换热器制造工艺指导流程模板.doc

筒节 Tube
section

1.材料确定：在材料管理员指导下，对材料标识确定。 Confirm material: under the guidance of materials administrator ,recognized the mark of the material。
2.依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、检验线。 According to process diagram ,layouting the material board on the shelves, cutting and draw the cutting line, plane edge, checking line.
3.坡口加工（见坡口工艺卡），完成后对坡口进行超声检测。Groove processing (see groove process card), Ultrasonic testing
after the completion of the groove。
4.卷板：将坡口加工完好板料置于卷板机上、下辊轮间，板料周长方向和辊轮垂直，纵向和辊轮平行。Coil: place the groove processing intact sheet on the rolling machine, between the upper and lower roller, the sheet perimeter direction is vertical to the roller, and the longitudinal is parallel to the rooler.
5.纵缝组对：将纵缝口两端对齐，控制错边量，错边小于1/4δ且小于2mm，并点上引弧板。 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 1/4δ and not greater than 2mm, and point the arc plate.
6.纵缝焊接，见焊接工艺卡。 Longitudinal seam welding, see the welding process card。
7.校园：不园度控制在0.5%DN,且小于5mm,DN≥1200,小于7mm；棱角度，控制在δS/10+2，且小于5mm。Regulate to make sure it circle: Park, control the degree of of-roundness at 0.5% the DN, and not more than 5mm, the DN ≥ 1200,not more than 7mm; the angularity, should be controlled at δS/10 +2, and not more than 5mm。

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。 According to the requirements of each tube section layout diagram,combine them, each seam is distributed in the 0 to 180 ° , Stagger 180 ° ,the circumferential seam combination gap is 0 ~ 2mm.
2.组对完成后，从0°、90°、180°、270°四个方位检测，直线度10%，且小于4.5mm。.Detect after the combination of the 0 °, 90 °, 180 °, 270 ° four orientation,10% straightness, and no larger than 4.5mm.
3.环缝棱角度控制在δS/10+2，且小于5mm错边量。 Control the ring slit angular degree at δS/10+2, no larger than 5mm Staggerion of the volume.
4.环缝组对时不可强行组装，可用加减丝扣调整间隙，间隙在0~1.5mm最好。 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.确定错边值后，依次从最好点入手，顺势而成，环缝错边量不得大于1/4δ板厚且小于2mm。 Determining the value of the Stagger， start from the best point by turn, homeopathy to be it, the circumferential seam should not be than 1/4δ plate thickness and not more than 2mm.
6.对组装后筒体进行直线度检测，四点方位，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 than 4.5mm。
筒体
和
法兰
组对 Tube
Body
And
Law
Orchid
Group
To

1.法兰必需是经过检验，贴有合格标签，对应流水号和产品编号。 The flange must be tested, labelled with a qualified label, the corresponding serial number and product number.
2.用直尺划出法兰螺栓孔跨中线,和筒体纵缝线平行组装。 Draw the flange bolt holes across the center line with a ruler, assemble and make sure it parallel to the cylinder longitudinal suture.
3.将装一端法兰筒体,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。 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.用铅垂线或水平尺将有一端法兰筒体调整好，要求0°~180°跨中线和铅垂线重合。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.组对另一端法兰，即管箱法兰铅垂线和跨中等分线要求和上法兰相同条件（即螺栓孔跨中）。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.装配间隙0~1.5mm，错边量0~2mm。The assembly gap is 0~ 1.5mm, the staggr mount is 0 ~ 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。 Detecte the level degrees of both ends of the flange, use the 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.检测、焊接完成后，对筒体环缝内打磨平，送探伤检测，要求RT≥（ ）%，Ⅲ级合格。 After detection and welding, polished flat within the seam of the cylinder ring, sending the flaw to detect, requst the RT ≥ () class, III qualified.

接管和法兰Nozzle and the flange
将坡口加工好接口和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。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, full penetration structure. After welding,having a non-destructive testing, the inspection standards is RT ≥ () class, III qualified.
支座点焊Supports
welding
1.按图对支座底板、筋板、立板进行组装前检验。In accordance with drawings, inspect the supports backplane, ribs, riser before assembling.
2.组装各部件，点固，加支撑件等，焊接。Assemble every component, solid point, support pieces, and welding.
接管支座和壳体组装Nozzle supports and shell assembling

1.按先前标出0°、90°、180°、270°方位点,延长在壳体上。Base on the previously marked 0 °, 90 °, 180 °, 270 compass points°, extending to the hcase.
2.画出接管、支座，预开孔，安装位置，即坐标点。Draw the nozzle, supports, pre-openings, the installation location, that is, the coordinates of points
3.检验合格后，开孔，然后打上坡口，角度为外坡口30°After Inspection, opening, then grooving,the angle of the outer groove is30 °
4.组对接管和壳体，组装前，接管必需将补强圈带上固定好，一起装配。Connect nozzle to shell, before assembling,the nozzle must fix the reinforcement ring,along with the equipment.
5.接管和壳体组对间隙为2~3mm，且间隙均匀。The gap of the nozzle and shell is 2 ~ 3mm, and the gap is uniform
6.焊接完成后，内接管须清根封底，焊缝打磨和母材齐，并倒2×45°圆角。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 box
1.封头：材质确定，标识移植，切割，外协模压，回厂检验，材质为（ ），δ（ ）。Head: Material confirmation , mark and transplante, cutting, outsourcing molding, back to the factory inspection, the material is (), δ ().
2.短节：材质确定 a.按排版图尺寸划线下料坡口加工。（见具体工艺文件） Short section: material confirmation a. Drawing, crossed material and groove processing by the size of the layout chart. (See the specific process documents).
b.卷板，纵缝焊接，校圆，纵缝RT≥（ ）%，Ⅲ级合格，车加工削薄。 b. coil, longitudinal seam welding , regulate round, longitudinal seam RT ≥ (), III class qualified ,vehicle processing thinning.
3.管箱法兰和短节组装：a.管箱法兰和短节组焊，封头和短节组焊。Flange and short section of the tube box assembly: a. tube box flange and a short section welding，the head and a short section welding。
b.对环缝进行射线检测。Ring sewn-ray detection.
c.和壳体联接，整体划线，开孔，接管组装，焊接，确保其整体一致性。Connection with the shell, the overall drawing，openings, nozzle assembly, welding, ensure that its overall consistency.
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需和固定端管板（ ）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 size must be consistent with the fixed end of the tube plate () notch.
e.做好热处理前支撑，预防热处理使隔板变形。
Do good support before heat treatment to prevent heat treatment so that bulkhead deformation
f.热处理完成冷却后，再加工密封面，确保法兰密封面和隔板端平面一致。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the outside
bonnet

1.封头:材质确定 划线,标识移植,切割,外协模压,回厂检验,贴合格标签。Head: The material confirmation, mark and transplante, cutting, outsourcing molded, back to the factory inspection, paste qualified label.
2.短节:材质确定 按图尺寸划线,切割,坡口精加工,卷板,焊接,校园。Short sections: materials confirmation drawing base on the size of the chart, cutting and finishing of the groove, plate bending, welding, regulate round.
3.法兰和封头，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。Flange and the head, a short section of welding: (a) welding the qualified head ,a short section and the corresponding flange, the stagger volume is controlled between 0 ~ 2mm.
b.环缝焊接，无损检测。(b).The girth welding, nondestructive testing.
c.划线开孔，安装管嘴和吊耳，焊接 (c). Drawing and opening, install the nozzle and lug ,welding.
d.和壳体、管箱、浮头盖，一并整体热处理。(d).The shell, tube box, floating cover, together with the overall heat treatment.

浮头盖Floating bonnet

1.拱盖：材质确定 划线下料，标识移植、切割，外协模压、回厂检验。Ledge: material confirmation Drawing and cutting, mark transplantation, cutting, outsourcing molding, back to the factory inspection.
2.浮头法兰：在材料检验员指定下领取贴有合格标签法兰。 Floating head flange: receive designated qualified label of the flange under the guidiance of the materials inspector .
3.将拱盖和浮头法兰组装，装配尺寸图。Assemble ledge and floating head flange, the assembly size shown in Figure。
4.焊接完成后，再按拱盖实形放样、隔板、切割、组装、焊接，确保隔板装配尺寸和浮动管板槽尺寸一致。After welding, the then loft base on the real shape, bulkhead,cutting, assembling, welding, ensure size of the bulkhead, assembly size and floating tube notch groove consistent.
5.和前壳体、外头盖及管箱一并进炉热处理。Having a heat treatment furnace to the front shell, the outside bonnet and the tube box .

管束tube bundle

换热管
1．材质确定：φ（ ）×（ ） 规格（ ）。Material confirmation: φ（ ）×（ ） Specification().
2．单管试压，试验压力为设计压力2倍，即（ ）MPa。Single-tube testing pressure,the pressure is 2 times the design pressure,that is () MPa.

管板
本锻件应按JB4726制造和验收，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。The forgings shall be JB4726 manufacture and acceptance ,PT detection, according to Figure NC loft, drilling, the bulkhead.slot milling, chamfer the groove, wire drawing hole tapping.
折流板
1.材质确定，Q235B，δ16，数控放样切割，去渣，整形，打垛点固焊。Material confirmation,Q235, δ16, CNC cutting loft, remove the residue, shaping, playing stack point of solid welding.
2.数控划线，钻孔，折流板车园，做标识次序号，单块剪切去毛刺。NC drawing, drilling, baffle to car round, mark the order number, a single block of shear deburring.
3.次序号移植，管孔倒角，折流板打磨，整形。Sequence number transplantation, pore chamfer, baffle polished, plastic
管束
其它
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。Distance tube machining, rod endpoint wire, slide the bypass damper shear cutting, 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: 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 farm
2.处理管板孔和管板面上油污、锈蚀等。Dealing with the tube sheet holes and the tube sheet surface oil, corrosion, etc.
3.穿管：穿管完成后再上浮动管板，定尺定位，点焊，再回管。Tube cross: crossing the tube ,then installing the floating tube sheet, length positioning, spot welding and then back to the tube.
4.管头焊、切管、打磨、浮动端管头焊，支耳调试，安装焊接，管头两端热处理。Tube head welding, tube cutting, polishing, floating side tube head welding, lugs debugging, install the welding, the tube head at both ends of heat treatment
5.胀管（见胀管工艺卡），胀管器按编号到仓库领用，规格为φ（ ）×（ ）—（ ）。Expander (see the expanding technology card), the expander by number to the warehouse recipients, specifications are φ（ ）×（ ）—（ ）.
6.安装滑道并焊接。Installation of slide and welding
管束
试压
管头试压，试验压力（ ）MPa（见试压工艺）水压试验时下列情况为合格：无渗漏，无可见变形，过程中无异常响声。Tube head pressure test, 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.

整体试 压overall pressure test

1.将管束试压合格后，装入壳体中After passing the pressure test,put the bundle into the shell.
2.安装两端管箱，浮头盖，装配时注意垫片保护，均匀将几件螺栓紧固。安装管箱，浮头盖时，一定做好隔板槽和隔板衔接口标识，稳合统一。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.螺栓拧紧时，要分步骤，先预紧等分四颗，即0°、90°、180°、270°，再逐步对称紧固。用力要均匀，最终对螺栓进行全方面紧固。When tightening the bolts, step by step, decile four first , namely, 0 °, 90 °, 180 °, 270 °, and then gradually tighten the symmetry. Forced evenly, at last full tightening the bolts.
4.将管箱上（ ）孔，即下端接管用盲板封住，紧螺栓，（ ）注水，用行车配合作业，上下往返起落，将管程中空气排净为止，状态为不显现汽泡静止面，再封住（ ）口，紧固螺栓。Tube box () hole, seal the bottom nozzle by 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 stationary surface, and then sealed () and tighten the bolts.
5.按试压工艺卡，分步骤循序淅升。According to the pressure test card, step-by-step sequential Hsi-l.
6.检验易池漏区、面和焊道，无泄漏，无异常响动为合格。Test the leak area, surface and weld, no leaks and no unusual ring for qualified.
7.组装外头盖，同上紧固螺母，封堵壳程（ ）口和外头盖下方管嘴。Assemble the bonnet, ditto fastening the nut and sealing the shell ()outlet and the nozzle below the outside bonnet.
8.（ ）和（ ）注水，同上方法排净空气，封住（ ）和（ ）口，紧固螺栓。()and () injection, ditto drain the air, seal () and() port and tighten the bolts.
9.稳步升压至试验区域线，检验，无漏点和异样响声为合格。Steady boost to the test area line, check no leak point and strange sound for qualified.
10.排净体内积水，用压缩空气吹干。Drain the body of water, dry with compressed air.

11.喷砂，外观处理，喷砂时对螺栓要做好保护方法，油漆（见工艺卡）包装。Sandblasting, processing the appearance,when blasting the bolts ,taking protective measures, painting (see process card) packaging.