热硫化橡胶衬里工艺规程中英.docx
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热硫化橡胶衬里工艺规程中英.docx
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热硫化橡胶衬里工艺规程中英
热硫化橡胶板衬里工艺规程
TechnicalSpecificationsforHot-VulcanizedRubberLining
1.目的
1.Purpose
规范热硫化橡胶衬里各道工序作业。
Thismanualisdesignedtostandardizealloperationprocessesofhot-vulcanizedrubberlinings.
2.适用范围
2.Scope
本工艺规程适用于硫化罐硫化,本体硫化,常压蒸汽、热水硫化橡胶衬里。
TheTechnicalSpecificationsisapplicabletotherubberliningsthatadoptsuchvulcanizationmethods:
boilervulcanization,directvulcanizationorthevulcanizationwithsteamorhotwaterundernormalpressure.
3.引用标准
3.References
GB18241.1-2001橡胶衬里第一部分设备防腐衬里
GB18241.1-2001RubberLining,PartI:
AnticorrosiveLiningsforEquipments
HGJ32-90橡胶衬里化工设备
HGJ32-90RubberLinedChemicalEquipments
4.职责
4.DutiesandResponsibilities
技术部:
负责控制工艺规程实施过程中的可操作性及工艺修订工作。
TechnicalDepartment:
responsibleforthecontrolofoperabilityandthetechnicalrevisiontotheTechnicalSpecificationsduringitsimplementation.
质检部:
负责各道工序质量控制,协助工艺规程修订。
QualityInspectionDepartment:
responsibleforthequalitycontrolofallprocessesandofferassistancetotherevisionoftheTechnicalSpecifications.
生产部:
负责工艺规程的实施工作,并及时反馈意见,协助工艺规程修订。
ProductionDepartment:
responsiblefortheimplementationoftheTechnicalSpecificationsandgivefeedbackstimelytohelpitsrevision.
5.热硫化橡胶衬里工艺流程
5.ProcessFlowofHot-VulcanizedRubberLinings
Inspection&treatmentofsteelbodyPreparationofrubber sheet
钢体检查处理胶板准备
SandblastingPreparationofrubbercementBlanking
喷砂胶浆制备下料
DedustingandcleaningCleaning
除尘、清洗清洗
Smearrubbercement
涂刷胶浆
StickbottomliningInspection&treatment
底层贴衬检查处理
Inspection&treatmentSticksurfacelining
检查处理面层贴衬
VulcanizationInspection&treatmentAcceptance&warehousing
硫化检查处理验收入库
6.橡胶衬里设备检查处理
6.InspectionandTreatmentofRubberLinedEquipments
6.1橡胶衬里设备、管道及管件结构设计制作应符合HGJ32-90标准中第4条规定。
6.1Thestructuraldesignandmanufactureoftherubberlinedequipments,pipesandpipefittingsshallbeinconformitywiththeprovisionsinArticle4ofStandardHGJ32-90.
6.2橡胶衬里设备金属壳体的制造、试验及验收执行HGJ32-90标准中第5条规定。
6.2Themanufacture,test,inspectionandacceptanceofmetalhousingsoftherubberlinedequipmentsshallbesubjecttotheprovisionsinArticle5ofStandardHGJ32-90.
6.3新制设备钢板表面应符合GB8923-88标准中A、B两种表面要求。
6.3ThesurfacesofsteelplatesofnewequipmentsshallmeettherequirementsforsurfacesoftypeAandBprovidedinStandardGB8923-88.
6.4橡胶衬里设备壳体表面缺陷足以影响衬里质量时,必须在衬里施工前进行补焊、打磨处理。
6.4Ifsurfacedefectonhousingofrubberlinedequipmentsisseriousenoughtodeterioratethequalityofthelining,repairweldingandpolishingshallbeperformedbeforetheoperationoflining.
6.5受压设备及真空设备壳体缺陷必须在衬里施工前全部进行补焊、打磨处理。
6.5Incaseofanydefectonhousingofpressure-bearingequipmentsorvacuumequipments,repairweldingandpolishingshallbeperformedbeforetheoperationoflining.
6.6橡胶衬里设备应符合图纸设计要求,并在衬里施工前完成所有检查、处理、验收工作。
6.6Therubberlinedequipmentsshallmeetthedesignrequirementsindrawingsandallinspection,treatmentandacceptanceworkfortheequipmentsshallhavebeenfinishedbeforetheoperationoflining.
6.7橡胶衬里设备设计时如需热处理,必须在衬里施工前按设计要求进行热处理。
6.7Ifheattreatmentisrequiredbythedesignofrubberlinedequipment,itshallbecarriedoutaccordingtothedesignrequirementsbeforetheoperationoflining.
6.8一般如管件等衬里件衬里施工(喷砂)前进行应酸洗处理。
6.8Generallyacidpicklingshallbeperformedforsomerubberlinedequipments,suchaspipefittings,beforetheoperationoflining(sandblasting).
7.胶浆制备工艺
7.PreparationProcessofRubberCement
7.1使用设备:
立式打浆机(防爆电机)
7.1Equipmentused:
verticalbeater(explosion-proofmotor)
7.2胶浆制备前应检查胶浆胶片及溶剂质量。
7.2Checkthequalityofrubbersheetandsolventbeforethepreparationofrubbercement.
7.3胶浆制备条件见表1。
7.3SeetheconditionsforrubbercementpreparationshowninTable1.
表1胶浆制备条件
Table1RubberCementPreparationConditions
项目
Item
胶浆胶:
溶剂
Ratioofrubberandsolvent
打浆时间
Beatingtime
停放时间
Standingtime
指标
Index
1:
6
1:
6
4-5h
4-5h
12h
12h
7.4胶浆制备过程中应远离火源,并控制打浆机温度。
7.4Therubbercementpreparationprocessshallbekeptawayfromfireandthebeatertemperatureshallbecontrolled.
7.5胶浆制备完毕检查质量合格后,倒入专用密封容器以备使用。
7.5Thepreparedrubbercementshallbeinspectedtoensurethequalityandthenpouredintospecialsealedcontainersforfutureuse.
8.衬里施工工艺
8.LiningOperationProcess
8.1一般要求
8.1Generalrequirements
8.1.1施工环境温度以15-30℃为宜,相对湿度不大于70%,温度低于15℃或不高于露点温度3℃时应采用增温措施,但不能使用明火,当温度高于35℃以上时应尽量缩短操作时间及避免阳光直照设备外壳。
当相对湿度高于70%以上时应采用除湿措施。
8.1.1Theambienttemperatureshallbewithin15-30°C,withRH(relativehumidity)≤70%.Whenitisbelow15°C,inparticular,nothigherthanthedewpointtemperature3°C,measuresshallbetakentoincreasethetemperaturebutopenfireisforbidden;whenitisabove35°C,thedurationofliningoperationshallbeshortenedtothegreatestextentandthedirectsunlightonhousingofrubberlinedequipmentshallbeavoided.
8.1.2施工现场应防尘、防火,保持干燥,通风良好,施工人员的手、工作服及衬里用具应保持清洁。
8.1.2Thesiteshallbedustproofandfireproof,keepdryandwellventilated.Thehandsandclothesofoperatorsandthetoolsusedinthisoperationshallbekeptclean.
8.1.3施工人员进入设备内施工应穿软底鞋以防止损坏衬里层。
8.1.3Operatorsshallwearsoft-soleshoeswhenworkinginsidetherubberlinedequipmenttopreventanydamagetothelinedarea.
8.2喷砂
8.2Sandblasting
8.2.1喷砂前橡胶衬里设备应完成所有检查处理验收工作。
8.2.1Allinspection,treatmentandacceptanceworkfortherubberlinedequipmentshallbecompletedbeforesandblasting.
8.2.2喷砂前应预先检查设备是否正常并穿戴劳保用品。
8.2.2Checkwhethertheequipmentisinnormalconditionandensuretheoperatorsareequippedwithprotectiveappliancesbeforesandblasting.
8.2.3喷砂用砂为钢砂,粒径为8-16目。
钢砂应不含有粘土及其它杂物。
使用前钢砂必须烘干或晒干,过筛后才能重新使用。
8.2.3Steelshotisusedforsandblasting,withgrainsize:
8-16meshes.Thereshallbenoclayorotherimpuritiesinit.Thesteelshotsshallbeovendriedordriedinsunlightbeforeuse.Thereuseisallowedonlyaftersieving.
8.2.4喷砂时应从设备一端开始,逐渐向另一端移动。
8.2.4Theoperationofsandblastingshallstartfromoneendoftheequipmentandmovetowardstheothergradually.
8.2.5喷砂时喷嘴与金属表面一般距50-80mm;喷射角度不小于30º,走枪速度均匀,不能有漏喷和欠喷现象。
8.2.5Atthetimeofsandblasting,thedistancebetweennozzleandmetalsurfaceisusually50-80mm,theinjectionangleshallbenotlessthan30°,themovingspeedofthegunshallbeeven.Neithermissingnorinsufficientblastingisallowedinsandblasting.
8.2.6喷砂质量等级应达到GB8923-88标准中Sa3级规定:
8.2.6SandblastingqualityshallmeettherequirementsofSa3-levelinStandardGB8923-88.
(1)显出均匀一致的金属本色。
(1)Showtheevenoriginalcolorofthemetal
(2)除净金属氧化物和其它附着物。
(2)Removeallmetallicoxideandotherattachments.
(3)喷砂后应处于干燥状态,不得被其它物质污染。
(3)Putindryconditionaftersandblastingandkeepawayfromcontaminants.
8.3衬里施工
8.3Liningoperation
8.3.1除尘、清洗
8.3.1Dedustingandcleaning
橡胶衬里设备喷砂验收合格后及时除清灰尘、砂粒,用溶剂清洗,以便涂刷第一遍胶浆以防返锈。
Afterthesandblastingisinspectedandaccepted,removethedustsandsandgrainstimelyandcleantheequipmentwithsolventtomakepreparationforthefirstcoatofrubbercementtopreventre-rusting.
8.4胶板准备
8.4Preparationofrubbersheet
8.4.1衬里胶板质量应符合GB18241.1-2001标准规定。
8.4.1ThequalityofrubbersheetusedasliningsshallconformtotheprovisionsofStandardGB18241.1-2001.
8.4.2衬里胶板在使用前应检验合格。
8.4.2Therubbersheetsshallbeinspectedtoverifyitsqualitybeforeuse.
8.4.3胶板复合
8.4.3Compositingofrubbersheets
胶板联合衬里时原则上衬里厚度不大于δ4mm的情况下在胶板下料贴衬前应将两种胶板复合成型,衬里厚度大于δ4mm时应采用分层贴衬。
具体工艺要求执行技术部门下达的工艺指令。
Whenusingsuchliningthatiscomposedoftwokindsofrubbersheets,inprinciple,iftheliningthicknessisnotlargethanδ4mm,thetworubbersheetsofdifferentkindsshallbecompositedtobeonepiecebeforeblankingandsticking;ifliningthicknessislargethanδ4mm,therubbersheetsshallbestickedlayerbylayer.ThespecifictechnicalrequirementsshallbesubjecttotheinstructionsissuedbyTechnicalDepartment.
8.5胶板下料
8.5Blankingofrubbersheet
8.5.1胶板下料前应检查胶板外观质量,并对不符合GB18241.1-2001标准要求的缺陷进行处理。
8.5.1Beforeblanking,theappearancequalityofrubbersheetsshallbeinspectedandpropertreatmentshallbecarriedoutforthedefectsinconsistentwiththeprovisionsofStandardGB18241.1-2001.
8.5.2下料时要求准确合理,尽量减少接缝数量,尽量减少贴衬应力,减轻贴衬难度。
8.5.2Blankingshallbeperformedcorrectlyandreasonablyinsuchawaytodecreaseseams,stressanddegreeofdifficultyinliningoperation.
8.5.3形状复杂的工件(部位)应预先制作样板,按样板下料。
8.5.3Fortheworkpiece(areas)withcomplicatedshape,blankingshallbeperformedaccordingtothetemplatethatismadeinadvance.
8.5.4管道胶板下料时,应按略小于管道内径的原则计算其周长(不包括接缝宽度),其总长度应等于管道实际长度加上法兰翻边。
8.5.4Asfortheliningsusedforpipes,duringblankingofrubbersheets,theperimetershallbecalculatedbasedonadiametervalueslightlysmallerthantheinnerdiameterofthepipe(excludingseamwidth),anditstotallengthshallbethesumoftheactualpipelengthandthefoldingedgeoftheflange.
8.5.5胶板下料时必须预留接缝宽度。
8.5.5Seamwidthmustbepresetduringblanking.
8.5.6胶板下料完毕后,对胶板接缝边进行削边,剖口宽度为胶板厚度的3.5-5倍。
8.5.6Afterblankingisfinished,cuttheseamingedgeofrubbersheet,withwidthofthecuttingopening3.5-5timesofrubbersheetthickness.
8.5.7剖口应宽窄一致,平直。
8.5.7Allopeningsshallbeinthesamewidthandkeepstraight.
8.5.8削剖口时注意接缝方向及介质流向,特别是联合衬里时必须严格注意。
8.5.8Whencuttingtheopening,attentionshallbepaidtothedirectionofseamandtheflowdirectionofmedium,especiallywhenusingsuchliningthatiscomposedoftwokindsofrubbersheets.
8.5.9胶板下料削边完毕后用溶剂清洗粘合面,并根据技术部门下达的工艺指令对贴合面进行打毛。
8.5.9Afterblankingandedgecutting,cleanthebondingsurfaceswithsolventandroughenthebondingsurfacesaccordingtothetechnicalinstructionsissuedbyTechnicalDepartment.
8.6涂刷胶浆
8.6Smearrubbercement
8.6.1胶浆使用前应充分搅匀,并检查胶
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