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1、SMS3128-2011第1版 复合板压力容器制造工艺规程THE FABRICATION PROCEDURE SPECIFICATION OF CLAD PLATE PRESURE VESSEL 上海森松压力容器有限公司地址：中国上海浦东新区金闻路29号邮编：201323传真：0086-21-33756881电话：0086-21-38112058E-mail： 2011年03月20日发布2011年03月20日实施 目 录1目的 Purpose为保证复合板制压力容器制造质量，正确指导施工、检验等，特制订本规程。This procedure is prepared for ensuring the
2、 fabrication quality of clad plate pressure vessel and guiding the construction, inspection and so on. 2适用范围Scope of application2.1.本规程适用于不锈钢、镍及镍基合金与碳钢、低合金钢,镍及镍基合金与不锈钢具有良好可焊性的复合板设备的制造。This procedure is applied to the equipment that fabrication with clad plates which have good weldability and are com
3、posed of stainless steel, nickel and nickel alloy with carbon steel or low alloy steel, nickel and nickel alloy with stainless steel.2.2.本规程不适用于钛、锆及其合金与钢或不锈钢的复合板设备的制造。This procedure is not applied to the equipment that fabrication with clad plates which are composed of titanium, zirconium or their a
4、lloy with steel or stainless steel.2.3.本规程为制造过程中必须遵循的工艺原则。工艺编制、施工制作、工序检验等各环节必须遵守。This procedure shall be complied as process principle during fabrication. Process compiled, construction, inspection and other processes shall comply with it.3. 原材料的管理The administration of material 原材料管理除遵守公司压力容器采购与材料管理
5、规程外，还应遵守以下规定：The administration of material shall comply with and conform to the following regulations: 3.1原材料的采购除遵照用户技术文件外，还应遵照NBT47002.1-2009压力容器爆炸复合板（不锈钢-钢复合板）、NBT47002.2-2009压力容器爆炸复合板（镍-钢复合板）The purchase of material shall comply with the documents submitted by buyer and conform to NBT47002.1-200
6、9 and NBT47002.2-2009.3.2材料验收合格后应做好标记，标记应采用无氯无硫记号笔书写，不得在复层打钢印。并对特材（不包括普通不锈钢）复层贴膜保护，复层为特材的应按特材设备材料保护及加工的重要注意事项要求进行保护。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 surfa
7、ce. The special 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材料堆放时复层应朝上，每层间应垫木板或橡胶板。The cladding shall be up when the plates are stacked, wood plate or rubber plate shall be put on between
8、them.3.4 吊运和摆料时，应避免复层表面划伤，不允许钢丝绳和其它碳钢夹具与复层直接接触，禁止在复层上走动，不得让复层沾染油污、铁离子或其它污物。吊运转序按设备内件零部件储存运输管理规程。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 surfa
9、ce shall be forbidden, 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，应检查材料表面质量，包括局部凹陷和划伤情况，表面质量合格才能下料，如复层表面有局部伤痕、刻槽等，则应修磨，修磨深度不应超过复层厚度的30%，且不大于1mm，修磨范围的斜度至少为1：3，且应有良好的圆滑过渡。Before cutting, the s
10、urface quality of 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 exceed 30% of the
11、clad layer thickness and not more than 1mm, the pitch of grind shall be 1:3 at least and have good smooth transition.4.2下料时，复层面应朝上，对于复合板总厚度不大于60mm，采用等离子直接切割；对于复合板总厚度大于60mm，应将割缝处的复层剥掉，然后用氧-乙炔切割，割口两边应涂保护涂料，如白垩粉等，以免飞溅物影响复层表面质量。切割前，应进行标记移植（先在复层用记号笔移植，待工件翻身后再在碳钢基层上移植并打钢印）。During cutting, the cladding sur
12、face shall be put up. 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 oxy-acetylene to cut them, the area ad
13、jacent to the cutting 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
14、plate is overturned.)4.3刨边机加工坡口时，严防刨边机机油污染复层表面，刨边机夹具处应用不锈钢垫板隔开。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用等离子或氧-乙炔切割的坡口
15、，需用砂轮或风铲打掉熔渣，并去除11.5mm的切割影响区，打磨过碳钢的砂轮片不得用来打磨复层（打磨碳钢的砂轮片应该用油漆做好标记，如用红色油漆）。The grooves which are cut by plasma or oxy-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
16、 steel shall not be used 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筒体下料尺寸要求：为了保证环缝组对错边量，对筒体展开长度应严格控制，相邻两筒节长度偏差不大于5mm；筒体展开长度应按封头实测外周长换算成内径，以内经为基准计算展开长度。对于厚壁容器要考虑卷制伸长量，具体按厚壁容器制造工艺规程确定。The requirements for th
17、e cutting dimension of 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 conver
18、sed to inner diameter according 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锥体下料尺寸要求：按有关文件规定及具体产品工艺文件要求放余量下料。The requir
19、ements of the cutting dimension 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，基层表面弱酸试验，具体按复合板坡口表面酸蚀试验流程。After the groove processed, the backing shall be tested by weak acid and the specific requirements a
20、ccording to .5冷作成形 Cold forming 筒体一般采取冷卷成形；锥体宜采取冷压成形。Shell is usually formed with cold rolling; cone is usually formed with cold pressing.5.1 卷板前必须将卷板机上辊表面的铁屑、毛刺、锈斑、油污等杂物清除干净，并用砂纸打磨光滑。Before rolling the plate, the iron, fragments, rust, oil and other contaminations on the surface of roller shall be
21、removed cleanly and ground smoothly by sand paper.5.2卷板机上辊应用塑料薄膜或不锈钢薄板包住，以保护复层表面。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 卷制前应先压头，压头应在油压机或卷板机上进行。如用油压机压头，在模具与复板之间应衬垫810mm厚不锈钢板。对于厚壁容器是否加放压头量以及成形前的准备，按厚壁容器制造
22、工艺守则规定执行。压头曲率用样板控制，样板弦长不小于300mm，并符合相关标准要求。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
23、vessel, whether the measure 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 comply with the requirement of correspo
24、nding regulation.5.4卷制时应控制上辊的下压量，在同一段区域不宜多次反复碾压。The down pressing measurement of up roller shall be controlled during rolling, and too many times on the same area is forbidden.5.5锥体冷压成形一般分2到3片压制，对于厚度大于60mm的锥体，应分成3片压制。压制前，在扇形板片上复层面画等分素线。压制时，复层与上模间应用810mm厚不锈钢板条垫好，然后沿素线压制。大、小口曲率用样板控制。The cone shall be
25、divided to two or three pieces 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 stainle
26、ss steel, and the cladding shall be pressed along the line. The former shall be used to control the big and small vent curvature.6热成形或温成形Hot forming or warm forming 凸形封头整体宜采取热成形或温成形。不得采用旋压成形。成形过程中，主要保证基层的力学性能和复层的耐腐蚀性能。如采取整体冷压成形应经工艺责任工程师批准。The gibbose head should be adopted hot forming or warm formin
27、g and the spin pressure forming 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对于奥氏体不锈钢复合板宜采取热成形，热
28、成形时，升温速度应较同等厚度的碳钢或合金钢慢。冲压时，为了避免温差应力过大而影响了两种不同金属间的结合强度，还应使模具有一定的预热温度。具体应按封头数据表要求执行。热成形一般采取控制温度成形，不另外热处理。对于特殊材料需要单独热处理的应制定具体工艺。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
29、 with same thickness during 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 form
30、ing usually adopts temperature 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对于其它材料的复合板成形，应根据材料的性能，包括相变特性，制订成形工艺。For other materials clad plate forming, the forming procedure shall be
31、prepared according to the properties of the material, including the photograph change character.6.3检验要求Inspection requirements6.3.1形状及尺寸检验按相应标准要求及具体工艺要求。The inspection of the shape and dimension shall be performed according to the requirements of the corresponding standards and the specific procedur
32、e.6.3.2成形后的封头应进行100%UT检测，检查复层与基层结合情况。The head after forming shall be inspected by 100% UT to check the coalescent conditions between cladding and backing.7组装和焊接Assembly and welding7.1 筒体组对时，应保证错边量不大于复层厚度的50%，且不大于2mm。对于具体设备有特殊要求时，按项目要求执行。对于接头错边处的焊缝应平滑过渡。During the shell assembly, the misalignment sha
33、ll be ensured to not more 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 组装时，尽量避免在复层上焊工装卡具，如必须焊时
34、，工装、卡具与复层接触的材料必须与复层材料相同。避免铁基金属与复层直接接触。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 c
35、lad layer directly. 7.3 设备开孔应从内向外切割，对于厚度不大于60mm的壳体用等离子切割，对于厚度大于60mm的壳体用氧-乙炔切割，氧-乙炔切割时应先将切割线处复层剥离，再由内向外切割。切割时应在割口两侧80mm宽的范围内涂上白垩粉或采用铝板保护，防止飞溅物落在复层表面。切割后应磨去熔渣，并对复层11.5mm切割热影响区予以去除。然后组装接管。The opening of the equipment shall be cut from inside to outside. For the total thickness of the shell not more tha
36、n 60mm, the plasma cutting shall be used; for the total thickness of the shell more than 60mm, the oxy-acetylene shall be used, the cladding that on the cutting seams shall be peeled off firstly and then use the oxy-acetylene to cut from inside to outside. During cutting, the area within 80mm width
37、adjacent to the cutting area shall 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.
38、 7.4 接管与壳体的连接型式应符合图1要求，R应根据接管壁厚确定，一般应大于3mm，基层R过渡层R复层R。接管与壳体的连接尺寸应符合常用焊接坡口型式及焊接工艺选用一般原则要求。焊接前应将接管抬起高于筒体约3mm或筒体板厚的10%，取小值。见图2。对于大开孔（DN300mm）接管焊接时应用防变形工装支撑。焊接后要保证耐蚀层的厚度，特别对于管壳式换热器的壳体与接管的连接，更要注意打磨后仍要保证耐蚀层厚度。换热器壳体接管焊接时，一般应从壳体内部将接管焊到壳体上，用胎具和千斤顶从内部将接管顶紧，并产生适量的反变形，然后从外部焊接管和补强圈，焊完冷却后才能拆除胎具。换热器壳体接管组装后必须经检验员检查
39、后才可焊接。The type of connection between 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 shel
40、l shall conform to the requirement. . 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 holes（DN300mm）welding, the defend deformation jigs shall be used for supporting and the thickness o
41、f corrosion resistance layer shall be ensured after welding. Especially for the connection between the shell and nozzle of tube-shell exchanger, the thickness of the corrosion resistance layer shall be ensured after grinding. During welding the nozzle to shell of heat exchanger, the nozzle is usuall
42、y welded to shell from inner of the shell 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 s
43、hell of heat exchanger shall be checked by inspector before welding. （此条在工序验收单中体现，并设置为停留点，检验员确认后再进行后续工作。）(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.)图1 图27.5 复合板设备主体纵环焊缝坡口要求结合面处基
44、层低于结合面11.5mm，见图3。The backing of main longitudinal and circumferential welds groove of the clad plate equipment on the coalescent area shall be lower than coalescent surface 11.5mm, see figure 3.图3对于内件要求焊在壳体基层的，应将复层剥槽，剥槽宽度应符合图4要求。剥掉部分焊接应按堆焊要求焊接。如果内件要求全焊透，应制定焊接工艺。For the internal which shall be welded
45、 to the backing of the shell, the cladding shall 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 complete welding, the welding procedure shall be
46、 prepared.图47.6 焊接Welding7.6.1不锈钢复合钢板容器连接复层的焊接（如壳体焊缝内表面）一般采用双层堆焊。堆焊层表面的化学成分应与复层金属相匹配。堆焊层厚度应至少等于复层厚度，但不应超过复层厚度的两倍。堆焊焊接方法优先采用氩弧焊，若采用手工焊条堆焊时，打底焊要求优先采用3.2焊条。堆焊后原则上不进行打磨，若具体项目要求进行打磨，或者焊接成型较差必须要打磨时，须通知检验员见证，并要求打磨后表面进行铁素体测定，铁素体含量12%为合格，超过12%需进行PMI检测。具体项目对铁素体含量有特殊要求时，按具体项目要求执行。The welding of cladding connection of the stainless steel clad plate vessel usually adopts double layer surfacing. The chemical composition 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 th
