Product technical features, process brief introduction
1. Main product specification series
50~50000L glass lined mixing container
50~60000L glass lined storage container
D grade stainless steel and carbon steel pressure vessels, tubular heat exchangers and other products.
2. Product implementation standards:
Products and materials in line with national standards and specifications and manufacturing, inspection and acceptance:
GB25025-2010 "Glass lining equipment Technical conditions"
GB/T25026-2017 "Glass-lined closed Mixing Vessel"
GB/T25027-2018 "Glass-lined open Mixing Container"
HG/T2373-2375-2017 "Glass Lined Storage Container"
GB/T150-2011 "Pressure Vessels"
TSG21-2016 "Fixed Pressure Vessel Safety Technical Supervision Regulations"
GB/T713-2014 "Steel Plate for Boilers and pressure vessels"
NB/T47013-2015 "Non-Destructive Testing of Pressure Equipment"
GB/T5117-1995 "Carbon Steel Electrode"
GB/T14957-2002 "Welding wire"
GB5293-1999 "Carbon steel submerged arc welding flux"
JB/T4708-2000 "Steel Pressure Vessel Welding Process Evaluation"
JB/T4709-2000 "Welding Procedures for Steel Pressure Vessels"
JB4744-2000 "Steel pressure vessel product welding test plate mechanical properties Inspection"
HG20592-2009 "Steel pipe flanges, gaskets, Fasteners"
GB7993-2003 "High voltage test method for enamel equipment under corrosion conditions"
GB/T7994-2005 "Hydraulic test method for enamel equipment"
GB/T7995-2005 "Test method for air tightness of enamel equipment"
3. Steel plate, kettle forming, glaze spraying and firing:
(1) Steel plate: steel plate material for kettle enamel substrate with excellent performance Q245R steel plate; The jacket is Q245R.
Steel plate standard: The material standard meets all the standards involved in the first article. Comply with the material requirements in the Pressure Vessel Quality Manual. The material must have the "Steel plate material Quality Certificate", the physical and chemical properties of the "steel plate material Quality Certificate" shall not be missing, and the red seal is qualified. The thickness error of the steel plate should be within the standard range.
The surface quality of the steel plate: it should be smooth and smooth, without serious scratches, and there should be no inclusions, layers, pits, rust and obvious processing marks.
The carbon content of the five elements of the steel plate is less than 0.19%, and the other elements meet the standard.
Physical and chemical properties of steel plate GB/T713-2014 "Steel plate for boilers and pressure vessels"
Chemical composition of steel plate %
C Si Mn P S
Q245R ≤0.20 ≤0.35 0.5-1.0 ≤0.025 ≤0.015
Steel plate Thickness /mm Tensile strength R/(N/mm2) Yield strength R/(N/mm2) Elongation A/% Temperature /ºC Impact absorption energy KV2/J 180° Bending test Bending diameter (b≥35mm)
Q245R >16-36 400-520 ≥245 ≥25 0 ≥31 d=1.5a
(2). Billet forming:
Head: 200-30000L steel plate head with fixed length plate head, 4000-60000L for the whole plate or splicing head.
A: If the splicing head is used, the residual height of the splicing weld shall be ≤1mm, and the residual height of the internal surface after welding shall be ≤1mm. After passing 100% X-ray inspection, the weld shall be polished to be flush with the base material, and the minimum wall thickness after the closure head is stamped shall not be less than the wall thickness designed in the drawing. The two steel plates should be moved to a non-enamel surface, and the pipe opening should avoid the weld, and should not be less than 150mm.
B: The inner surface of the enamel surface (enamel surface) must be mechanically polished after the molding of the head.
C: The punching of the head meets the requirements of the process card, the punching arc should be uniform, and the tearing height of the punching edge should not exceed the amount of the slope mouth.
Pipe mouth: the blank surface of the pipe mouth shall not have cracks, wrinkles, and layers. The material meets the welding and enamel requirements. The groove processing shall comply with the welding specifications, the inner surface is smooth, no oxide skin and pits are allowed, and the pipe mouth flange shall not be deformed. In order to prevent corrosion on the outside of the pipe mouth caused by material overflow of the pipe mouth flange, the plane flange of the pipe mouth can be flanged with enamel as required to prevent corrosion on the outside of the pipe mouth.
Cylinder molding: geometric size in line with GB25025, GB150 and enterprise standard process card provisions. The amount of the wrong side of the weld edge Angle meets the requirements of GB150 and GB25025, and the point fixed arc plate on both sides of the longitudinal seam of the cylinder (Class A weld) meets the welding process requirements. The inner surface is mechanically polished to reveal metallic color.
The billet manufacturing process according to the process table card and drawings processing and manufacturing, a piece of a card, and the same flow, the billet must be clear (workpiece printing number, welder printing number).
High neck flange: high neck flange is the main pressure element. The physical and chemical indexes of the material meet GB25025 and GB150, requiring the whole rolling, after passing the inspection, mechanical processing.
Flange processing tolerance:
DN DN D D1 R H b h Diameter difference
800-1200 ±0.5 ±1.0 ±1.0 ±2.0 ±1.0 ±0.4 ±0.5 2.0
1300-2000 ±0.7 ±1.5 ±1.5 ±2.0 ±1.5 ±0.5 ±0.1 3.0
The plane of the flange is smooth and flat, the arc transition has no edges and corners, the flatness tolerance of the flange is not more than 1.5 mm, and the width of the flange sealing surface is not less than 15 mm.
Welding of the upper head group: the parallelism between the stirring hole plane and the lower plane of the head is less than 0.01DN, and the wrong edge of the waist weld of the pipe mouth is less than 2mm. Reducer support plane and mixing hole flatness ≤3mm, support center distance error ≤2mm, support division circle center and mixing hole center concentricity ≤2mm, the implementation of standard HG/T2637 and meet the requirements of the process card.
Upper and lower ring assembly:
Upper joint ring group welding: the longitudinal seam of the corresponding cylinder body is polished until it is flush with the base material, the parallelism error between the upper joint ring and the B1 seam when installed is less than 3mm, the spacing is 200mm, and the welding is automatic after completion. When welding, the kettle body is tilted 45°, and the welding point weld pool is always in a horizontal state.
U-shaped lower ring: the straight ring point of the lower ring is fixed under the pipe port head, and the concentricity with the center of the discharge port is less than 2mm.
After the upper and lower joint rings are welded, the surface weld is polished to be free of welding slag, burr and splash. Brush the upper and lower girth welds with lime white powder water. After completely drying, brush the back of the welds with kerosene as penetrant. After half an hour, it is qualified that there is no trace of kerosene on the surface of the lime powder. Implement standard GB25025.
Polishing: The use of automatic polishing respectively to the head, cylinder and weld for grinding, grinding to the base metal flush, and reveal the metal color. If it is found that there is a layer of skin, cracks, etc., it must be tested with hydrochloric acid brush, and unqualified must return to the previous process, replacement or repair.
(3) Enamel:
The surface glaze is imported with original enamel: European Czech "Merritt" enamel, strong acid resistance (warranty period of 2 years).
High-quality bottom glaze: The use of our company for many years of research and development of patented technology bottom glaze (patent number: ZL 2014 1 0087523.4), the bottom glaze and steel plate chemical bond form is more firm, better adhesion performance, temperature range is larger, better fusion of the expansion coefficient of steel plate and surface glaze.
Surface glaze:
A, wider corrosion resistance range (PH1 to PH14)
B. Excellent resistance to mechanical shock and wear
C, good adhesion resistance
D, suitable for a variety of materials, with multi-functional performance
E, comply with GMP cleaning, cleaning and disinfection requirements
F, suitable for high pressure and full vacuum under high temperature conditions
G, the use of special water-colored porcelain glaze color, easy to observe the adhesion of materials
H, enamel surface without repair
Surface glaze physical and chemical properties test report
The inspection item standard specifies the inspection method of the inspection result
Acid resistance ≤0.5g/*day 0.21GB /T7989
Alkali resistance ≤8.0g/*day 2.85GB /T7988
The temperature difference changes rapidly ≥200ºC 260 GB/T7987
Mechanical impact resistance ≥220*10-3J 270*10-3 GB/T7993
The corrosion rate is the result of 1 day 24 hours continuous test. The good range is defined as the corrosion rate of less than 0.1mm/year and the service life of more than 5 years. The usable range is defined as a corrosion rate between 0.1-0.2mm/year and a service life between 2-5 years. The range of prudent use is defined as the corrosion rate of 0.2mm/year or more, and the service life of 1-2 years or less.
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