的材料必須與復(fù)層材料一樣。防止

34、鐵基金屬與復(fù)層直接接觸。During assembly, the clamp welded to cladding should be avoided as far as possible, if it must be done, frock and clamp which contact with the cladding, the material of them shall be same with the clad material. In order to avoid ferro-material to contact with clad layer directly. 7.3 設(shè)備

35、開孔應(yīng)從向外切割，對(duì)于厚度不大于60mm的殼體用等離子切割，對(duì)于厚度大于60mm的殼體用氧-乙炔切割，氧-乙炔切割時(shí)應(yīng)先將切割線處復(fù)層剝離，再由向外切割。切割時(shí)應(yīng)在割口兩側(cè)80mm寬的圍涂上白堊粉或采用鋁板保護(hù)，防止飛濺物落在復(fù)層外表。切割后應(yīng)磨去熔渣，并對(duì)復(fù)層11.5mm切割熱影響區(qū)予以去除。然后組裝接收。The opening of the equipment shall be cut from inside to outside. For the total thickness of the shell not more than 60mm, the plasma cutting sha

36、ll be used; for the total thickness of the shell more than 60mm, the o*y-acetylene shall be used, the cladding that on the cutting seams shall be peeled off firstly and then use the o*y-acetylene to cut from inside to outside. During cutting, the area within 80mm width adjacent to the cutting area s

37、hall be protected by painting chalkiness powder or covered with aluminum plate to avoid the spatter dropping on the cladding surface. The slag shall be removed by grinding after cutting and the 11.5mm HAZ of the cladding also shall be removed, then assemble the nozzles. 7.4 接收與殼體的連接型式應(yīng)符合圖1要求，R應(yīng)根據(jù)接收壁

38、厚確定，一般應(yīng)大于3mm，基層R過渡層R復(fù)層R。接收與殼體的連接尺寸應(yīng)符合常用焊接坡口型式及焊接工藝選用一般原則要求。焊接前應(yīng)將接收抬起高于筒體約3mm或筒體板厚的10%，取小值。見圖2。對(duì)于大開孔DN300mm接收焊接時(shí)應(yīng)用防變形工裝支撐。焊接后要保證耐蝕層的厚度，特別對(duì)于管殼式換熱器的殼體與接收的連接，更要注意打磨后仍要保證耐蝕層厚度。換熱器殼體接收焊接時(shí)，一般應(yīng)從殼體部將接收焊到殼體上，用胎具和千斤頂從部將接收頂緊，并產(chǎn)生適量的反變形，然后從外部焊接收和補(bǔ)強(qiáng)圈，焊完冷卻后才能撤除胎具。換熱器殼體接收組裝后必須經(jīng)檢驗(yàn)員檢查后才可焊接。The type of connection betwe

39、en nozzle and shell shall conform to the requirement of figure 1. R shall be confirmed according to the thickness of nozzle wall and is more than 3mm generally, and the base R the transition layer R the cladding R. The dimension of connection between nozzle and shell shall conform to the requirement

40、. Before welding, the nozzle shall be put up more than the shell about 3mm or 10% of shell thickness and choose the small value, see figure 2. For the big opening holesDN300mmwelding, the defend deformation jigs shall be used for supporting and the thickness of corrosion resistance layer shall be en

41、sured after welding. Especially for the connection between the shell and nozzle of tube-shell e*changer, the thickness of the corrosion resistance layer shall be ensured after grinding. During welding the nozzle to shell of heat e*changer, the nozzle is usually welded to shell from inner of the shel

42、l firstly and should be tightened with block and jack from inner of the shell, and make it to product suitable opposition distortion, then weld the nozzle and reinforcement from outside, the block only can be removed after welding. The assembly of nozzle and shell of heat e*changer shall be checked

43、by inspector before welding. 此條在工序驗(yàn)收單中表達(dá)，并設(shè)置為停留點(diǎn)，檢驗(yàn)員確認(rèn)后再進(jìn)展后續(xù)工作。(This one shall be present on the procedure checklist, and the stop point shall be set up on here, other procedure can be done only after the inspector confirmation.)圖1 圖27.5 復(fù)合板設(shè)備主體縱環(huán)焊縫坡口要求結(jié)合面處基層低于結(jié)合面11.5mm，見圖3。The backing of main longi

44、tudinal and circumferential welds groove of the clad plate equipment on the coalescent area shall be lower than coalescent surface 11.5mm, see figure 3.圖3對(duì)于件要求焊在殼體基層的，應(yīng)將復(fù)層剝槽，剝槽寬度應(yīng)符合圖4要求。剝掉局部焊接應(yīng)按堆焊要求焊接。如果件要求全焊透，應(yīng)制定焊接工藝。For the internal which shall be welded to the backing of the shell, the cladding s

45、hall be grooved and the width of the groove shall conform to the requirement of figure 4. The welding of the grooved shall be performed according to the requirement of surfacing. If the internal requested to plete welding, the welding procedure shall be prepared.圖47.6 焊接Welding7.6.1不銹鋼復(fù)合鋼板容器連接復(fù)層的焊接如

46、殼體焊縫外表一般采用雙層堆焊。堆焊層外表的化學(xué)成分應(yīng)與復(fù)層金屬相匹配。堆焊層厚度應(yīng)至少等于復(fù)層厚度，但不應(yīng)超過復(fù)層厚度的兩倍。堆焊焊接方法優(yōu)先采用氬弧焊，假設(shè)采用手工焊條堆焊時(shí)，打底焊要求優(yōu)先采用3.2焊條。堆焊后原則上不進(jìn)展打磨，假設(shè)具體工程要求進(jìn)展打磨，或者焊接成型較差必須要打磨時(shí)，須通知檢驗(yàn)員見證，并要求打磨后外表進(jìn)展鐵素體測定，鐵素體含量12%為合格，超過12%需進(jìn)展PMI檢測。具體工程對(duì)鐵素體含量有特殊要求時(shí)，按具體工程要求執(zhí)行。The welding of cladding connection of the stainless steel clad plate vessel us

47、ually adopts double layer surfacing. The chemical position of the surfacing layer surface shall match with the cladding metal. The thickness of the surfacing layer shall be at least equal to and not more than two times of the thickness of the cladding. GTAW shall be adopted firstly, if adopting SMAW

48、, the 3.2 electrodeshall be used on root welding firstly. After surfacing, the surfacing surface neednt be ground, in case of the specific project request grinding or the welding forming is bad and the surface must be ground, the inspector shall be notified to witness. The ferrite content of the gri

49、nding surface shall be measured and the content of the ferrite less than 12% is acceptance and more than 12% is needed to be checked by PMI. The special requests for the ferrite contents of the specific project shall be performed according to the specific requirements of the project.7.6.2正式施焊前，應(yīng)按NB/

50、T47014的規(guī)定對(duì)復(fù)層進(jìn)展堆焊焊接工藝評(píng)定。當(dāng)有晶間腐蝕要求時(shí)，焊接工藝評(píng)定應(yīng)按有關(guān)標(biāo)準(zhǔn)進(jìn)展晶間腐蝕試驗(yàn)。焊接工藝評(píng)定所用的母材、焊接材料、熱處理制度均應(yīng)與產(chǎn)品一致熱處理時(shí)間允許累積計(jì)算。Before welding, the cladding surfacing welding procedure shall be qualified according to the provisions of NB/T47014. When the intergranular corrosion is requested, the welding procedure qualification shal

51、l include the intergranular corrosion test according to the related standards. Allthe base-metals, welding materials and the heat treatment procedures of welding procedure qualification shall be same with the product (the time of heat treatment permitted to calculate by cumulate).7.6.3具體設(shè)備的焊接按焊接工藝要求

52、施焊。The welding for the specific equipment shall be performed according to .7.6.4對(duì)于焊縫返修去除不合格焊縫時(shí)，應(yīng)保護(hù)好焊縫兩側(cè)的復(fù)層外表，如涂白堊粉或蓋鋁板保護(hù)。For repairing welds, the cladding surface adjacent to the welds shall be protected when removing the disqualification welds, such as painting the chalkiness powder or covered with

53、 aluminum plate. 8熱處理Heat treatment8.1零部件的熱處理：Heat treatment of the ponents8.1.1不銹鋼與碳鋼、低合金鋼復(fù)合板制封頭，錐體等零部件的熱成型工藝應(yīng)由工藝部門提交給外協(xié)單位，超過相變溫度的加熱工藝應(yīng)帶母材試板。The hot forming procedures for heads, cones or other ponents which are made of stainless steel with carbon steel, or low alloy steel clad plate shall be submi

54、tted to sub-contractor by process department, the base-metal test plate shall be taken when the temperature of which e*cesses the photography transfer temperature.8.1.2鎳及鎳基合金與碳鋼、低合金鋼復(fù)合板制封頭，錐體等零部件的熱成型工藝應(yīng)由工藝部門提交給外協(xié)單位，母材試板的要求與8.1.1一樣。The hot forming procedures for heads, cones or other ponents which are made of nic