钢管热镀锌φ生产线技术操作规程样本.doc
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1、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、
2、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 ro
3、ller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 Pa
4、ckaging 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 cleaning3.2、火炕工序11 Heating 3.3、锌锅工序11 Dipping3.4、内外吹工序12 Blowing3.5、钝化水洗工序12 Passi
5、vation and wash3.6、检验工序12 Check 3.7、司炉工12 Operators 修订情况统计12 Record of revision12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
6、 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
7、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 114生产线 产品纲领 main parameters of 114 production line 序号number规格 specification壁厚mmThickness单重kg/mUnit weight6m重 kgWeight 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
8、间 小时Running time per year年产量吨Yearly yield by weight年面积 产量 m2Yearly yield by area10.52.65 1.22 7.321100800077040180014400136800020.252.65 1.58 9.488448000770313.25 2.44 14.6454680006283013501080084780041.253.25 3.14 18.84424800062851.53.25 3.61 21.653688000628623.55.130.6261800058210450360026190072.5
9、3.756.5139.062058000544104503600244800834.058.4750.82157800050352251800114525944.6512.172.610980004385225180098550计 1004500360002935575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 p
10、ipe weight and yield based on raw pipes. Because consumption of acid, solvent and zinc is related to and calculated by pipes surface area, production data should include both weight yield and area yield.四试生产说明 Starting-up illustration4.1镀锌炉点火和升温 Galvanizing furnace ignition and heating up 4.1.1 在锌锅内
11、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
12、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 sak
13、e 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-up4.2.1炉料 furnace material: 1#锌锭 155吨 zinc ingot 155 ton 铅锭 15吨 lead ingot 15 ton4.2.2.盐酸:37%盐酸比
14、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 hyd
15、rochloric 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
16、 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
17、 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 pipes surface; 3. improve uniformity of galvanizing coat; reduce protuberance caused by uneven zinc distribution.铝过
18、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 me
19、thod. 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 114生产线 114 production line序号规格壁厚mm单重kg/m6m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10.52.65 1.22 7.32110080007706.59.2/91 1.194831491#双管20.252.65 1.58 9.488448
20、0007708.5 7/69 0.8270621641#双管313.25 2.44 14.64546800062813.24.55/450.543382732#双管41.253.25 3.14 18.844248000628173.5/35 0.4034303942#双管51.53.25 3.61 21.65368800062819.6 3/300.35302631082#双管623.65 5.1030.6260800055827.72.2/220.2521194623#双管72.53.656.5139.06205800055817.63.4/340.434304793#单管834.058.4
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