換熱器制造工藝指導(dǎo)流程

1、筒節(jié) Tubesection1.材料確認：在材料管理員的指導(dǎo)下，對材料的標記確認。 Confirm material: under the guidance of materials administrator ,recognized the mark of the material。2.根據(jù)工藝排版圖將板料平鋪于切割架上，號料劃出切割線、刨邊線、檢查線。 According to process diagram ,layouting the material board on the shelves, cutting and draw the cutting line, plane edge

2、, checking line.3.坡口加工（見坡口工藝卡），完成后對坡口進行超聲檢測。Groove processing (see groove process card), Ultrasonic testingafter the completion of the groove。4.卷板：將坡口加工完好的板料置于卷板機上、下輥輪間，板料周長方向與輥輪垂直，縱向與輥輪平行。Coil: place the groove processing intact sheet on the rolling machine, between the upper and lower roller, the

3、sheet perimeter direction is vertical to the roller, and the longitudinal is parallel to the rooler.5.縱縫組對：將縱縫口兩端對齊，控制錯邊量，錯邊不大于1/4且不大于2mm，并點上引弧板。 Combine the longitudinal seam: Align both ends of the longitudinal seam, control the amount of the Staggered side,the staggered side is not greater than 1

4、/4 and not greater than 2mm, and point the arc plate.6.縱縫焊接，見焊接工藝卡。 Longitudinal seam welding, see the welding process card。7.校園：不園度控制在0.5%DN,且不大于5mm,DN1200,不大于7mm；棱角度，控制在S/10+2，且不大于5mm。Regulate to make sure it circle: Park, control the degree of of-roundness at 0.5% the DN, and not more than 5mm, t

5、he DN 1200,not more than 7mm; the angularity, should be controlled at S/10 +2, and not more than 5mm。筒體 TubeBody1.將各筒節(jié)按排版圖要求組對，各縫分布于0180，互錯180，環(huán)縫組對間隙02mm。 According to the requirements of each tube section layout diagram,combine them, each seam is distributed in the 0 to 180 , Stagger 180 ,the circu

6、mferential seam combination gap is 0 2mm.2.組對完畢后，從0、90、180、270四個方位檢測，直線度10%，且不大于4.5mm。.Detect after the combination of the 0 , 90 , 180 , 270 four orientation,10% straightness, and no larger than 4.5mm.3.環(huán)縫棱角度控制在S/10+2，且不大于5mm錯邊量。 Control the ring slit angular degree at S/10+2, no larger than 5mm St

7、aggerion of the volume.4.環(huán)縫組對時不可強行組裝，可用加減絲扣調(diào)節(jié)間隙，間隙在01.5mm最佳。 When combine the Circumferential seam ,we must not assemble forcibly,use the available subtraction threaded to adjust the gap, the gap is at best in the 0 1.5mm.5.確定錯邊值后，依次從最佳點入手，順勢而成，環(huán)縫錯邊量不得大于1/4板厚且不大于2mm。 Determining the value of the Sta

8、gger， start from the best point by turn, homeopathy to be it, the circumferential seam should not be than 1/4 plate thickness and not more than 2mm.6.對組裝后的筒體進行直線度檢測，四點方位，其最大差值不得大于4.5mm。Test the straightness after assembling the cylinder, four piont position, the maximum difference is not greater tha

9、n 4.5mm。筒體與法蘭組對 TubeBodyAndLawOrchidGroupTo1.法蘭必須是經(jīng)過檢驗，貼有合格標簽的，對應(yīng)的流水號和產(chǎn)品編號的。 The flange must be tested, labelled with a qualified label, the corresponding serial number and product number.2.用直尺劃出法蘭螺栓孔跨中線,與筒體縱縫線平行組裝。 Draw the flange bolt holes across the center line with a ruler, assemble and make su

10、re it parallel to the cylinder longitudinal suture.3.將裝一端法蘭的筒體,縱縫方向轉(zhuǎn)至90和270方位(即水平方向左、右兩側(cè)),均分法蘭孔,四等分。 Turn the one end installed flange of the cylinder, longitudinal seam direction to the 90 and 270 azimuth (horizontal left and right sides direction), divided equally flange holes, quartered。4.用鉛垂線或水平

11、尺將有一端法蘭的筒體調(diào)節(jié)好，要求0180跨中線與鉛垂線重合。Adjust the one end flange of the cylinder by the plumb line or level ruler, require the 0 to 180 crossing center line and plumb line to coincide with each other.5.組對另一端法蘭，即管箱法蘭鉛垂線與跨中等分線要求與上法蘭相同條件（即螺栓孔跨中）。Assemble the other end of the flange, thus the tube box flange plu

12、mb line shares the same condition with the middle-point line (thus the bolt hole is at the middle).6.裝配間隙01.5mm，錯邊量02mm。The assembly gap is 0 1.5mm, the staggr mount is 0 2mm.7.檢測兩端法蘭面水平度，用卷尺在0、90、180、270四個方位，測得殼體長，長度偏差2mm。筒體總長控制在（ ）3mm。 Detecte the level degrees of both ends of the flange, use the

13、tape measure at 0 , 90 , 180 , 270 four cardinal position, measure the shell length, the deviation is 2mm. The barrel length is contled at () 3mm。8.檢測、焊接完畢后，對筒體環(huán)縫內(nèi)打磨平，送探傷檢測，要求RT（ ）%，級合格。 After detection and welding, polished flat within the seam of the cylinder ring, sending the flaw to detect, requ

14、st the RT () class, III qualified.接管與法蘭Nozzle and the flange將坡口加工好的接口與相對應(yīng)法蘭進行組裝，要求：間隙34mm，錯邊在1.5mm以下，氬弧焊打底，全熔透結(jié)構(gòu)。焊接完成后送無損檢測，檢驗標準RT（ ）%，級合格。Assemble the groove machined nozzle with the corresponding flange， requirements: the gap is 3 4mm, the staggered side is less than 1.5mm, argon arc bottoming, fu

15、ll penetration structure. After welding,having a non-destructive testing, the inspection standards is RT () class, III qualified.支座點焊Supportswelding1.按圖對支座的底板、筋板、立板進行組裝前的檢查。In accordance with drawings, inspect the supports backplane, ribs, riser before assembling.2.組裝各部件，點固，加支撐件等，焊接。Assemble every c

16、omponent, solid point, support pieces, and welding.接管支座與殼體組裝Nozzle supports and shell assembling1.按先前標出的0、90、180、270方位點,延長在殼體上。Base on the previously marked 0 , 90 , 180 , 270 compass points, extending to the hcase.2.畫出接管、支座，預(yù)開孔，安裝位置，即坐標點。Draw the nozzle, supports, pre-openings, the installation loc

17、ation, that is, the coordinates of points3.檢驗合格后，開孔，然后打上坡口，角度為外坡口30After Inspection, opening, then grooving,the angle of the outer groove is30 4.組對接管與殼體，組裝前，接管必須將補強圈帶上固定好，一起裝配。Connect nozzle to shell, before assembling,the nozzle must fix the reinforcement ring,along with the equipment.5.接管與殼體組對間隙為2

18、3mm，且間隙均勻。The gap of the nozzle and shell is 2 3mm, and the gap is uniform6.焊接完畢后，內(nèi)接管須清根封底，焊縫打磨與母材齊，并倒245圓角。 CONTROL ShockwaveFlash.ShockwaveFlash.10 After welding, to nozzle requires to clear the root of the back cover, weld and polise to ensure the base metal level, and the fillet is 2 45 .管箱Tube

19、box1.封頭：材質(zhì)確認，標記移植，切割，外協(xié)模壓，回廠檢驗，材質(zhì)為（ ），（ ）。Head: Material confirmation , mark and transplante, cutting, outsourcing molding, back to the factory inspection, the material is (), ().2.短節(jié)：材質(zhì)確認 a.按排版圖尺寸劃線下料坡口加工。（見具體工藝文件） Short section: material confirmation a. Drawing, crossed material and groove process

20、ing by the size of the layout chart. (See the specific process documents). b.卷板，縱縫焊接，校圓，縱縫RT（ ）%，級合格，車加工削薄。 b. coil, longitudinal seam welding , regulate round, longitudinal seam RT (), III class qualified ,vehicle processing thinning.3.管箱法蘭與短節(jié)組裝：a.管箱法蘭與短節(jié)組焊，封頭與短節(jié)組焊。Flange and short section of the t

21、ube box assembly: a. tube box flange and a short section welding，the head and a short section welding。b.對環(huán)縫進行射線檢測。Ring sewn-ray detection.c.與殼體聯(lián)接，整體劃線，開孔，接管組裝，焊接，確保其整體一致性。Connection with the shell, the overall drawing，openings, nozzle assembly, welding, ensure that its overall consistency.d.卸下管箱，對接管

22、法蘭清根封底，劃出隔板安裝線，再按封頭實樣放樣切割，裝配隔板和焊接，裝配要求：每層隔板端口尺寸必須與固定端管板（ ）槽一致吻合。(d) Remove the tube box, clear the root of the nozzle of the flange, draw the bulkhead install line, and then cutting base on the real shape of the head, assembling the bulkhead and welding, assembly requirements:each partition port siz

23、e must be consistent with the fixed end of the tube plate () notch.e.做好熱處理前支撐，防止熱處理使隔板變形。 CONTROL ShockwaveFlash.ShockwaveFlash.10 Do good support before heat treatment to prevent heat treatment so that bulkhead deformationf.熱處理完畢冷卻后，再加工密封面，保證法蘭密封面與隔板端平面一致。After the heat treatment and cooling, repro

24、cessing the sealing surface to ensure the flange sealing surface and the baffle-side plane consistent.外頭蓋the outsidebonnet1.封頭:材質(zhì)確認 劃線,標記移植,切割,外協(xié)模壓,回廠檢驗,貼合格標簽。Head: The material confirmation, mark and transplante, cutting, outsourcing molded, back to the factory inspection, paste qualified label.2.短

25、節(jié):材質(zhì)確認 按圖尺寸劃線,切割,坡口精加工,卷板,焊接,校園。Short sections: materials confirmation drawing base on the size of the chart, cutting and finishing of the groove, plate bending, welding, regulate round.3.法蘭與封頭，短節(jié)組焊：a.將合格封頭和短節(jié)及對應(yīng)法蘭組焊，錯邊量控制在02mm之間。Flange and the head, a short section of welding: (a) welding the quali

26、fied head ,a short section and the corresponding flange, the stagger volume is controlled between 0 2mm.b.環(huán)縫焊接，無損檢測。(b).The girth welding, nondestructive testing.c.劃線開孔，安裝管嘴和吊耳，焊接 (c). Drawing and opening, install the nozzle and lug ,welding.d.與殼體、管箱、浮頭蓋，一并整體熱處理。(d).The shell, tube box, floating cov

27、er, together with the overall heat treatment.浮頭蓋Floating bonnet1.拱蓋：材質(zhì)確認 劃線下料，標記移植、切割，外協(xié)模壓、回廠檢驗。Ledge: material confirmation Drawing and cutting, mark transplantation, cutting, outsourcing molding, back to the factory inspection.2.浮頭法蘭：在材料檢驗員指定下領(lǐng)取貼有合格標簽的法蘭。 Floating head flange: receive designated q

28、ualified label of the flange under the guidiance of the materials inspector .3.將拱蓋與浮頭法蘭組裝，裝配尺寸如圖。Assemble ledge and floating head flange, the assembly size shown in Figure。4.焊接完畢后，再按拱蓋的實形放樣、隔板、切割、組裝、焊接，確保隔板裝配尺寸與浮動管板槽尺寸一致。After welding, the then loft base on the real shape, bulkhead,cutting, assembli

29、ng, welding, ensure size of the bulkhead, assembly size and floating tube notch groove consistent.5.與前殼體、外頭蓋及管箱一并進爐熱處理。Having a heat treatment furnace to the front shell, the outside bonnet and the tube box .管束tube bundle換熱管1材質(zhì)確認：（ ）（ ） 規(guī)格（ ）。Material confirmation: （ ）（ ） Specification().2單管試壓，試驗壓力為

30、設(shè)計壓力的2倍，即（ ）MPa。Single-tube testing pressure,the pressure is 2 times the design pressure,that is () MPa.管板本鍛件應(yīng)按JB4726制造與驗收，進行PT檢測，依圖數(shù)控放樣、鉆孔、隔板槽銑加工、倒坡口、拉絲孔攻絲。The forgings shall be JB4726 manufacture and acceptance ,PT detection, according to Figure NC loft, drilling, the bulkhead.slot milling, chamfe

31、r the groove, wire drawing hole tapping.折流板1.材質(zhì)確認，Q235B，16，數(shù)控放樣切割，去渣，整形，打垛點固焊。Material confirmation,Q235, 16, CNC cutting loft, remove the residue, shaping, playing stack point of solid welding.2.數(shù)控劃線，鉆孔，折流板車園，做標記順序號，單塊剪切去毛刺。NC drawing, drilling, baffle to car round, mark the order number, a single

32、block of shear deburring.3.順序號移植，管孔倒角，折流板打磨，整形。Sequence number transplantation, pore chamfer, baffle polished, plastic管束其它輔件加工定距管機加工，拉桿端點過絲，滑道旁路擋板剪切下料、整形。Distance tube machining, rod endpoint wire, slide the bypass damper shear cutting, shaping.管束組裝1.立架：先將固定管板直于工裝平臺架上，依次按圖安裝拉桿、距管、折流板，鎖緊拉桿螺姆。Stands:

33、first fixed tube plate straight to the tooling platform rack, followed by the plan to install the rod ,the distance tube, baffle, locking lever screw farm2.處理管板孔和管板面上的油污、銹蝕等。Dealing with the tube sheet holes and the tube sheet surface oil, corrosion, etc.3.穿管：穿管完畢后再上浮動管板，定尺定位，點焊，再回管。Tube cross: cros

34、sing the tube ,then installing the floating tube sheet, length positioning, spot welding and then back to the tube.4.管頭焊、切管、打磨、浮動端管頭焊，支耳調(diào)試，安裝焊接，管頭兩端熱處理。Tube head welding, tube cutting, polishing, floating side tube head welding, lugs debugging, install the welding, the tube head at both ends of heat

35、 treatment5.脹管（見脹管工藝卡），脹管器按編號到倉庫領(lǐng)用，規(guī)格為（ ）（ ）（ ）。Expander (see the expanding technology card), the expander by number to the warehouse recipients, specifications are （ ）（ ）（ ）.6.安裝滑道并焊接。Installation of slide and welding管束試壓管頭試壓，試驗壓力（ ）MPa（見試壓工藝）水壓試驗時下列情況為合格：無滲漏，無可見變形，過程中無異常響聲。Tube head pressure test,

36、 the test pressure is () MPa (see Pressure Test) .hydrostatic test, the following conditions are eligible: no leakage, no visible distortion, no abnormal noise in the process.整體試 壓overall pressure test1.將管束試壓合格后，裝入殼體中After passing the pressure test,put the bundle into the shell.2.安裝兩端管箱，浮頭蓋，裝配時注意墊片的

37、保護，均勻?qū)准菟ňo固。安裝管箱，浮頭蓋時，一定做好隔板槽和隔板銜接口標記，穩(wěn)合統(tǒng)一。Install both ends of tube box, floating bonnet ,pay attention to the protection of the gasket assembly, bolt a few pieces evenly. When installing the pipe box, floating head cover, be sure to do the partition groove and clapboard convergence mouth mark, stable co-unified.3.螺栓擰緊時，要分步驟，先預(yù)緊等分四顆，即0、90、180、270，再逐步對稱緊固。用力要均勻，最后對螺栓進行全面緊固。When tightening the bolts, step by step, decile four first , namely, 0 , 90 ,