换热器制造工艺指导流程7979.docx

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1、浮头式换热器制造工艺作业指导书 Floating head heat exchanger manufacturing operating instructions筒节Tuubesecttionn1.材料料确认：在材料料管理员员的指导导下，对对材料的的标记确确认。CConffirmmmateeriaal: undder thee guuidaancee off mmateeriaals admminiistrratoor ,reccognnizeed tthe marrk oof tthe matteriial。2.根据据工艺排排版图将将板料平平铺于切切割架上上，号料料划出切切割线、刨刨边线、检

2、检查线。According to process diagram ,layouting the material board on the shelves, cutting and draw the cutting line, plane edge, checking line.3.坡口口加工（见见坡口工工艺卡），完完成后对对坡口进进行超声声检测。Groove processing (see groove process card), Ultrasonic testingafteer tthe commpleetioon oof tthe grooovee。4.卷板板：将坡坡口加工工完好的的板

3、料置置于卷板板机上、下下辊轮间间，板料料周长方方向与辊辊轮垂直直，纵向向与辊轮轮平行。Coil: place the groove processing intact sheet on the rolling machine, between the upperand lower roller, the sheet perimeter direction is vertical to the roller, and thelongitudinal is parallel to the rooler.5.纵缝缝组对：将纵缝缝口两端端对齐，控控制错边边量，错错边不大大于1/4且且不大于于2mm，并

4、并点上引引弧板。Combinethe longitudinal seam: Alignboth ends of the longitudinal seam, control the amount of the Staggeredside,thestaggered side is not greater than 1/4 and not greater than 2mm, and point the arc plate.6.纵缝缝焊接，见见焊接工工艺卡。Longitudinal seam welding, see the welding process card。7.校园园：不园园度控制制在0.

5、5%DDN,且且不大于于5mmm,DNN12200,不大于于7mmm；棱角角度，控控制在S/100+2，且且不大于于5mm。Reggulaate to makke ssuree itt ciirclle: Parrk, coontrrol thee deegreee oofof-rrounndneessaat 00.5% thhe DDN, andd noot mmoree thhan 5mmm, tthe DN 112000,nootmoore thaan 77mm; thhe aanguularrityy, sshouuld be conntroolleed aat S/110 +2, a

6、ndd noot mmoree thhan 5mmm。筒体 TTubeeBoddy1.将各各筒节按按排版图图要求组组对，各各缝分布布于01800，互互错1880，环环缝组对对间隙002mm。Acccorddingg tootheereqquirremeentssofeachh tuube secctioon llayoout diaagraam,ccombbinee thhem, eaach seaam iis ddisttribbuteed iin tthe 0 tto 1180 ,Staaggeer 1180 ,tthe cirrcummferrenttiall seeam commbin

7、natiion gapp iss 0 22mm.2.组对对完毕后后，从00、990、1180、2770四四个方位位检测，直直线度110%，且且不大于于4.55mm。.Deteect aftter thee coombiinattionn off thhe 00 , 900 , 1880 , 2270 ffourr orrienntattionn,10% sttraiighttnesss, andd noo laargeer tthann 4.5mmm.3.环缝缝棱角度度控制在在S/100+2，且且不大于于5mm错边边量。CConttroll thhe rringg sllit anggulaa

8、r ddegrree at S/110+22, nno llargger thaan 55mm Staaggeerioon oof tthe vollumee.4.环缝缝组对时时不可强强行组装装，可用用加减丝丝扣调节节间隙，间间隙在001.5mm最佳佳。Whenn coombiine thee Ciircuumfeerenntiaal sseamm ,wwe mmustt noot aasseemblle foorciiblyy,usse tthe avaailaablee suubtrracttionn thhreaadedd too addjusst tthe gapp, tthe gap

9、p iss att beest in thee 0 11.5mmm.5.确定定错边值值后，依依次从最最佳点入入手，顺顺势而成成，环缝缝错边量量不得大大于1/4板板厚且不不大于22mm。Dettermminiing thee vaaluee off thheSttaggger，staart froom tthe besst ppoinnt bby tturnn, hhomeeopaathyy too bee itt,thhe ccirccumffereentiial seaamshhoulld nnot be thaan 11/4 pllatee thhickknesss aand nott m

10、oore thaan 22mm.6.对组组装后的的筒体进进行直线线度检测测，四点点方位，其其最大差差值不得得大于44.5mmm。Testt thhe sstraaighhtneess aftter asssembblinng tthe cyllindder, foour pioont possitiion, thhe mmaxiimummdiffferrencce iis nnot greeateer tthann 4.5mmm。筒体与法兰组对TuubeBBodyyAnddLawwOrcchiddGrooupTTo1.法兰兰必须是是经过检检验，贴贴有合格格标签的的，对应应的流水水号和产产品编号

11、号的。TThe flaangee muust be tesstedd,labeelled witth aa quualiifieed llabeel, thee coorreespoondiing serriall nuumbeer aand prooducct nnumbber.2.用直直尺划出出法兰螺螺栓孔跨跨中线,与筒体体纵缝线线平行组组装。DDraww thhe fflannge bollt hholees aacrooss thee ceenteer llinee wiith a rruleer, asssembbleandd maake surre iit pparaalleel

12、tto tthe cyllindder lonngittudiinall suuturre.3.将装装一端法法兰的筒筒体,纵纵缝方向向转至990和和2700方位位(即水水平方向向左、右两两侧),均分法法兰孔,四等分分。Tuurn thee onne eend insstallledd fllangge oof tthe cyllindder, loongiituddinaal sseamm diirecctioon tto tthe 90 aand 2700 aziimutth (horrizoontaal lleftt annd rrighht ssidees ddireectiion),

13、ddiviidedd eqquallly flaangee hooless, qquarrterred。4.用铅铅垂线或或水平尺尺将有一一端法兰兰的筒体体调节好好，要求求01800跨中中线与铅铅垂线重重合。AAdjuust thee onne eend flaangee off thhe ccyliindeer bby tthe pluumb linne oor lleveel rruleer, reqquirre tthe 0 too 1880 crrosssingg ceenteer llinee annd pplummb llinee too cooinccidee wiith eacc

14、h ootheer.5.组对对另一端端法兰，即即管箱法法兰铅垂垂线与跨跨中等分分线要求求与上法法兰相同同条件（即即螺栓孔孔跨中）。Assemble the other end of the flange, thus the tube box flange plumb line shares the same condition with the middle-point line (thus the bolt hole is at the middle).6.装配配间隙001.5mm，错错边量002mmm。Theeasseemblly ggap is 0 1.55mm, thhe sstagg

15、rr moountt iss 0 22mm.7.检测测两端法法兰面水水平度，用用卷尺在在0、990、1180、2770四四个方位位，测得得壳体长长，长度度偏差22mm。筒筒体总长长控制在在（ ）33mm。Dettecttethhe lleveel ddegrreess off booth endds oof tthe flaangee, uuse thee taape meaasurre aat 00 , 900 , 1880 , 2270 foour carrdinnal possitiion, meeasuuretthe sheell lenngthh, tthe devviattionn

16、 iss 2mm. Thhe bbarrrel lenngthh iss coontlled at () 33mm。8.检测测、焊接接完毕后后，对筒筒体环缝缝内打磨磨平，送送探伤检检测，要要求RTT（ ）%，级合格格。Afteer ddeteectiion andd weeldiing, poolisshedd fllat witthinn thhe sseamm off thhe ccyliindeer rringg, ssenddingg thhe fflaww too deetecct,reqqustt thhe RRT () cllasss, IIII qquallifiied.接管与

17、法法兰Noozzlle aand thee fllangge将坡口加加工好的的接口与与相对应应法兰进进行组装装，要求求：间隙隙344mm，错错边在11.5mmm以下下，氩弧弧焊打底底，全熔熔透结构构。焊接接完成后后送无损损检测，检检验标准准RT（ ）%，级级合格。Assemblethe groove machined nozzlewith the corresponding flange， requirements: the gap is 3 4mm, the staggered sideis less than 1.5mm, argon arc bottoming, full penetra

18、tion structure. After welding,having a non-destructive testing, the inspection standards is RT () class, III qualified.支座点焊焊Suppporrtswelddingg1.按图图对支座座的底板板、筋板板、立板板进行组组装前的的检查。In accordance with drawings, inspectthe supports backplane, ribs, riser before assembling.2.组装装各部件件，点固固，加支支撑件等等，焊接接。Asssemmbl

19、ee evveryy coompoonennt, sollid poiint, suuppoort pieecess, aand welldinng.接管支座座与壳体体组装NNozzzlessuppporttsannd sshelll aasseembllingg1.按先先前标出出的0、900、1180、2770方方位点,延长在在壳体上上。Basee onn thhe pprevviouuslyy maarkeed 00 , 900 , 1880 , 2270 comppasss poointts, exxtenndinng tto tthe hcaase.2.画出出接管、支座，预预开孔，安安

20、装位置置，即坐坐标点。DDraww thhe nnozzzle, suuppoortss, ppre-opeeninngs, thhe iinsttalllatiion loccatiion, thhat is, thhe ccoorrdinnatees oof ppoinnts3.检验验合格后后，开孔孔，然后后打上坡坡口，角角度为外外坡口330Afteer IInsppecttionn, oopenningg, tthenn grooovinng,thee annglee off thhe oouteer ggrooove is300 4.组对对接管与与壳体，组组装前，接接管必须须将补强强圈

21、带上上固定好好，一起起装配。Connectnozzle to shell, before assembling,the nozzle must fix the reinforcement ring,along with the equipment.5.接管管与壳体体组对间间隙为223mm，且且间隙均均匀。TThe gappof thee noozzlle aandsshelll iis 22 3mmm, aand thee gaap iis uunifformm6.焊接接完毕后后，内接接管须清清根封底底，焊缝缝打磨与与母材齐齐，并倒倒2445圆圆角。AAfteer wwelddingg, tt

22、o nnozzzle reqquirres to cleear thee rooot of thee baack covver, weeld andd poolisse tto eensuure thee baase mettal levvel, annd tthefillletiis 22 45 .管箱Tubee boox1.封头头：材质质确认，标标记移植植，切割割，外协协模压，回回厂检验验，材质质为（ ），（ ）。Head: Material confirmation, markand transplante, cutting, outsourcing molding, back to t

23、he factory inspection, the material is (), ().2.短节节：材质质确认 a.按排版版图尺寸寸划线下下料坡口口加工。（见见具体工工艺文件件） SShorrt ssecttionn: mmateeriaal cconffirmmatiion a. Drawwingg, ccrosssedd maaterriall annd ggrooove proocesssinng bby tthe sizze oof tthe layyoutt chhartt. (Seee thhe sspeccifiic pproccesss doocummentts). bb.

24、卷板板，纵缝缝焊接，校校圆，纵纵缝RTT（ ）%，级合格格，车加加工削薄薄。 bb. ccoill, llonggituudinnal seaam wwelddingg ,reggulaate rouund, loongiituddinaal sseamm RTT (), IIII cclasss qquallifiied ,vehhiclle pproccesssingg thhinnningg.3.管箱箱法兰与与短节组组装：aa.管箱箱法兰与与短节组组焊，封封头与短短节组焊焊。Fllangge aand shoort secctioon oof tthe tubbe bbox asssem

25、bbly: a. ttubee boox fflannge andd a shoort secctioon wwelddingg，thhe hheadd annd aa shhortt seectiion welldinng。b.对环环缝进行行射线检检测。RRingg seewn-rayy deetecctioon.c.与壳壳体联接接，整体体划线，开开孔，接接管组装装，焊接接，确保保其整体体一致性性。Coonneectiion witth tthe sheell, thhe ooverralll drrawiing，openings, nozzle assembly, welding, ens

26、ure that its overall consistency.d.卸下下管箱，对对接管法法兰清根根封底，划划出隔板板安装线线，再按按封头实实样放样样切割，装装配隔板板和焊接接，装配配要求：每层隔隔板端口口尺寸必必须与固固定端管管板（ ）槽一一致吻合合。(dd) RRemoove thee tuube boxx, ccleaar tthe roootoff thhenoozzlle oof tthe flaangee, ddraww thhe bbulkkheaadinnstaall linne, andd thhen cutttinng bbasee onn thhe rreall shh

27、apee off thheheead, asssemmbliing thee buulkhheadd annd wwelddingg, aasseemblly rrequuireemennts:eacch pparttitiion porrt ssizeemusst bbe cconssisttentt wiith thee fixeed eend of thee tuube plaate () nottch.e.做好好热处理理前支撑撑，防止止热处理理使隔板板变形。Do ggoodd suuppoortbbefoore heaat ttreaatmeent to preevennt hheat

28、t trreattmennt sso tthatt buulkhheadd deeforrmattionnf.热处处理完毕毕冷却后后，再加加工密封封面，保保证法兰兰密封面面与隔板板端平面面一致。After the heat treatment and cooling, reprocessing the sealing surface to ensure the flange sealing surface and the baffle-side plane consistent.外头盖tthe outssideebonnnet1.封头头:材质质确认划划线,标标记移植植,切割割,外协协模压,回厂

29、检检验,贴贴合格标标签。HHeadd: TThe matteriialcconffirmmatiion,marrk aand traanspplannte, ccutttingg, ooutssourrcinng mmoldded, baack to thee faactoory insspecctioon, passte quaaliffiedd laabell.2.短节节:材质质确认 按按图尺寸寸划线,切割,坡口精精加工,卷板,焊接,校园。Short sections: materials confirmation drawing base on the size of the chart

30、, cutting and finishing of the groove, plate bending, welding, regulate round.3.法兰兰与封头头，短节节组焊：a.将将合格封封头和短短节及对对应法兰兰组焊，错错边量控控制在002mmm之间间。Fllangge aand thee heead, a shoort secctioon oof wwelddingg: (a) welldinng tthe quaaliffiedd heead ,a sshorrt ssecttionn annd tthe corrressponndinng fflannge, thhe s

31、stagggerr voolumme iis cconttrollledd beetweeen 0 2mmm.b.环缝缝焊接，无无损检测测。(b).The girrth welldinng, nonndesstruuctiive tesstinng.c.划线线开孔，安安装管嘴嘴和吊耳耳，焊接接(c).Drawwingg aand opeeninng, insstalll tthe nozzzlee annd llug ,welldinng.d.与壳壳体、管管箱、浮浮头盖，一一并整体体热处理理。(dd).TThe sheell, tuube boxx, ffloaatinng ccoveer,

32、toggethher witth tthe oveeralll hheatt trreattmennt.浮头盖FFloaatinng bbonnnet1.拱盖盖：材质质确认 划划线下料料，标记记移植、切切割，外外协模压压、回厂厂检验。Ledge: material confirmation Drawing andcutting, mark transplantation, cutting, outsourcing molding, back to the factory inspection.2.浮头头法兰：在材料料检验员员指定下下领取贴贴有合格格标签的的法兰。Floating head fl

33、ange: receive designated qualified label of the flangeunder the guidiance of the materials inspector .3.将拱拱盖与浮浮头法兰兰组装，装装配尺寸寸如图。Asseemblle lledgge aand flooatiing heaad fflannge, thhe aasseemblly ssizee shhownn inn Fiigurre。4.焊接接完毕后后，再按按拱盖的的实形放放样、隔隔板、切切割、组组装、焊焊接，确确保隔板板装配尺尺寸与浮浮动管板板槽尺寸寸一致。After welding

34、, the then loft base on the realshape, bulkhead,cutting, assembling, welding, ensure size of the bulkhead, assembly size and floating tube notch groove consistent.5.与前前壳体、外外头盖及及管箱一一并进炉炉热处理理。Haavinnga heaat ttreaatmeent furrnacce tto tthe froont sheell, thhe ooutssidee boonneet aand thee tuube boxx .

35、管束tuube bunndlee换热管1材质质确认：（ ）（ ） 规格（ ）。MMateeriaal cconffirmmatiion:（ ）（ ） SSpeccifiicattionn().2单管管试压，试试验压力力为设计计压力的的2倍，即即（ ）MMPa。Single-tube testing pressure,the pressure is 2 times the design pressure,that is () MPa.管板本锻件应应按JBB47226制造造与验收收，进行行PT检检测，依依图数控控放样、钻钻孔、隔隔板槽铣铣加工、倒倒坡口、拉拉丝孔攻攻丝。TThe forrginng

36、s shaall be JB447266 maanuffactturee annd aacceeptaancee ,PT dettecttionn, aaccoordiing to Figguree NCC looft, drrilllingg, tthe bulkkheaad.sslott miilliing, chammferrthee grroovve, wirre ddrawwingg hoole tapppinng.折流板1.材质质确认，QQ2355B，16，数数控放样样切割，去去渣，整整形，打打垛点固固焊。MMateeriaal cconffirmmatiion,Q2335, 16

37、6,CNCC cuuttiing lofft,rremoove thee reesiddue, shhapiing, pllayiing staack poiint of sollid welldinng.2.数控控划线，钻钻孔，折折流板车车园，做做标记顺顺序号，单单块剪切切去毛刺刺。NCC drrawiing, drrilllingg, bbafffle to carr rooundd,markk thhe oordeer nnumbber, a sinnglee bllockk off shhearr deeburrrinng.3.顺序序号移植植，管孔孔倒角，折折流板打打磨，整整形。SSe

38、quuencce nnumbber trannspllanttatiion, poore chaamfeer, baffflee poolisshedd, pplassticc管束其它辅件加工定距管机机加工，拉拉杆端点点过丝，滑滑道旁路路挡板剪剪切下料料、整形形。Diistaancee tuube macchinningg, rrod enddpoiint wirre, sliide thee byypasss ddampper sheear cutttinng, shaapinng.管束组装1.立架架：先将将固定管管板直于于工装平平台架上上，依次次按图安安装拉杆杆、距管管、折流流板，锁锁紧拉

39、杆杆螺姆。Stands: 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.处理理管板孔孔和管板板面上的的油污、锈锈蚀等。Dealing with the tube sheet holes and the tube sheet surface oil, corrosion, etc.3.穿管管：穿管管完毕后后再上浮浮动管板板，定尺尺定位

40、，点点焊，再再回管。Tube cross: crossingthe tube ,then installingthe floating tube sheet, length positioning, spot welding and then back to the tube.4.管头头焊、切切管、打打磨、浮浮动端管管头焊，支支耳调试试，安装装焊接，管管头两端端热处理理。Tuube heaad wwelddingg, ttubee cuuttiing, poolisshinng, flooatiing sidde ttubee heead welldinng, luugs debbugggin

41、gg, iinsttalll thhe wwelddingg, tthe tubbe hheadd att booth endds oof hheatt trreattmennt5.胀管管（见胀胀管工艺艺卡），胀胀管器按按编号到到仓库领领用，规规格为（ ）（ ）（ ）。Expander (see the expanding technology card), the expander by number to the warehouse recipients, specifications are （ ）（ ）（ ）.6.安装装滑道并并焊接。Installation of slide and

42、welding管束试压管头试压压，试验验压力（ ）MPPa（见见试压工工艺）水水压试验验时下列列情况为为合格：无渗漏漏，无可可见变形形，过程程中无异异常响声声。Tuube heaad ppresssurre ttestt, tthe tesst ppresssurre iis () MMPa (seee PPresssurre TTestt) .hyddrosstattic tesst, thee foolloowinng ccondditiionss arre eeliggiblle: no leaakagge, no vissiblle ddisttorttionn, nno aabnoo

43、rmaal nnoisse iin tthe proocesss.整体试压压oveeralll ppresssurre ttestt1.将管管束试压压合格后后，装入入壳体中中Afteer ppasssingg thhe ppresssurre ttestt,puut tthe bunndleeintoo thhe sshelll.2.安装装两端管管箱，浮浮头盖，装装配时注注意垫片片的保护护，均匀匀将几件件螺栓紧紧固。安安装管箱箱，浮头头盖时，一一定做好好隔板槽槽和隔板板衔接口口标记，稳稳合统一一。Innstaallbbothh ennds of tubbe bbox, flloattingg

44、boonneet ,payy atttenntioon tto tthe prootecctioon oof tthe gasskett asssemmblyy, bboltta ffew pieecess eveenlyy. WWhenn innstaalliing thee piipe boxx, ffloaatinng hheadd cooverr, bbe ssuree too doo thhe pparttitiion grooovee annd cclappboaard connverrgennce mouuth marrk, staablee coo-unnifiied.3.螺栓

45、栓拧紧时时，要分分步骤，先先预紧等等分四颗颗，即00、990、1180、2770，再再逐步对对称紧固固。用力力要均匀匀，最后后对螺栓栓进行全全面紧固固。Whenntighhtenningg thhe bboltts, steep bby sstepp, ddeciile fouur fiirstt , nammelyy, 00 , 900 , 1880 , 2270 , andd thhen graaduaallyy tiightten thee syymmeetryy. FForcced eveenlyy, att laast fulll ttighhtenningg thhe bboltt

46、s.4.将管管箱上（ ）孔孔，即下下端接管管用盲板板封住，紧紧螺栓，（ ）注注水，用用行车配配合作业业，上下下来回起起落，将将管程中中空气排排净为止止，状态态为不显显现汽泡泡静止面面，再封封住（ ）口口，紧固固螺栓。Tube box () hole, sealthe bottom nozzleby the blind plate,bolt, () inject, operate with a driving car, up and down, until draining the process air of the tube , the state does not show bubble

47、stationarysurface, and then sealed () and tighten the bolts.5.按试试压工艺艺卡，分分步骤循循序淅升升。Accoordiing to theepresssurre ttestt caard, sttep-by-steep ssequuenttiall Hssi-ll.6.检验验易池漏漏区、面面和焊道道，无泄泄漏，无无异常响响动为合合格。TTestt thhe lleakk arrea, suurfaace andd weeld, noo leeakss annd nno uunussuall riing forr quualiifieed.7.组装装外头盖盖，同上上紧固螺螺