钢管热镀锌φ生产线技术操作规程样本.doc

目 录 Contents
第一部分 生产概况……………………………………………………………………2
Section one General description of the production line
一、生产工艺步骤图……………………………………………………………………2
Process flow diagram
二、工艺平面部署示意图………………………………………………………………2
Layout sketch
三、原料规格及实施标准………………………………………………………………2
Specification of material and its criteria
四、试生产说明…………………………………………………………………………3
Starting-up illustration
第二部分 设备关键技术性能 ………………………………………………………5
Section two Main technical characteristics of the equipments
一、钢管前处理段………………………………………………………………………4
Pre-treatment of steel pipes
二、烘干炉………………………………………………………………………………5
Drying oven
三、入料辊道……………………………………………………………………………6
Feeding rollers
四、镀锌炉………………………………………………………………………………6
Galvanizing furnace
五、镀锌锅………………………………………………………………………………8
Galvanizing vat
六、浸锌机构……………………………………………………………………………8
Dipping unit
七、拨料机构……………………………………………………………………………8
Kick out unit
八、提升机构……………………………………………………………………………8
Lifting unit
九、磁力辊………………………………………………………………………………8
Magnetic roller
十、外吹…………………………………………………………………………………8
External blowing
十一、磁力辊升降机构…………………………………………………………………9
Elevation device of magnetic roller
十二、曳出辊道…………………………………………………………………………9
Pulling out roller
十三、猫头叉横移机构…………………………………………………………………9
Fork-shaped transverse moving device
十四、内吹和升降机构…………………………………………………………………9
Internal blowing and elevation device
十五、冷却水槽…………………………………………………………………………9
Cooling water tank
十六、检验台架…………………………………………………………………………10
Check table
十七、钝化辊道…………………………………………………………………………10
Passivation roller
十八、钝化喷淋站………………………………………………………………………10
Spraying station for passivation
十九、烘干台架…………………………………………………………………………10
Drying table
二十、打印辊道…………………………………………………………………………10
Stamp roller
二一、打印机……………………………………………………………………………10
Stamp machine
二二、六角打包设备……………………………………………………………………10
Packaging tools
二三、除尘器……………………………………………………………………………10
Cleaner
二四、电器设备…………………………………………………………………………10
Electrical device
第三部分 镀锌车间技术操作规程……………………………………………………11
Section three Operating instruction of galvanizing workshop
一、 目标…………………………………………………………………………………11
Purposes
二、 使用范围……………………………………………………………………………11
Applying scope
三、 工作程序……………………………………………………………………………11
Working procedures
3.1、酸洗工序…………………………………………………………………………11
Acid cleaning
3.2、火炕工序…………………………………………………………………………11
Heating
3.3、锌锅工序…………………………………………………………………………11
Dipping
3.4、内外吹工序………………………………………………………………………12
Blowing
3.5、钝化水洗工序……………………………………………………………………12
Passivation and wash
3.6、检验工序…………………………………………………………………………12
Check
3.7、司炉工……………………………………………………………………………12
Operators
修订情况统计……………………………………………………………………………12
Record of revision

…………………………………………12
第一部分 生产概况 Section one General description of the production line
一． 生产工艺步骤图 Process flow diagram
钢管热镀锌生产线是将成品黑管经过表面处理后自动侵锌，在钢管内外表面镀一层耐腐蚀、表面光洁锌层生产设备。Steel pipe hot-dip galvanizing line is the automatic equipments to produce resistant and smooth layer on the surface of raw pipes after cleaning.

黑管raw pipes

涂溶剂 applying impregnant

空冷natural cooling

烘干 drying

水冷 cooling with water

碱洗脱脂alkali cleaning
热浸锌 hot-dipping

检验 check

盐酸洗 acid treatment

外吹 external blowing

打印 stamp

漂洗 water cleaning
内吹 internal blowing

入库 entering warehouse

二．工艺平面部署示意图（附）Layout sketch (enclosed)
三．原料规格及实施标准Specification of material and its criteria
φ114生产线 产品纲领 main parameters of φ114 production line
序号number
规格 specification
壁厚mm
Thickness
单重kg/m
Unit weight
6m重 kg
Weight per 6m
小时 产量 支/时
Yield by pieces
小时产量千克/时
Yield by weight
面积
产量
m2/时
yield by area
所占 百分比%
Proportion
年工作 时间
小时
Running time per year
年产量吨
Yearly yield by weight
年面积 产量 m2
Yearly yield by area

1
0.5"
2.65
1.22
7.32
1100
8000
770
40
1800
14400
1368000
2
0.25"
2.65
1.58
9.48
844
8000
770
3
1"
3.25
2.44
14.64
546
8000
628
30
1350
10800
847800
4
1.25"
3.25
3.14
18.84
424
8000
628
5
1.5"
3.25
3.61
21.65
368
8000
628
6
2"
3.5
5.1
30.6
261
8000
582
10
450
3600
261900
7
2.5"
3.75
6.51
39.06
205
8000
544
10
450
3600
244800
8
3"
4.05
8.47
50.82
157
8000
503
5
225
1800
114525
9
4"
4.65
12.1
72.6
109
8000
438
5
225
1800
98550

计
100
4500
36000
2935575
实施标准：（GB3091-93）Designed according to criteria (GB3091-93)
注：支重及产量均以黑管计算。因酸、熔剂及锌消耗和镀管内外表面积相关，故生产统计除统计重量产量外，还需统计镀锌表面积产量，上述消耗也以表面积为基数进行考评。
Note: statistics of single pipe weight and yield based on raw pipes. Because consumption of acid, solvent and zinc is related to and calculated by pipe’s surface area, production data should include both weight yield and area yield.
四．试生产说明 Starting-up illustration
4.1镀锌炉点火和升温 Galvanizing furnace ignition and heating up
4.1.1 在锌锅内码放好锌锭和铅锭后可进行点火,高炉煤气热值极低,续燃能力差,较难点火.
经商议确定用液化气罐胶管及1.5米长1/2”（？）钢管组成燃烧器作为辅助火源进行点火。Piled zinc and lead ingots, and use a piece of rubber tube and 1.5 meter long steel pipe as a auxiliary burning device to ignite the main fire, because blast-furnace gas has low calorific value and is hard to light up.
点火前应准备8套燃烧器对8套烧嘴同时进行强迫点火。Prepare 8 sets of burning device to light 8 burners simultaneously.
因为镀锌炉在此之前曾经过水，但时间已过去4-5个月估量已自然风干。但为保险起见，升温时拟合适延缓升温梯度，并合适增加110℃区（显含水蒸发）及300℃区（结晶水去除）保温时间以期炉体安全渡过升温期。The furnace might have been contacted with water and got dry after 4-5 months exposure to air. But still for sake of safety, laggard and placid heating speed is recommended, elongate time at temperature of 110℃(flowing water evaporation) and 300℃(crystal water evaporation).
4.2.试生产用料准备 Raw pipes preparation for start-up
4.2.1炉料 furnace material: 1#锌锭 155吨 zinc ingot 155 ton
铅锭 15吨 lead ingot 15 ton
4.2.2.盐酸:37%盐酸比重为1.19，试生产时一条线先配2槽酸按17%浓度配制约需浓盐酸20吨. 正常生产时每日约消耗2(8”)-7(1/2”)吨不等浓酸,依据供货条件和生产计划可确定维持生产必需贮备量. Hydrochloric aid: its solution of 37% concentration has specific gravity of 1.19. Confect two tanks of 17% hydrochloric acid for one production line before start-up, and around 20 ton of high-concentration hydrochloric acid may be needed. In normal production, 2(8”)-7(1/2”) ton of 37% acid are consumed per day, so some stock of it is necessary to maintain continuous production with respect to delivery and production plan.
4.2.3 熔剂铵锌比按1.6:1，浓度按450克/升配制，一槽熔剂需用氯化铵4.7吨，氯化锌2.9吨。Proportion for ammonium and zinc in solvent is 1.6:1, almost 450g per liter. One tank of solvent needs 4.7 ton of ammonium chloride and 2.9 ton of zinc chloride.
4.2.4 锌铝合金：含10%锌铝合金100千克，在生产过程逐步加入，锌液中铝含量为50g/吨。添加铝目标一为预防锌液氧化，二为增加镀锌管表面亮度，三为增加镀层表面均匀性，预防因为锌层表面产生过大晶花而出现鼓棱。Zinc and aluminum alloy: 100kg of zinc-aluminum alloy with 10% of zinc is added into solvent, keeping aluminum content of 50g per ton in solvent. The function of aluminum is: 1. prevent oxidation to zinc solvent; 2. increase brightness of galvanized pipe’s surface; 3. improve uniformity of galvanizing coat; reduce protuberance caused by uneven zinc distribution.
铝过多会阻碍合金层形成而出现漏镀现象。Excessive aluminum may impede form of alloy coat, and the result is that the coat may not be integral.
4.2.5 钝化剂准备：钝化箱一次投放量为350升，其消耗和配制请和供给厂家联络。
Prepare passivation additives: adds 350L of it to passivation case for one time, and consult supplier for its consumption and confecting method.
4.3.工艺参数 process parameters
4.3.1 产品基础参数和设备运行参数 equipments and operation parameters
φ114生产线 φ114 production line
序号
规格
壁厚mm
单重kg/m
6m重 kg
小时 产量 支/时
小时产量千克/时
面积
产量
m2/时
生产节奏
秒
螺旋转速/调频
Rpm/ Hz
曳出速度
m/s
大磁辊电机频率
Hz

小磁辊电机频率
Hz

内吹时间
s
浸锌时间
s
所用螺旋
生产方法
1
0.5"
2.65
1.22
7.32
1100
8000
770
6.5
9.2/91
1.1
94
83
1
49
1#
双管
2
0.25"
2.65
1.58
9.48
844
8000
770
8.5
7/69
0.82
70
62
1
64
1#
双管
3
1"
3.25
2.44
14.64
546
8000
628
13.2
4.55/45
0.5
43
38
2
73
2#
双管
4
1.25"
3.25
3.14
18.84
424
8000
628
17
3.5/35
0.40
34
30
3
94
2#
双管
5
1.5"
3.25
3.61
21.65
368
8000
628
19.6
3/30
0.35
30
26
3
108
2#
双管
6
2"
3.65
5.10
30.6
260
8000
558
27.7
2.2/22
0.25
21
19
4
62
3#
双管
7
2.5"
3.65
6.51
39.06
205
8000
558
17.6
3.4/34
0.4
34
30
4
79
3#
单管
8
3"
4.05
8.47
50.82
157
8000
503
23
2.6/26
0.3
26
23
4
80
4#
单管
9
4"
4.65
12.2
73.2
109
8000
438
33
1.8/18
0.21
18
16
5
116
4#
单管
114线小磁辊电机 114 line small magnetic roller motor n=1460rpm i=23 r=100mm
大磁辊电机 large magnetic roller motor n=1460rpm i=59 r=225mm

4.3.2 温度参数：temperature parameters
4.3.2.1 烘干炉温度：120-200℃（热电偶显示）drying oven temperature: 120-200℃ (measured with TC)
4.3.2.2 熔剂温度：70-80℃（温度计人工测量）flux temperature: 70-80℃ (measured with thermometer manually)
4.3.2.3 锌液温度：450±5℃（热电偶测量或手持高温温度计人工测量）zinc pool temperature: 450±5℃ (measured with TC or thermometer manually)
4.3.2.4 水冷槽水温：70-80℃（温度计人工测量）temperature of cooling water tank 70-80℃ （measured with thermometer）
4.3.3 前处理操作和管理：pre-treatment and regulation
4.3.3.1 酸洗液检测制度：rules on check pickling liquid
1）检测内容 a)HCl 浓度 check items: a) HCI concentration
b)铁离子浓度 b) iron ion concentration
2）检测频度：4小时/次 check frequency: every 4 hours
3）酸浓度不足可经过添加新酸给予调整以提升酸洗速度。When acid concentration gets below the required level, add some new to maintain acid washing efficiency.
4）铁盐浓度操标时应予排放。Expel pickling liquid when iron ion exceed requirements
排放标准：铁离子浓度﹥200g/升 expel standard: iron ion concentration over 200g/liter
或FeCl2浓度﹥450g/升 or FeCl2 over 450g/liter
HCl浓度﹤4% HCI concentration less than 4%
4.3.3.2 酸洗操作：acid washing operation
酸洗使用天车成捆进行移位和翻动，每个酸槽中均置放有3个梯形石，酸洗时经过天车吊带收放和梯形石散捆作用，使钢管表面相互磨擦，促进除锈。在整个酸洗过程，这种吊带收放操作最少需进行4-5次。There are 3 ladder-shaped stones in each acid-washing tank, and use crane to move and rotate bundles of pipes. Through crane’s motion of raise and drop, friction among the pipes can helpful with removing rust on pipes’ surface. During whole acid washing process, raise-and-drop motion should be performed for 4-5 times.
钢管表面油污阻碍除锈并造成漏镀，为此钢管运输移位严禁使用钢丝绳（包含焊管车间），应改用尼龙吊带。Oil stain on pipe’s surface impede removing rust and cause incompletion of galvanizing, so steel wire rope can not be applied when transferring the steel pipes(including the welding workshop), only nylon belt is acceptable.
盐酸酸洗除化学作用外，它对氧化铁皮还有机械剥离作用使氧化铁皮积存在槽底，为阻断积存氧化皮继续消耗盐酸，提议建立倒槽操作制度，每班应进行一次倒槽操作，将槽底积存含大量氧化铁皮污泥冲洗洁净。
Apart from chemical reaction, pickling with HCL can have mechanical effect on oxidation scale. To prevent stocking oxidation scale continually consume HCL, Trough operating system should be regulated.
4.3.3.3 漂洗操作：漂洗应在流动水中进行，并进行两次漂洗，漂洗水可经过再生处理后循环使用，但处理站需对回流使用水铁盐含量和游离酸含量进行测控，回用水盐酸浓度不得高于4g/升，铁盐浓度不得大于3g/升。
4.3.3.3 Rinsing operation: rinsing is carried out in the flowing water and proceeds twice rinsing. Rinsing water can be reused through regeneration. But processing plant can track to iron salt and free acid of recycled water, and the HCL concentration must less than 4g/liter, iron salt concentration less than 3g/liter
4.3.3.4 熔剂检测制度：flux test and inspection system
1）检测内容：a)游离HCl 浓度 free HCL concentration
b)铁离子浓度 iron ion concentration
c) PH值 PH value
2）检测频度：4小时/次 4 hour/time
3）要求：PH值需控制在3.5-4.5范围内，通常情况下，因为酸洗残留物缘故，熔剂液多少含有游离酸，PH值均较低。PH值大于4.5将引发ZnCl2析出，降低溶剂效用，应加HCl给予调整；PH值小于3.2或游离HCl 浓度大于2g/升时，熔剂作用将降低，需加NH4OH 或 加入锌灰给予调整。
3) Requirements: PH value must be controlled in the range of 3.5-4.5. generally speaking, due to pickling residue resistance, flux contain suitable free acid which cause PH in a low valve, PH value is more than 4.5, which cause ZnCl2 salted out. In order to lower flux influence, HCL should be adjusted properly. PH value less than 3.2 or free HCL concentration more than 2g/liter, flux effect will be lower and more NH4OH should be added or add zinc ash.
4.3.3.5 涂熔剂操作： Flux operation
熔剂须经过连续过滤和加热，过滤机每班最少进行一次反冲清洗，滤芯需定时更新。Flux need continually filtering and heating, filter should be flushing each work, and filter core should be changed regularly
熔剂洁净是否对锌耗有很大影响，经过试生产应建立一套严格熔剂管理制度。
The clean of flux have a great influence on zinc consumption. Through trial production, one set of flux management regulation should be set.
4.4成品质量检验： finished product quality inspection
4.4.1 外观漏镀检验。
4.4.2 镀层均匀性检验：硫酸铜腐蚀试验。Coating uniformity inspection: copper sulfate test
4.4.3 镀层厚度检验：超声测厚仪。 Coating thickness inspection: ultrasonic thickness measurement instrument
4.4.4 镀层重量检验：氯化锑置换试验。Coating weight inspection: butter of antimony
4.5.热调试规格： 1/2”双管生产（114线）；hot testing specification: 1/2”double pipe production
4”单管生产（114线）；4”single pipe production

第二部分 设备关键技术性能

一． 钢管前处理段 Pretreatment
1.1Hcl酸洗槽5个：HCL pickling bath 5
尺寸：长×宽×深=7.6m×1.5m×1.5m
Dimension: length×width×depth=7.6m×1.5m×1.5m
结构：玻璃钢夹层结构，槽壁和槽底用钢结构框架加固，槽低用花岗岩块铺垫。
Structure: FRP sandwich structure, bath wall and bath base are strengthened by constructed steel structure, and base used in moonstone
酸洗槽之间用衬塑钢管连接在一起，并配有耐酸泵管路系统又和贮酸罐及排污沟连接，可实现酸洗槽加酸、排污、和酸槽之间“倒槽”操作。

1.2清洗水槽2个：cleaning water tank:2
尺寸：长×宽×深=7.6m×1.5m×1.5m
Dimension: length×width×depth=7.6m×1.5m×1.5m
结构：和1.1相同。
Structure: same as 1.1
1.3熔剂槽2个：Flux bath:2
尺寸：长×宽×深=7.6m×1.5m×1.5m
Dimension: length×width×depth=7.6m×1.5m×1.5m
结构：和1.1相同。
配有熔剂过滤机一台，利用过滤机泵将熔剂槽槽液连续抽出、过滤，并经过一个换热面积为3m2石墨热交换器，将熔剂加热到80℃左右，加热介质为蒸气，温度利用温度调整阀控制。
Equipped with 1 set flux filter, which draw out solution in flux bath through pump of filter, and then fliter by graphite heat exchanger in exchange area of 3 m2. When flux is warming-up to 80 ℃, that is flux has become steam. At that time, temperature is controlled by adjusting valve.
二．烘干炉 drying furnace
尺寸：长×宽=8m×7m
Dimension: length×width= 8m×7m
传动：制动电机：YEJ100L——3，n=1500 r.p.m， N=3kw；
Diving: driving motor: YEJ100L——3，n=1500 r.p.m， N=3kw；
行星摆线减速器：XWEDE3-4P-74-289，I=289，n=5 r.p.m；
Planetary cycloid reducer: XWEDE3-4P-74-289，I=289，n=5 r.p.m；
链轮：t=391.9，Z=8，每步2齿需3秒。
Sprocket: t=391.9，Z=8，每步2齿需3秒
烘干炉底板为铸铁双面肋板，下部为烘干炉烟道，烟道内敷设有ф114钢管换热器，换热气面积为20m2，利用烟气余热加热筋板以烘干钢管，另外有一台循环风机，风量为6600NM3/h，N=5.5Kw，将烘干炉膛内空气引入烟道内换热器，经加热后又喷入炉膛内，以增强钢管加热效果，烟道入口温度约600℃，出口温度约200℃，烟气量约为1200NM3/h，每小时供热量约为156500大卡。
Drying furnace setting is made of double cast iron ribbed plate and flue below it. ф114 pipe heat exchanger inside the flue with exchange area of 20m2. The working principle is drying pipes through waste gases warming up stiffened plates. Except for heat exchanger, circulator with air-volume 6600NM3/h，N=5.5Kw draw air in the drying furnace chamber into heat exchanger in the flue, and then puff into chamber after heating to strengthen heat effect of pipes. Inlet temperature of flue is about 600℃, and