钢管热镀锌φ114生产线技术操作规程

页码1/19钢管热镀锌φ114生产线技术操作规程文件编号修改码版本号目录Contents第一部分生产概况……………………………………………………………………2SectiononeGeneraldescriptionoftheproductionline一、生产工艺流程图……………………………………………………………………2Processflowdiagram二、工艺平面布置示意图………………………………………………………………2Layoutsketch三、原料规格及执行标准………………………………………………………………2Specificationofmaterialanditscriteria四、试生产说明…………………………………………………………………………3Starting-upillustration第二部分设备的主要技术性能………………………………………………………5SectiontwoMaintechnicalcharacteristicsoftheequipments一、钢管前处理段………………………………………………………………………4Pre-treatmentofsteelpipes二、烘干炉………………………………………………………………………………5Dryingoven三、入料辊道……………………………………………………………………………6Feedingrollers四、镀锌炉………………………………………………………………………………6Galvanizingfurnace五、镀锌锅………………………………………………………………………………8Galvanizingvat六、浸锌机构……………………………………………………………………………8Dippingunit七、拨料机构……………………………………………………………………………8Kickoutunit八、提升机构……………………………………………………………………………8Liftingunit九、磁力辊………………………………………………………………………………8Magneticroller十、外吹…………………………………………………………………………………8Externalblowing十一、磁力辊升降机构…………………………………………………………………9Elevationdeviceofmagneticroller十二、曳出辊道…………………………………………………………………………9Pullingoutroller十三、猫头叉横移机构…………………………………………………………………9Fork-shapedtransversemovingdevice十四、内吹和升降机构…………………………………………………………………9Internalblowingandelevationdevice十五、冷却水槽…………………………………………………………………………9Coolingwatertank页码2/19钢管热镀锌φ114生产线技术操作规程文件编号修改码版本号十六、检查台架…………………………………………………………………………10Checktable十七、钝化辊道…………………………………………………………………………10Passivationroller十八、钝化喷淋站………………………………………………………………………10Sprayingstationforpassivation十九、烘干台架…………………………………………………………………………10Dryingtable二十、打印辊道…………………………………………………………………………10Stamproller二一、打印机……………………………………………………………………………10Stampmachine二二、六角打包设备……………………………………………………………………10Packagingtools二三、除尘器……………………………………………………………………………10Cleaner二四、电器设备…………………………………………………………………………10Electricaldevice第三部分镀锌车间技术操作规程……………………………………………………11SectionthreeOperatinginstructionofgalvanizingworkshop一、目的…………………………………………………………………………………11Purposes二、使用范围……………………………………………………………………………11Applyingscope三、工作程序……………………………………………………………………………11Workingprocedures3.1、酸洗工序…………………………………………………………………………11Acidcleaning3.2、火炕工序…………………………………………………………………………11Heating3.3、锌锅工序…………………………………………………………………………11Dipping3.4、内外吹工序………………………………………………………………………12Blowing3.5、钝化水洗工序……………………………………………………………………12Passivationandwash3.6、检验工序…………………………………………………………………………12Check3.7、司炉工……………………………………………………………………………12Operators修订状况记录……………………………………………………………………………12Recordofrevision…………………………………………12页码3/19钢管热镀锌φ114生产线技术操作规程文件编号修改码版本号第一部分生产概况SectiononeGeneraldescriptionoftheproductionline一．生产工艺流程图Processflowdiagram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、表面光洁锌层的生产设备。Steelpipehot-dipgalvanizinglineistheautomaticequipmentstoproduceresistantandsmoothlayeronthesurfaceofrawpipesaftercleaning.黑管rawpipes涂溶剂applyingimpregnant空冷naturalcooling烘干drying水冷coolingwithwater碱洗脱脂alkalicleaning热浸锌hot-dipping检验check盐酸洗acidtreatment外吹externalblowing打印stamp漂洗watercleaning内吹internalblowing入库enteringwarehouse二．工艺平面布置示意图（附）Layoutsketch(enclosed)三．原料规格及执行标准Specificationofmaterialanditscriteriaφ114生产线产品大纲mainparametersofφ114productionline序号number规格specification壁厚mmThickness单重kg/mUnitweight6m重kgWeightper6m小时产量支/时Yieldbypieces小时产量公斤/时Yieldbyweight面积产量m2/时yieldbyarea所占比例%Proportion年工作时间小时Runningtimeperyear年产量吨Yearlyyieldbyweight年面积产量m2Yearlyyieldbyarea10.52.651.227.321100800077040180014400136800020.252.651.589.488448000770313.252.4414.64546800062830135010800847800页码4/19钢管热镀锌φ114生产线技术操作规程文件编号修改码版本号41.253.253.1418.84424800062851.53.253.6121.653688000628623.55.130.6261800058210450360026190072.53.756.5139.062058000544104503600244800834.058.4750.82157800050352251800114525944.6512.172.610980004385225180098550计1004500360002935575执行标准：（GB3091-93）Designedaccordingtocriteria(GB3091-93)注：支重及产量均以黑管计算。因酸、熔剂及锌的消耗与镀管的内外表面积有关，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核。Note:statisticsofsinglepipeweightandyieldbasedonrawpipes.Becauseconsumptionofacid,solventandzincisrelatedtoandcalculatedbypipe’ssurfacearea,productiondatashouldincludebothweightyieldandareayield.四．试生产说明Starting-upillustration4.1镀锌炉的点火与升温Galvanizingfurnaceignitionandheatingup4.1.1在锌锅内码放好锌锭与铅锭后可进行点火,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米长的1/2”（？）钢管组成的燃烧器作为辅助火源进行点火。Piledzincandleadingots,anduseapieceofrubbertubeand1.5meterlongsteelpipeasaauxiliaryburningdevicetoignitethemainfire,becauseblast-furnacegashaslowcalorificvalueandishardtolightup.点火前应准备8套燃烧器对8套烧嘴同时进行强迫点火。Prepare8setsofburningdevicetolight8burnerssimultaneously.由于镀锌炉在此之前曾经过水，但时间已过去4-5个月估计已自然风干。但为保险起见，升温时拟适当延缓升温梯度，并适当增加110℃区（显含水的蒸发）及300℃区（结晶水的去除）的保温时间以期炉体安全渡过升温期。Thefurnacemighthavebeencontactedwithwaterandgotdryafter4-5monthsexposuretoair.Butstillforsakeofsafety,laggardandplacidheatingspeedisrecommended,elongatetimeattemperatureof110℃(flowingwaterevaporation)and300℃(crystalwaterevaporation).4.2.试生产用料准备Rawpipespreparationforstart-up4.2.1炉料furnacematerial:1#锌锭155吨zincingot155ton铅锭15吨leadingot15ton4.2.2.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”)吨不等的浓酸,根据供货条件与生产计划可确定维持生产必要的储备量.Hydrochloricaid:itssolutionof37%concentrationhasspecificgravityof1.19.Confecttwotankso