CN112570998A - Manufacturing process method of air cooling pipeline of thermal generator set - Google Patents

Manufacturing process method of air cooling pipeline of thermal generator set Download PDF

Info

Publication number
CN112570998A
CN112570998A CN202011468630.3A CN202011468630A CN112570998A CN 112570998 A CN112570998 A CN 112570998A CN 202011468630 A CN202011468630 A CN 202011468630A CN 112570998 A CN112570998 A CN 112570998A
Authority
CN
China
Prior art keywords
assembly
welding
plate
inspection
section
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CN202011468630.3A
Other languages
Chinese (zh)
Other versions
CN112570998B (en
Inventor
张宝平
赵智峰
夏建东
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
China Second Metallurgy Group Co Ltd
Original Assignee
China Second Metallurgy Group Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by China Second Metallurgy Group Co Ltd filed Critical China Second Metallurgy Group Co Ltd
Priority to CN202011468630.3A priority Critical patent/CN112570998B/en
Publication of CN112570998A publication Critical patent/CN112570998A/en
Application granted granted Critical
Publication of CN112570998B publication Critical patent/CN112570998B/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)

Abstract

The invention discloses a manufacturing process method of an air cooling pipeline of a thermal generator set, which comprises the following steps: compiling an operation instruction book according to the construction drawing; performing panel review, sequentially performing steel plate sand blasting, template manufacturing and template checking, and simultaneously sequentially performing sheet metal unfolding, allowance control and typesetting programming; performing plate splicing, performing numerical control blanking and manual material marking, and performing net size blanking and remaining waste material blanking; rolling and forming, wherein a straight pipe is formed at one time, an iron sheet sample plate is checked, a conical section is formed in different areas, a three-dimensional sample plate is checked, the chord length is monitored in real time, and a guide plate is rolled and the iron sheet sample plate is checked; carrying out curvature inspection, secondary material marking, perimeter inspection, lead cutting and ovality inspection; performing integral assembly, including elbow assembly, tee assembly and cross assembly; performing size retest; welding and flaw detection are carried out; polishing and processing; the effect is as follows: the manufacturing quality of the air cooling pipeline is ensured.

Description

Manufacturing process method of air cooling pipeline of thermal generator set
Technical Field
The invention relates to the technical field of pipeline manufacturing, in particular to a manufacturing process method of an air cooling pipeline of a thermal generator set.
Background
The air cooling pipeline of the thermal generator set is complex in structure, the number of special-shaped parts is large, the difficulty in lofting and forming manufacturing of elbows and tee joints is high, and particularly, the difficulty in manufacturing the semi-closed steam distribution pipeline is increased for the manufacturing process of the structural form. For this reason, a manufacturing process for such engineering is developed for such engineering practice. The process technology has obvious effect in the manufacturing of the air cooling pipeline of a certain project, is successful, and achieves the expected effect by adopting feasible technical measures and strict control means in the construction process.
Disclosure of Invention
Therefore, the invention provides a manufacturing process method of an air cooling pipeline of a thermal generator set, which aims to solve the problems in the prior art.
In order to achieve the above purpose, the invention provides the following technical scheme:
according to the first aspect of the invention, the manufacturing process method of the air cooling pipeline of the thermal generator set comprises the following steps: step S100, compiling an operation instruction book according to a construction drawing; s200, performing panel review, sequentially performing steel plate sand blasting, template manufacturing and template inspection, and simultaneously sequentially performing sheet metal unfolding, margin control and typesetting programming; step S300, splicing plates, performing numerical control blanking and manual material marking, and performing net size blanking and remaining waste material blanking; s400, rolling and forming, wherein a straight pipe is formed at one time, an iron sheet sample plate is checked, a conical section is formed in different areas, a three-dimensional sample plate is checked, chord length is monitored in real time, and a guide plate is rolled and the iron sheet sample plate is checked; s500, curvature inspection, secondary material marking, perimeter inspection, lead cutting and ovality inspection are carried out; s600, carrying out integral assembly, including elbow assembly, tee assembly and cross assembly; step S700, performing size review; step S800, welding and flaw detection are carried out; and S900, polishing and handing over.
Further, in the sheet metal unfolding process of the step S200, unfolding of the straight section cylindrical section according to the intermediate diameter, adopting manual lofting, and reserving welding shrinkage allowance and field installation allowance; adjusting the actual cutting track during the sheet metal unfolding of the elbow, namely performing discontinuous point sampling lofting on the elbow according to the principle that the difference value between the arc length and the chord length is less than or equal to 5mm, wherein the actual point sampling interval is 50-100mm, lofting is performed on the section of the shovel groove by taking the pitch diameter as the reference, and the section of the non-shovel groove is unfolded by taking the actual contact surface; all the components are unfolded by 90 degrees, 180 degrees, 270 degrees and 360 degrees of graduation lines; the rolled and formed components are ensured to be consistent and meet the requirements of drawings; the inclination deviation of the end face is not more than 1% of the outer diameter and not more than 3 mm; when the allowable deviation of the circumference of the elbow is that the nominal diameter is more than 1000mm, the allowable deviation is +/-6 mm; when the nominal diameter is less than or equal to 1000mm, the allowable deviation is +/-4 mm; the expansion of the tee meets the requirement of a drawing, and the tee is divided into a large small opening, an embedded section, a diversion bend and a straight section at the lower part, wherein the straight section cylinder section is manufactured firstly, and then the material is numbered for the second time after the straight section cylinder section is formed.
Further, in the rolling and forming process of step S400, for the rolling of the straight section, only the iron sheet sample plate is used for correction, and the graduation lines of 90 °, 180 °, 270 ° and 360 ° are marked, and for the continuous change of the curvature of each point in the arc length direction where the large and small openings belong to the conical section, two three-dimensional sample plates are used to ensure the accuracy of the taper; when pre-bending, a guide plate is arranged; when the centering is carried out, a normal line is formed on the cylinder body at intervals of 100mm by taking a small opening as a reference, when the rolling is carried out, the normal line and an upper rolling shaft line of the four-roller machine are always positioned on a plane vertical to the side rollers, and the rolling direction is always carried out according to the normal line by taking the middle of three adjacent normal lines as the reference; in the rolling process, comparing and measuring chord lengths by using a sample plate in each area of each roll, wherein the chord length measuring method is to measure the chord length at the normal line of the center of the end and the rolled area; the butt joint longitudinal seam is not more than 10% of the wall thickness and not more than 3 mm; the butt joint longitudinal seam 200mm away from the pipe end is not more than 2 mm; the other parts are not larger than 1 mm; the vertical allowable deviation of the end surface of the reel pipe and the central line is not more than 1% of the outer diameter of the reel pipe and not more than 3mm, and the straightness deviation of each meter of straight pipe is not more than 2 mm; during correction, after each section of cylinder is pressed by a fetal membrane for the first time, a three-dimensional template is used for checking the forming error amount, and a correction lath is added according to the forming error amount for correction; if the barrel is regularly changed after lathing, the amount of resilience is inspected every time, the lathing can be directly corrected by adding the lath, if the barrel is locally irregularly changed, the lath needs to be additionally added locally for correction, meanwhile, a three-dimensional sample plate is used for marking a forming contour line on the barrel, a size check point is determined, and local forming inspection is directly carried out by using the size.
Further, before the whole assembly in step S600, the requirements to be met are: at the joint spliced on site, the error between the perimeter and the drawing is not more than 2mm, and the ellipse is not more than 5 mm; at the spliced interface in the field, the error of two adjacent ends is not more than 2mm, and the ellipse is not more than 5 mm; the vertical allowable deviation of the end surface of the reel pipe and the central line is not more than 2mm, and the straightness deviation of each meter of straight pipe is not more than 2 mm; after each section of the barrel is processed to be qualified, the barrel can be pre-assembled, the whole assembly must be carried out on the solid ground, and an assembly operation platform is laid before the assembly and is carried out in a segmented mode from bottom to top.
Further, in step S600, assembling and welding the semi-closed pipeline, manufacturing a mold before rolling, adopting i-steel as a main beam of the mold, straightening to a range of ± 2mm, taking anti-deformation measures in the assembling process, and checking the accuracy of the dimension at any time in the welding process of the mold; after welding, the mould is leveled and fixed firmly to prevent displacement.
Further, in step S600, during the assembly process of the side plates and the cylinder, the cylinder is welded and corrected and the size is checked before the assembly, and the inner groove of the cylinder is checked, trimmed and polished; converting the assembly size of the side plate and the cylinder into a measurable size and marking the measurable size on a workshop manufacturing drawing; the side plate and the assembly mould are firmly fixed, positioning points are drawn on the side plate, an assembly line is drawn along the length direction, and temporary supports are welded; and (3) hanging the side plate on the barrel, aligning the center and the positioning size, checking the welding gap between the side plate and the barrel, and spot-welding the barrel and the side plate.
Further, after the whole assembly in step S600 is completed, assembly inspection is performed: the upper opening of the steel plate ring of the cylinder body is horizontal, the height difference is less than or equal to 4mm, and the vertical height difference of the cylinder body is checked to be +/-5 mm.
Further, after the whole assembly in step S600 is completed, the assembly inspection further includes: the deviation of the radius of the shell steel plate ring from the design value is +/-5 mm.
Further, after the whole assembly in step S600 is completed, the assembly inspection further includes: and checking the ovality of the interface of the assembly on the spot, wherein the maximum and minimum diameter difference is required to be not more than 2D/1000, and D is the design diameter.
Further, after the whole assembly in step S600 is completed, the assembly inspection further includes: the technical requirements of the splicing assembly on the staggered edge amount and the end gap of the groove are in accordance with the requirements of electric welding, and the transverse seam is less than or equal to 3 mm; the vertical seam is less than or equal to 3 mm; the limit deviation of the end part of the groove is +/-3 mm.
The invention has the following advantages: convenient installation and use are basic starting points, and the manufacturing quality of the air cooling pipeline is ensured by being assisted with practical technical measures.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below. It should be apparent that the drawings in the following description are merely exemplary, and that other implementation drawings can be derived from the drawings provided by those of ordinary skill in the art without any creative effort.
The structures, ratios, sizes, and the like shown in the present specification are only used for matching with the contents disclosed in the specification, so as to be understood and read by those skilled in the art, and are not used to limit the conditions under which the present invention can be implemented, so that the present invention has no technical significance, and any structural modifications, changes in the ratio relationship, or adjustments of the sizes, without affecting the effects and the achievable by the present invention, should still fall within the scope of the present invention.
Fig. 1 is a flowchart of a manufacturing process method of an air cooling pipeline of a thermal generator set according to some embodiments of the present invention.
Fig. 2 is a cutting and layout diagram of a flow guide assembly in a thermal generator set air cooling pipeline manufacturing process method according to some embodiments of the present invention.
Fig. 3 is a flow guide three-way component and a blanking diagram of a thermal generator set air cooling pipeline manufacturing method according to some embodiments of the present invention.
Fig. 4 is a middle-to-middle line drawing of a thermal generator set air cooling pipeline manufacturing process method according to some embodiments of the present invention.
Fig. 5 is a rolling directional diagram of a thermal generator set air cooling pipeline manufacturing process method according to some embodiments of the present invention.
Fig. 6 is a schematic calibration diagram of a thermal generator set air cooling pipeline manufacturing method according to some embodiments of the present invention.
Fig. 7 is an assembly flow chart of an elbow of a thermal generator set air cooling pipeline manufacturing process method according to some embodiments of the present invention.
Detailed Description
The present invention is described in terms of particular embodiments, other advantages and features of the invention will become apparent to those skilled in the art from the following disclosure, and it is to be understood that the described embodiments are merely exemplary of the invention and that it is not intended to limit the invention to the particular embodiments disclosed. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1 to 7, a manufacturing method of an air cooling pipeline of a thermal generator set in this embodiment includes the following steps: s100, manufacturing an operation instruction book according to the construction drawing; s200, performing plate rechecking, namely performing steel plate sand blasting, template manufacturing and template checking in sequence, and simultaneously performing sheet metal unfolding, margin control and typesetting programming in sequence; step S300, splicing plates, performing numerical control blanking and manual material marking, and performing net size blanking and remaining waste material blanking; s400, rolling and forming, wherein a straight pipe is formed at one time, an iron sheet template is checked, a conical section is formed in different areas, a three-dimensional template is checked, chord length is monitored in real time, and a guide plate is rolled and the iron sheet template is checked; s500, curvature inspection, secondary material marking, perimeter inspection, lead cutting and ovality inspection are carried out; s600, carrying out integral assembly, including elbow assembly, tee assembly and cross assembly; step S700, performing size re-inspection; step S800, welding and flaw detection are carried out; and S900, polishing and handing over.
Aiming at the characteristics and difficulties of the construction, the whole construction process is subdivided and optimized, and the technological process for manufacturing the air cooling pipeline is shown in the figure 1 by combining the requirements of field installation.
Throughout the whole process flow, the fact that metal plates are unfolded in the pipeline manufacturing process, semi-closed pipelines are rolled and formed, and elbows and tees are assembled in the three most important stages of the construction process can be easily found out: firstly, the metal plate unfolding is a prerequisite of the whole project, the precision of the metal plate unfolding not only meets the requirement in design, but also must meet the precision requirements of convenient rolling and convenient assembly; secondly, the forming and correction of the pipeline play a role in starting and starting in the whole construction process and are a central link of the construction; finally, the assembly of the semi-closed pipeline, the elbow and the tee joint is the last inspection of the construction quality; with pre-installation, all problems not previously apparent are reflected at this point.
Aiming at the problems which may occur and have occurred in the construction process, the technical key points of the air cooling pipeline construction are summarized as follows.
As shown in fig. 2, the sheet metal unfolding of the bend is the basis of the project, and the prerequisite for the unfolding is to know the actual lengths of all lines constituting the unfolding map; considering that all the solid lengths cannot be or are not necessarily obtained in the actual blanking assembly process, the actual cutting track is adjusted, namely, the elbow is subjected to discontinuous point sampling lofting according to the principle that the difference value between the arc length and the chord length is less than or equal to 5mm, and the actual point sampling interval is 50-100 mm; firstly, because the section of the elbow is a curve, lofting is carried out on the section of the shovel groove by taking the middle diameter as a reference, and the section of the shovel groove is unfolded by taking the actual contact surface (lofting is carried out on the high end of the inclined cut pipe according to the inner skin, and lofting is carried out on the low end of the inclined cut pipe according to the outer skin); secondly, in order to control the error of group timing, dividing lines of 90 degrees, 180 degrees, 270 degrees and 360 degrees are marked on the unfolding of all the components (2 mm gaps are embedded in the numerical control cutting process); thirdly, in consideration of avoiding the appearance of cross-shaped welding seams and the balance of mechanical properties in the assembly process, the same elbow can be unfolded in different forms (the butt joint position is composed of 90 degrees, 180 degrees, 270 degrees and 360 degrees, but not the only), and the rolled and molded components are ensured to be consistent and meet the requirements of drawings; fourthly, the inclination deviation of the end face is not more than 1 percent of the outer diameter and is not more than 3 mm; fifth, the allowable deviation of the elbow circumference should conform to: when the nominal diameter is larger than 1000mm, the allowable deviation is +/-6 mm; when the nominal diameter is 1000mm or less, the allowable deviation is + -4 mm.
Because the tee joint is complex in forming, in order to ensure the assembly precision, the tee joints in various forms are specially split and adjusted differently; no matter how the splitting and the adjustment are made, the requirements of the drawing are met, so that the rolling group can be conveniently assembled for the purpose, and the structure can be effectively and reasonably differentiated; tee joint: the device is divided into a large and small opening, an embedded section, a diversion bend and a straight section at the lower part (the straight section cylinder section is manufactured firstly, and then the material is manufactured for the second time after molding); fig. 3 shows a lofting view of a diversion bend, an embedding section and a large and small opening respectively from top to bottom.
Therefore, for the structural member with a complex structure, the principle of manufacturing is to differentiate the structural member into a simple and reliable single structural body, and then the structural member is spliced and assembled again by an effective process method; the difficult split that becomes easy like this, at first let the work progress become to simplify controllable, secondly make our equipment satisfy the needs of component, more importantly not only satisfied the construction requirement and more improved the unloading precision of component, make the book system in later stage and group link more convenient.
Rolling and forming: the forming and correction of each cylinder section of the pipeline play a role in starting and finishing in the whole construction process, and different rolling methods are adopted for different structural members; for the rolling of the straight section, only an iron sheet sample plate is used for correcting, and a (90-degree 180-degree 270-degree 360-degree) graduation line is marked; however, as for the big and small openings belonging to the cone section and the curvature of each point in the arc length direction of the big and small openings continuously changes, two (big opening and small opening) three-dimensional templates are needed to ensure the accuracy of the taper; the conical section is more complex than the straight section, and the manufacturing difficulty is higher; therefore, the quality of each process must be ensured to ensure the manufacturing quality of the cylinder section, particularly the manufacturing quality of the conical section, and the process quality is ensured by seeking a reasonable and practical manufacturing process; considering the plate rolling working performance of the four-roller plate rolling machine and the taper and radian of the rolled plate, a waste steel plate is firstly used as a test paper, and after the taper is reached, the formal rolling of the cone is carried out; the adjusting points, especially the supporting rollers, are not required to be randomly moved in the normal rolling process.
Pre-bending: because only the part of the steel plate contacted with the upper roller can be bent, two ends of the steel plate are respectively provided with a section of length which can not be bent, and the section of length becomes a residual straight edge; through comprehensive consideration of equipment capacity, resource saving, construction period shortening and the like, the method with the guide plate is most practical and effective; the process is selected, so that the problem that the two ends, particularly the two ends of a small opening, are upwarped is solved, and a foundation is laid for later preassembly.
Centering: as shown in fig. 4, due to the particularity of the cone, the normal of each cross section of the cylinder is not a parallel straight line when the normal is reflected on the flat plate, so when the cone is rolled, firstly, a normal is drawn on the cylinder at intervals of 100mm by taking a small opening as a reference; as shown in fig. 5, when rolling, the normal line is always on the plane perpendicular to the side rollers with the upper roller line of the four-roller machine; taking the middle of three adjacent normal lines as a reference (the ABC area takes the B normal line as the reference, the BCD area takes the C normal line as the reference, and so on), and rolling the rolling direction in the area according to the normal line all the time; in the rolling process, comparing and measuring chord lengths by using a sample plate in each area of each roll, wherein the chord length measuring method is to measure the chord length of the end A and the normal line of the center of the rolled area; for example, AB chord length is measured after rolling an ABC area, AC chord length is measured after rolling a BCD area, rolling of the next area is performed after the previous area meets the requirements of a sample plate and chord length, and the like, and finally, a KLM area is rolled to enable AL chord length to meet the requirements, and AL is automatically overlapped to form a side to form a complete closed opening.
The non-fit clearance between the sample plate and the inner wall of the pipe is in accordance with the following regulations: the butt joint longitudinal seam is not more than 10% of the wall thickness and not more than 3 mm; the butt joint longitudinal seam 200mm away from the pipe end is not more than 2 mm; the other parts are not larger than 1 mm; the vertical allowable deviation of the end surface of the reel pipe and the central line is not more than 1% of the outer diameter of the reel pipe and not more than 3mm, and the straightness deviation of each meter of straight pipe is not more than 2 mm; the method well ensures the rolling of the cone section, particularly avoids the problem of angle crossing of the cylinder body in the rolling process, and greatly reduces the subsequent correction value; the method well ensures the rolling of the conical section, particularly avoids the problem of the angle channeling of the cylinder body in the rolling process, and greatly reduces the subsequent correction value.
And (3) correction: in the rolling process, the condition of over-bending or insufficient curvature is avoided, and the forming defects of the cylinder at each position can be found through the inspection of the three-dimensional template; the correction becomes an essential maintenance means; there are no non-classifications for the repair method: hot pressing and cold pressing; hot pressing is flame correction, the forming effect of the hot-pressed cylinder is good, the resilience is very small, the forming effect of the cold-pressed cylinder is not ideal, the resilience is large, sometimes the resilience conditions are inconsistent and uneven, the cold-pressed cylinder cannot be formed at one time generally, and the cylinder can be formed finally only by correcting through a flame correction method; however, most of the cylinders are blanked in a net size, flame correction is inevitable, certain shrinkage is generated, the size of the assembled cylinders is changed, the hot-press correction position is annealed once, the specific technical index of the parent metal is changed, the instability of future use is increased, and cold press forming is the primary choice for ensuring the construction quality.
In the rolling process of the cylinder body, a cold press molding process is required; in order to control the cold-press forming quality, the following method is adopted: after each section of cylinder is pressed by a fetal membrane for the first time, checking the forming error by using a three-dimensional template; adding correction strips according to the amount of molding error gives correction see fig. 6; (the width of the correcting board is generally 40mm, the thickness is determined by the error value, the number of the board strips can be increased according to the actual situation, and the pressing sequence is that the height direction is corrected firstly, and then the opening direction is corrected); if the lath is added, the barrel is changed regularly, the amount of resilience is inspected each time, the lath can be directly corrected, and if the barrel is locally changed irregularly, the lath needs to be added locally for correction; simultaneously, a forming contour line is marked on the cylinder by using a three-dimensional sample plate, a size check point is determined, and local forming check is directly carried out by using the size; by implementing the process, the difficulty of the cold pressing technology of the cone section cylinder is well solved, and good conditions are provided for the assembly of the next stage.
The following problems are also noted: the steel plate enters a roller of the plate bending machine, and the end line of the steel plate is parallel to the roller; therefore, a theodolite can be erected at the edge of the plate bending machine for correction; the descending speed of the compression roller of the plate bending machine is slowly carried out, and crown blocks are matched in the rolling process to prevent the steel plate from deforming due to self-weight sag and influencing the formation of radian; the radian of the steel plate is continuously checked by the sample plate in the coiling process, and after complete coincidence, the steel plate can be used as a support to protect the radian of the steel plate.
The following requirements must be met before assembly to enter the assembly stage: at the interface spliced on site, the error between the perimeter and the drawing is not more than 2mm, and the ellipse is not more than 5 mm; at the spliced interface in the field, the error of two adjacent ends is not more than 2mm, and the ellipse is not more than 5 mm; the vertical allowable deviation of the end surface of the reel pipe and the central line is not more than 2mm, and the straightness deviation of each meter of straight pipe is not more than 2 mm; pre-installing each section of cylinder after each section of cylinder is qualified; the whole assembly must be carried out on solid ground, and an assembly operating platform should be laid before the assembly, and the assembly is carried out from bottom to top in sections.
The assembly of the elbow is shown in fig. 7, namely the assembly of the diversion elbow, the assembly of the elbow and the assembly of the tee joint component.
Assembling and welding the semi-closed pipeline: the semi-closed pipeline has no actual force application point, and the accurate type of the closed opening is difficult to ensure in the rolling process, so that a mould is manufactured before rolling so as to ensure the precision of the closed opening; in order to ensure the size precision of the two side plates, the assembly of the side plates and the cylinder body is carried out on a mould; therefore, the precision of the clamping fixture is particularly important; in order to ensure the rigidity, I-shaped steel is adopted as a main beam of the clamping fixture; and straightening to be within the range of +/-2 mm, and adopting proper reversible deformation measures (generally, the size of two ends of the mould is plus 3mm, and the middle part is minus 3 mm) in the assembling process; the accuracy of the size is checked at any time in the welding process of the clamping fixture, so that deformation is prevented; after welding, leveling the mould and firmly fixing to prevent displacement; the length of the mould is required to meet the requirement of manufacturing the longest cylinder.
And (3) rounding the barrel section: 1/4-1/6 circumference sample plates are made before the reel pipe, so that the roundness of the reel pipe is verified; the inch is mastered in the pre-bending process, the sample board card is used for reference at any time, the bending angle is processed no matter what the size, and the next process can be carried out after the bending angle meets the requirement; the circle is coiled without one-time positioning, and the stress is released by performing micro calibration for a plurality of turns, and a sample plate is not used for reference; the radian plate is directly added at the joint to ensure the roundness of the longitudinal seam; cleaning up the cut iron oxide before coiling; for some cylinder sections with larger deformation, the rolling machine can be reused for circle correction after the longitudinal seam welding is finished, so that the integral roundness of the cylinder sections and the alignment error variables of the annular welding seam and the longitudinal welding seam are ensured to be within a standard range; after the rolling, multi-directional supports (available waste materials) are arranged on each cylindrical section about 200mm away from the pipe orifice so as to absolutely ensure that each section of cylindrical section does not generate large elastic deformation and plastic deformation before and during the assembly.
Assembling a cylinder body: before assembly, the method is characterized in that a batching list is strictly checked besides the correction of deformation caused by welding and raw materials, whether longitudinal seams are staggered by more than 200mm and site hole opening positions are staggered strictly according to design requirements is judged, and the circumferential seam distance of a steam pipe section is at least 500 mm; during assembly, the parts are fastened by adopting a fixture to control the assembly and welding gaps, and a spot welding fixture positioning method is not suitable; during group combination, the angle size of the paper is converted into a measurable size; strictly checking and controlling the misalignment amount; the cylinder formed by the cylinder sections and the cylinder section assembly is carried out on a special platform or a clamping fixture, the mutual alignment of the perimeter of two ends and a central line sample punching point is ensured so as to ensure the straight line after each cylinder section assembly, and the ovality of a pipe orifice is ensured by arranging a diagonal bracing in the first cylinder section.
And (3) welding sequence: single welding seam welding sequence: adopting automatic submerged arc welding and manual arc welding on the inner side (if the assembly gap can not meet the requirements of automatic submerged arc welding, properly welding a temporary back-sealing welding seam on the outer side by the manual arc welding), back gouging and adopting automatic submerged arc welding and manual arc welding on the outer side; the welding sequence of the cylinder body is as follows: single cylinder section longitudinal joint and cylinder section annular joint; 2 lifting lugs are arranged on each section of pipeline, the lifting lugs are arranged in positions to ensure that the lifted pipeline is level and balanced in stress, the size and the thickness of a base plate of each lifting lug are calculated, circular seams and longitudinal seams are staggered by more than 200mm during welding, and the welding angle of each lifting lug meets the requirement and needs to be subjected to dye penetrant inspection; the pipeline serial number is written according to the component number of the layout drawing, and the serial number is sprayed at the position 100mm away from the pipe port by using a marker pen or paint; the assembly of the eccentric reducer is strictly checked and controlled and is confirmed by pre-assembly after the manufacture is finished.
The side plate is assembled with the cylinder body: before assembly, barrel welding correction and size inspection are carried out, and an inner groove of the barrel is inspected, trimmed and polished; converting the assembly size of the side plate and the cylinder into a measurable size and marking the measurable size on a workshop manufacturing drawing; special attention needs to be paid to the assembly size at the large head and the small head; the side plate and the assembly mould are firmly fixed, positioning points are drawn on the side plate, an assembly line is drawn along the length direction, and temporary supports are welded; the length of the side plate should be ensured to avoid affecting the assembly of the sealing plate; grinding the butt weld joint on the inner side of the side plate; hanging the side plate on the barrel, aligning the center and the positioning size, checking the welding gap between the side plate and the barrel, and spot-welding the barrel and the side plate; and (4) assembling and aligning the cylinder body and the side plate.
Assembling the inner support and the outer reinforcing ring/adjusting ring (welding the outer reinforcing ring/adjusting ring and the side plate is carried out after the side plate is straightened); an internal support is additionally arranged at the opening end of the cylinder body to prevent the cylinder body from expanding and deforming; when the side plate and the reinforcing ring/adjusting ring are combined, the joint is tightly closed, so that an overlarge gap is avoided between the side plate and the reinforcing ring/adjusting ring, and the side plate is greatly deformed during welding; the outer reinforcing ring and the inner supporting ring are large enough to be welded with the edge plate (R is larger than 25mm or the position is welded with a section firstly) so as to ensure the continuity and the penetrability of the welding seam of the edge plate; the drawing position of the outer reinforcing ring and the consistency/straightness of the position of the bolt hole are ensured; the distance between the two reinforcing rings and the inspection tolerance of the distance between the reinforcing rings and the pipe end are 2 per mill, and the reinforcing rings cannot be skewed so as to ensure the smooth installation of other accessories on site; assembling a support; the position of a support (particularly a fixed support) and a bolt hole on the support are strictly controlled; adjusting the welding deformation of the support base plate; splicing of the adjusting ring is reduced as much as possible, and the adjusting ring is welded with the cylinder after ground assembly welding with double-sided grooves and qualified magnetic powder detection; a single-side groove is formed at the joint of the adjusting ring and the side plate; the adjusting ring is arranged on the diameter-variable side to facilitate field installation and better control the roundness of the diameter-variable ring, and the inner diameter of the adjusting ring is not larger than the designed size; assembling a sealing plate, confirming the size of the sealing plate and a drain hole, and ensuring the position and the levelness/verticality of the sealing plate during assembling; welding seams with the side plates (the outer sides are easy to leak welding or welding can not be well performed due to the fact that a support blocks the space, a method for properly finishing the side plates or a front-back welding sequence of supporting and sealing plates can be adopted) are welded after the side plates are straightened; since the sealing plate is located inside the steam pipeline, inspection and repair of the sealing plate are difficult in case of leakage on site, and therefore, the welding seam must be subjected to magnetic powder inspection to ensure welding quality.
The welding sequence is as follows: spot welding of the side plate and the cylinder assembly, welding of an inner support spacer, welding of an adjusting ring/a reinforcing ring/a support/a sealing plate, welding of an inner welding seam (key inspection and control) of the side plate and the cylinder, welding of an outer welding seam of the side plate and the cylinder, and welding of the side plate and the adjusting ring/the reinforcing ring/the sealing plate; assembling accessories, wherein the connecting plates of the air walls are in the same straight line and at an inclined angle; and the height of the welding seam is enough; assembling the manhole, paying attention to the arrangement direction of the flange holes, wherein the welding line of the reinforcing plate cannot be overlapped with the welding line of the cylinder body and is staggered by 100 mm; adjusting the tyre to be stripped, leveling the width direction of the side plate, adjusting the straightness (required to be 1/1000 and 10mm at the maximum) in the length direction, and checking the overall size of the cylinder to meet the requirements of specifications and SPX (spray gauge) when the size of an upper opening and the size of a lower opening are 0-10 mm (the key point of checking is the joint with the tube bundle); after the adjustment is qualified, the welding seams of the side plate, the adjusting ring, the reinforcing ring and the sealing plate are finished; inspecting leakage of welding seams between the side plates and the cylinder body; the supports arranged on the cylinder sections at the two ends of each section of cylinder body prevent larger deformation.
And (4) testing the adjacent cylinder ports on the same platform, and performing at least one row of test assembly on the first row so as to find the deviation and correct the deviation in time.
After the sectional assembly, the total height and the angle among the cylinder hole, the supporting seat and the turning point are required to be ensured to meet the design requirements, and the subsequent processes can be carried out; allowable deviation of each part: the deviation value of the center of the cylinder steel plate ring to the inspection center on the assembly platform is less than or equal to 1/1000H and less than or equal to 10 mm; the upper opening of the steel plate ring of the cylinder body is horizontal, and the height difference is less than or equal to 4 mm; checking the vertical height difference of the cylinder body to be +/-5 mm; the deviation of the radius R of the shell steel plate ring from the design value is +/-5 mm; checking the ovality of the field assembly interface, and requiring that the maximum and minimum diameter difference is not more than 2D/1000(D is the design diameter); the technical requirements of the joint misalignment amount and the end gap of the groove to be assembled are met by the requirements of electric welding: the transverse seam is less than or equal to 1/10t (t is the thickness of the steel plate) and is not more than 3 mm; the vertical seam is less than or equal to 3 mm; the limit deviation of the end part of the groove is +/-3 mm.
After the barrel is preassembled and adjusted, a sample punching mark is formed at the assembling position of the two sections of the barrel sections of the interface in a field assembly manner, and the sample punching mark can be sent.
Although the invention has been described in detail above with reference to a general description and specific examples, it will be apparent to one skilled in the art that modifications or improvements may be made thereto based on the invention. Accordingly, such modifications and improvements are intended to be within the scope of the invention as claimed.
In the present specification, the terms "upper", "lower", "left", "right", "middle", and the like are used for clarity of description, and are not intended to limit the scope of the present invention, and changes or modifications in the relative relationship may be made without substantial changes in the technical content.

Claims (10)

1. A manufacturing process method of an air cooling pipeline of a thermal generator set is characterized by comprising the following steps:
step S100, compiling an operation instruction book according to a construction drawing;
s200, performing panel review, sequentially performing steel plate sand blasting, template manufacturing and template inspection, and simultaneously sequentially performing sheet metal unfolding, margin control and typesetting programming;
step S300, splicing plates, performing numerical control blanking and manual material marking, and performing net size blanking and remaining waste material blanking;
s400, rolling and forming, wherein a straight pipe is formed at one time, an iron sheet sample plate is checked, a conical section is formed in different areas, a three-dimensional sample plate is checked, chord length is monitored in real time, and a guide plate is rolled and the iron sheet sample plate is checked;
s500, curvature inspection, secondary material marking, perimeter inspection, lead cutting and ovality inspection are carried out;
s600, carrying out integral assembly, including elbow assembly, tee assembly and cross assembly;
step S700, performing size review;
step S800, welding and flaw detection are carried out;
and S900, polishing and handing over.
2. The manufacturing process method of the air cooling pipeline of the thermal generator set according to the claim 1, characterized in that in the sheet metal unfolding process of the step S200, the straight section cylinder sections are unfolded according to the middle diameter, manual lofting is adopted, and welding shrinkage allowance and field installation allowance are reserved;
adjusting the actual cutting track in the metal plate unfolding of the elbow, namely performing discontinuous point sampling lofting on the elbow according to the principle that the difference value between the arc length and the chord length is less than or equal to 5mm, wherein the actual point sampling interval is 50-100mm, lofting is performed on the section of the shovel groove by taking the pitch diameter as the reference, and the section of the non-shovel groove is unfolded by taking the actual contact surface; all the components are unfolded by marking graduation lines of 90 degrees, 180 degrees, 270 degrees and 360 degrees; the rolled and formed components are ensured to be consistent and meet the requirements of drawings; the inclination deviation of the end face is not more than 1% of the outer diameter and not more than 3 mm; when the allowable deviation of the circumference of the elbow is that the nominal diameter is more than 1000mm, the allowable deviation is +/-6 mm; when the nominal diameter is less than or equal to 1000mm, the allowable deviation is +/-4 mm;
the expansion of the tee meets the requirement of a drawing, and the tee is divided into a large small opening, an embedded section, a diversion bend and a straight section at the lower part, wherein the straight section cylindrical section is manufactured firstly, and then the material is numbered for the second time after the straight section cylindrical section is formed.
3. The manufacturing process method of the air-cooled pipeline of the thermal generator set according to claim 1, wherein in the rolling and forming process of the step S400, for the rolling of the straight section, only an iron sheet sample plate is used for correction, and division lines of 90 °, 180 °, 270 ° and 360 ° are marked, and for the continuous change of curvature of each point in the arc length direction of the large and small openings belonging to the conical section, two three-dimensional sample plates are used to ensure the accuracy of the taper;
when pre-bending, a guide plate is arranged;
when the alignment is carried out, a normal line is drawn at intervals of 100mm on the cylinder body by taking a small opening as a reference, when the rolling is carried out, the normal line and an upper rolling shaft line of the four-roller machine are always positioned on a plane vertical to the side rollers, and the rolling direction is always carried out according to the normal line by taking the middle of three adjacent normal lines as a reference; in the rolling process, comparing and measuring chord lengths by using a sample plate in each area of each roll, wherein the chord length measuring method is to measure the chord length at the normal line of the center of the end and the rolled area; the butt joint longitudinal seam is not more than 10% of the wall thickness and not more than 3 mm; the butt joint longitudinal seam 200mm away from the pipe end is not more than 2 mm; the other parts are not larger than 1 mm; the vertical allowable deviation of the end surface of the reel pipe and the central line is not more than 1% of the outer diameter of the reel pipe and not more than 3mm, and the straightness deviation of each meter of straight pipe is not more than 2 mm;
during correction, after each section of cylinder is pressed by a fetal membrane for the first time, a three-dimensional template is used for checking the forming error amount, and a correction lath is added according to the forming error amount for correction; if the lath is added, the barrel is changed regularly, the springback amount of each time is inspected, the lath can be directly corrected, if the barrel is locally irregular, the lath needs to be additionally added for correction, meanwhile, a three-dimensional sample plate is used for marking a forming contour line on the barrel, a size check point is determined, and the size is directly used for local forming inspection.
4. The manufacturing process method of the air cooling pipeline of the thermal generator set according to claim 1, wherein the requirements to be met before the integral assembly in the step S600 are as follows: at the interface spliced on site, the error between the perimeter and the drawing is not more than 2mm, and the ellipse is not more than 5 mm; at the spliced interface in the field, the error of two adjacent ends is not more than 2mm, and the ellipse is not more than 5 mm; the vertical allowable deviation of the end surface of the reel pipe and the central line is not more than 2mm, and the straightness deviation of each meter of straight pipe is not more than 2 mm; after each section of the barrel is processed to be qualified, the barrel can be pre-assembled, the whole assembly must be carried out on the solid ground, and an assembly operating platform is laid before the assembly and is carried out in a segmented mode from bottom to top.
5. The manufacturing method of the air-cooled pipeline of the thermal generator set according to claim 4, wherein in the step S600, assembling and welding of the semi-closed pipeline are performed, a clamping fixture is manufactured before rolling, a main beam of the clamping fixture is made of I-steel and is straightened to be within +/-2 mm, a reversible deformation measure is adopted in the assembling process, and the accuracy of the size is checked at any time in the welding process of the clamping fixture; after welding, the mould is leveled and fixed firmly to prevent displacement.
6. The manufacturing process method of the air cooling pipeline of the thermal generator set according to claim 5, wherein in the step S600, during the assembly process of the side plate and the cylinder body, the cylinder body is welded and corrected and the size is checked before the assembly, and the inner groove of the cylinder body is checked, repaired and polished; converting the assembly size of the side plate and the cylinder into a measurable size and marking the measurable size on a workshop manufacturing drawing; the side plate and the assembly mould are firmly fixed, positioning points are drawn on the side plate, an assembly line is drawn along the length direction, and temporary supports are welded; and (3) hanging the side plate on the barrel, aligning the center and the positioning size, checking the welding gap between the side plate and the barrel, and spot-welding the barrel and the side plate.
7. The manufacturing process method of the air cooling pipeline of the thermal generator set according to claim 1, wherein after the whole assembly in the step S600 is completed, assembly inspection is performed: the upper opening of the steel plate ring of the cylinder body is horizontal, the height difference is less than or equal to 4mm, and the vertical height difference of the cylinder body is checked to be +/-5 mm.
8. The manufacturing process method of the air-cooling pipeline of the thermal generator set according to claim 7, wherein after the whole assembly in the step S600 is completed, the assembly inspection further comprises: the deviation of the radius of the steel plate ring of the shell from the design value is +/-5 mm.
9. The manufacturing process method of the air-cooling pipeline of the thermal generator set according to claim 8, wherein after the whole assembly in the step S600 is completed, the assembly inspection further comprises: and checking the ovality of the field assembly to the interface, wherein the maximum and minimum diameter difference is required to be not more than 2D/1000(D is the design diameter).
10. The manufacturing process method of the air-cooling pipeline of the thermal generator set according to claim 9, wherein after the whole assembly in the step S600 is completed, the assembly inspection further comprises: the technical requirements of the misalignment amount of the splicing matching port and the end gap of the groove are in accordance with the requirements of electric welding, and the transverse seam is less than or equal to 3 mm; the vertical seam is less than or equal to 3 mm; the limit deviation of the end part of the groove is +/-3 mm.
CN202011468630.3A 2020-12-06 2020-12-06 Manufacturing process method of air cooling pipeline of thermal generator set Active CN112570998B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202011468630.3A CN112570998B (en) 2020-12-06 2020-12-06 Manufacturing process method of air cooling pipeline of thermal generator set

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202011468630.3A CN112570998B (en) 2020-12-06 2020-12-06 Manufacturing process method of air cooling pipeline of thermal generator set

Publications (2)

Publication Number Publication Date
CN112570998A true CN112570998A (en) 2021-03-30
CN112570998B CN112570998B (en) 2024-01-05

Family

ID=75134953

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202011468630.3A Active CN112570998B (en) 2020-12-06 2020-12-06 Manufacturing process method of air cooling pipeline of thermal generator set

Country Status (1)

Country Link
CN (1) CN112570998B (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113305513A (en) * 2021-06-09 2021-08-27 中国电建集团四川工程有限公司 On-site factory manufacturing construction method for circulating water pipeline
CN113351686A (en) * 2021-06-21 2021-09-07 中国船舶重工集团柴油机有限公司 Correcting method for gas turbine low-pressure outer cylinder combined cylinder front guide plate
CN114406623A (en) * 2022-02-28 2022-04-29 凯奇集团有限公司 Forming method of stainless steel sliding cylinder elbow
CN115302118A (en) * 2022-08-12 2022-11-08 哈尔滨锅炉厂有限责任公司 Forming method of circular arc tube panel

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB561051A (en) * 1942-07-17 1944-05-03 British Power Boat Company Ltd Improvements in or relating to the manufacture of curved pipings or ducts
FR1420397A (en) * 1964-07-20 1965-12-10 Machine for the manufacture of frustoconical sheet material containers, more especially yoghurt pots
RU2406580C1 (en) * 2010-01-11 2010-12-20 Министерство промышленности и торговли РФ (МИНПРОМТОРГ РОССИИ) Method of pipeline production
CN202400284U (en) * 2011-12-19 2012-08-29 大连中远船务工程有限公司 Large-caliber air channel structure for ship cabin
CN105351626A (en) * 2015-11-25 2016-02-24 中国能源建设集团广东省电力设计研究院有限公司 Novel supporting hanger system for heat primary air channel on outlet of thermal power plant air preheater
CN107876943A (en) * 2017-11-30 2018-04-06 南通蓝岛海洋工程有限公司 A kind of building technology of wind-power tower
CN108581378A (en) * 2018-04-13 2018-09-28 中船黄埔文冲船舶有限公司 A kind of production method of hull elbow connection pipe
CN110744271A (en) * 2019-11-01 2020-02-04 五矿二十三冶建设集团第二工程有限公司 Gas pipe network water-seal triangular method assembling construction method

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB561051A (en) * 1942-07-17 1944-05-03 British Power Boat Company Ltd Improvements in or relating to the manufacture of curved pipings or ducts
FR1420397A (en) * 1964-07-20 1965-12-10 Machine for the manufacture of frustoconical sheet material containers, more especially yoghurt pots
RU2406580C1 (en) * 2010-01-11 2010-12-20 Министерство промышленности и торговли РФ (МИНПРОМТОРГ РОССИИ) Method of pipeline production
CN202400284U (en) * 2011-12-19 2012-08-29 大连中远船务工程有限公司 Large-caliber air channel structure for ship cabin
CN105351626A (en) * 2015-11-25 2016-02-24 中国能源建设集团广东省电力设计研究院有限公司 Novel supporting hanger system for heat primary air channel on outlet of thermal power plant air preheater
CN107876943A (en) * 2017-11-30 2018-04-06 南通蓝岛海洋工程有限公司 A kind of building technology of wind-power tower
CN108581378A (en) * 2018-04-13 2018-09-28 中船黄埔文冲船舶有限公司 A kind of production method of hull elbow connection pipe
CN110744271A (en) * 2019-11-01 2020-02-04 五矿二十三冶建设集团第二工程有限公司 Gas pipe network water-seal triangular method assembling construction method

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113305513A (en) * 2021-06-09 2021-08-27 中国电建集团四川工程有限公司 On-site factory manufacturing construction method for circulating water pipeline
CN113351686A (en) * 2021-06-21 2021-09-07 中国船舶重工集团柴油机有限公司 Correcting method for gas turbine low-pressure outer cylinder combined cylinder front guide plate
CN114406623A (en) * 2022-02-28 2022-04-29 凯奇集团有限公司 Forming method of stainless steel sliding cylinder elbow
CN114406623B (en) * 2022-02-28 2023-09-22 凯奇集团有限公司 Forming method of stainless steel sliding tube elbow
CN115302118A (en) * 2022-08-12 2022-11-08 哈尔滨锅炉厂有限责任公司 Forming method of circular arc tube panel

Also Published As

Publication number Publication date
CN112570998B (en) 2024-01-05

Similar Documents

Publication Publication Date Title
CN112570998A (en) Manufacturing process method of air cooling pipeline of thermal generator set
WO2019104814A1 (en) Construction process for wind power tower barrel
CN111532379A (en) Ship anchor platform structure and machining method thereof
CN112342922B (en) Method for manufacturing streamline steel arch with special-shaped section box-type steel structure
CN104843357B (en) Tank of benzene hydrogenation engineering and manufacturing and mounting method thereof
CN108687489B (en) manufacturing method of large hopper
CN105421211A (en) Manufacturing method for large-span single-arch-rib steel box arch
CN110039217A (en) A kind of upside-down mounting mode storage tank concentricity, ovality control construction method
CN102011455A (en) Complex annular shed bending and twisting component and manufacturing method thereof
CN100484700C (en) Automatic manufacturing technique of large sized steel pipe
CN107489163B (en) method for mounting ring bolt of metallurgical industrial furnace body
CN114888524A (en) Arching method for large-scale inner flange connection trestle
CN113718631A (en) Steel bridge hyperbolic paraboloid thin plate dense rib plate unit and manufacturing method thereof
CN101870041B (en) Mounting technique for double-deck floating roof structure of large storage tank
CN113814676A (en) Manufacturing method of large-diameter tower equipment
CN109340452B (en) Installation and construction method of 56-inch oil and gas transmission pipeline
CN113020901A (en) Steel plate splicing construction process for large-diameter variable-diameter section steel pipe pile
CN217378980U (en) Cup-shaped foundation assembled aluminum mold device for railway traction substation/pavilion equipment framework
CN108951883B (en) High-precision embedded part installation method for nuclear power station
CN206382799U (en) A kind of group mounted welder taken over applied to chemical industry with flange
CN112360630B (en) Hovercraft gas turbine hydraulic exhaust pipe cover and machining method thereof
CN115679027B (en) Assembling construction method for blast furnace hot-air bustle pipe
CN115263049B (en) Nuclear power station large-diameter reactor core carbon steel shaft integrated module structure and construction method thereof
CN118664267A (en) Large rectangular steel structure installation method connected with concrete pipeline
CN114850628B (en) Combined construction method for butt joint of double 90-degree bent pipes with S-shaped structures

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination
GR01 Patent grant
GR01 Patent grant