热硫化橡胶衬里工艺规程-中英.doc

热硫化橡胶板衬里工艺规程Technical Specifications for Hot-Vulcanized Rubber Lining1. 目的1. Purpose规范热硫化橡胶衬里各道工序作业。This manual is designed to standardize all operation processes of hot-vulcanized rubber linings. 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。The Technical Specifications is applicable to the rubber linings that adopt such vulcanization methods: boiler vulcanization, direct vulcanization or the vulcanization with steam or hot water under normal pressure.3. 引用标准3. ReferencesGB18241.1-2001 橡胶衬里 第一部分 设备防腐衬里GB18241.1-2001 Rubber Lining, Part I: Anticorrosive Linings for EquipmentsHGJ32-90 橡胶衬里化工设备HGJ32-90 Rubber Lined Chemical Equipments4. 职责4. Duties and Responsibilities 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。Technical Department: responsible for the control of operability and the technical revision to the Technical Specifications during its implementation.质检部：负责各道工序质量控制，协助工艺规程修订。Quality Inspection Department: responsible for the quality control of all processes and offer assistance to the revision of the Technical Specifications.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。Production Department: responsible for the implementation of the Technical Specifications and give feedbacks timely to help its revision. 5. 热硫化橡胶衬里工艺流程5. Process Flow of Hot-Vulcanized Rubber LiningsInspection & treatment of steel body Preparation of rubbersheet钢体检查处理 胶板准备Sand blasting Preparation of rubber cement Blanking喷砂 胶浆制备 下料Dedusting and cleaning Cleaning除尘、清洗 清洗Smear rubber cement涂刷胶浆Stick bottom lining Inspection & treatment底层贴衬 检查处理Inspection & treatment Stick surface lining检查处理 面层贴衬Vulcanization Inspection & treatment Acceptance & warehousing硫化 检查处理 验收入库6. 橡胶衬里设备检查处理6. Inspection and Treatment of Rubber Lined Equipments6.1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。6.1 The structural design and manufacture of the rubber lined equipments, pipes and pipe fittings shall be in conformity with the provisions in Article 4 of Standard HGJ32-90.6.2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。6.2 The manufacture, test, inspection and acceptance of metal housings of the rubber lined equipments shall be subject to the provisions in Article 5 of Standard HGJ32-90.6.3新制设备钢板表面应符合GB8923-88标准中A、B两种表面要求。6.3 The surfaces of steel plates of new equipments shall meet the requirements for surfaces of type A and B provided in Standard GB8923-88.6.4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。6.4 If surface defect on housing of rubber lined equipments is serious enough to deteriorate the quality of the lining, repair welding and polishing shall be performed before the operation of lining.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。6.5 In case of any defect on housing of pressure-bearing equipments or vacuum equipments, repair welding and polishing shall be performed before the operation of lining.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。6.6 The rubber lined equipments shall meet the design requirements in drawings and all inspection, treatment and acceptance work for the equipments shall have been finished before the operation of lining.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。6.7 If heat treatment is required by the design of rubber lined equipment, it shall be carried out according to the design requirements before the operation of lining.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。6.8 Generally acid pickling shall be performed for some rubber lined equipments, such as pipe fittings, before the operation of lining (sand blasting).7.胶浆制备工艺7. Preparation Process of Rubber Cement7. 1使用设备：立式打浆机（防爆电机）7.1 Equipment used: vertical beater (explosion-proof motor)7.2胶浆制备前应检查胶浆胶片及溶剂质量。7.2 Check the quality of rubber sheet and solvent before the preparation of rubber cement.7.3胶浆制备条件见表1。7.3 See the conditions for rubber cement preparation shown in Table 1.表1 胶浆制备条件Table 1 Rubber Cement Preparation Conditions项 目Item胶浆胶：溶剂Ratio of rubber and solvent打浆时间Beating time停放时间Standing time指 标Index1：61:64-5h4-5h12h12h7.4胶浆制备过程中应远离火源，并控制打浆机温度。7.4 The rubber cement preparation process shall be kept away from fire and the beater temperature shall be controlled.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。7.5 The prepared rubber cement shall be inspected to ensure the quality and then poured into special sealed containers for future use. 8.衬里施工工艺8. Lining Operation Process8.1一般要求8.1 General requirements8.1.1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。8.1.1 The ambient temperature shall be within 15-30C, with RH (relative humidity) 70%. When it is below 15C, in particular, not higher than the dew point temperature 3C, measures shall be taken to increase the temperature but open fire is forbidden; when it is above 35C, the duration of lining operation shall be shortened to the greatest extent and the direct sunlight on housing of rubber lined equipment shall be avoided. 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。8.1.2 The site shall be dust proof and fire proof, keep dry and well ventilated. The hands and clothes of operators and the tools used in this operation shall be kept clean. 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。8.1.3 Operators shall wear soft-sole shoes when working inside the rubber lined equipment to prevent any damage to the lined area.8.2喷砂8.2 Sand blasting8.2.1喷砂前橡胶衬里设备应完成所有检查处理验收工作。8.2.1 All inspection, treatment and acceptance work for the rubber lined equipment shall be completed before sand blasting.8.2.2喷砂前应预先检查设备是否正常并穿戴劳保用品。8.2.2 Check whether the equipment is in normal condition and ensure the operators are equipped with protective appliances before sand blasting.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。8.2.3 Steel shot is used for sand blasting, with grain size: 8-16 meshes. There shall be no clay or other impurities in it. The steel shots shall be oven dried or dried in sunlight before use. The reuse is allowed only after sieving.8.2.4喷砂时应从设备一端开始，逐渐向另一端移动。8.2.4 The operation of sand blasting shall start from one end of the equipment and move towards the other gradually.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30，走枪速度均匀，不能有漏喷和欠喷现象。8.2.5 At the time of sand blasting, the distance between nozzle and metal surface is usually 50-80mm, the injection angle shall be not less than 30, the moving speed of the gun shall be even. Neither missing nor insufficient blasting is allowed in sand blasting.8.2.6喷砂质量等级应达到GB8923-88标准中Sa3级规定：8.2.6 Sand blasting quality shall meet the requirements of Sa3-level in Standard GB8923-88.(1) 显出均匀一致的金属本色。(1) Show the even original color of the metal(2) 除净金属氧化物和其它附着物。(2) Remove all metallic oxide and other attachments.(3)喷砂后应处于干燥状态，不得被其它物质污染。(3) Put in dry condition after sand blasting and keep away from contaminants.8.3衬里施工8.3 Lining operation8.3.1除尘、清洗8.3.1 Dedusting and cleaning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。After the sand blasting is inspected and accepted, remove the dusts and sand grains timely and clean the equipment with solvent to make preparation for the first coat of rubber cement to prevent re-rusting. 8.4胶板准备8.4 Preparation of rubber sheet8.4.1衬里胶板质量应符合GB18241.1-2001标准规定。8.4.1 The quality of rubber sheet used as linings shall conform to the provisions of Standard GB18241.1-2001.8.4.2衬里胶板在使用前应检验合格。8.4.2 The rubber sheets shall be inspected to verify its quality before use.8.4.3胶板复合8.4.3 Compositing of rubber sheets胶板联合衬里时原则上衬里厚度不大于4mm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4mm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。When using such lining that is composed of two kinds of rubber sheets, in principle, if the lining thickness is not large than 4mm, the two rubber sheets of different kinds shall be composited to be one piece before blanking and sticking; if lining thickness is large than 4mm, the rubber sheets shall be sticked layer by layer. The specific technical requirements shall be subject to the instructions issued by Technical Department. 8.5胶板下料8.5 Blanking of rubber sheet8.5.1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。8.5.1 Before blanking, the appearance quality of rubber sheets shall be inspected and proper treatment shall be carried out for the defects inconsistent with the provisions of Standard GB18241.1-2001.8.5.2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。8.5.2 Blanking shall be performed correctly and reasonably in such a way to decrease seams, stress and degree of difficulty in lining operation. 8.5.3形状复杂的工件（部位）应预先制作样板，按样板下料。8.5.3 For the workpiece (areas) with complicated shape, blanking shall be performed according to the template that is made in advance. 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。8.5.4 As for the linings used for pipes, during blanking of rubber sheets, the perimeter shall be calculated based on a diameter value slightly smaller than the inner diameter of the pipe (excluding seam width), and its total length shall be the sum of the actual pipe length and the folding edge of the flange. 8.5.5胶板下料时必须预留接缝宽度。8.5.5 Seam width must be preset during blanking. 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。8.5.6 After blanking is finished, cut the seaming edge of rubber sheet, with width of the cutting opening 3.5-5 times of rubber sheet thickness.8.5.7剖口应宽窄一致，平直。 8.5.7 All openings shall be in the same width and keep straight. 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。8.5.8 When cutting the opening, attention shall be paid to the direction of seam and the flow direction of medium, especially when using such lining that is composed of two kinds of rubber sheets.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。8.5.9 After blanking and edge cutting, clean the bonding surfaces with solvent and roughen the bonding surfaces according to the technical instructions issued by Technical Department. 8.6涂刷胶浆 8.6 Smear rubber cement8.6.1胶浆使用前应充分搅匀，并检查胶浆浓度，如浓度过大时用溶剂稀释。8.6.1 Before use, mix the rubber cement well and check the density. If the density is too high, use solvent to dilute it. 8.6.2设备喷砂清洗完毕后，应在4h内涂刷底涂L-01（灰色），L-01（灰色）涂刷2小时后再涂刷L02（黑色）8.6.2 The primer coat L-01 (grey) shall be smeared within 4 hours after sand blasting and cleaning of the equipment and L02 (black) shall be smeared 2 hours after coating of L01.8.6.3钢体刷胶浆二遍。（L-02黑色胶粘剂涂刷2小时后涂刷第一遍胶浆，第一遍胶浆溶剂完全挥发后才能进行第二遍胶浆涂刷）。8.6.3 The rubber cement shall be smeared on steel body by two times. (The first coat of rubber cement shall be smeared 2 hours after the coating of L-02 black adhesive, and after the first coat of rubber cement has volatilized completely, the second coating shall be carried out.)8.6.4胶浆涂刷次数：金属壳体表面涂刷二遍底涂、二遍胶浆、胶板表面涂刷二遍，双层贴衬时，胶板表面各涂刷胶浆二遍。8.6.4 Number of coats of rubber cement: two primer coats and two coats of rubber cement on surface of metal housing, two coats of rubber cement on surface of rubber sheets, two coats for each surface if the lining is composed of two layers. 8.6.5多层贴衬时，底层贴衬完毕后，必须用溶剂清洗粘合面后再涂刷胶浆。8.6.5 For the lining that is composed of multiple layers, after the bottom lining is sticked, use solvent to clean the bonding surface before smearing rubber cement. 8.6.6胶浆涂刷时应薄而均匀，防止胶浆堆积、流淌或起泡。8.6.6 When smearing rubber cement, the rubber cement shall be thin and even and piling up, flowing or blistering shall be prevented. 8.6.7前后两遍胶浆的涂刷方向应依次交错涂刷。 8.6.7 The two coats of rubber cement shall be smeared in stagger directions.8.6.8涂刷管道胶浆时，管道应斜放并转动。8.6.8 When smearing rubber cement on pipes, the pipe shall be inclined and rotated.8.6.9设备壳体不影响衬里质量的缺陷在涂刷未遍胶浆前，用同类胶条填平。8.6.9 The defect on housing of equipment that doesnt affect the quality of lining shall be filled with the same kind of rubber strip before the final coating of rubber cement. 8.6.10涂刷最后一遍胶浆后，必须在3h内进行贴衬。8.6.10 Lining must be sticked within 3 hours after the final coating of rubber cement. 8.6.11胶浆涂刷后，应防止灰尘、油、水或其它杂物落入。8.6.11 The entering of dust, oil, water or other impurities shall be prevented after the coating of rubber cement.8.6.12胶粘剂配比：8.6.12 Proportioning of the adhesive:A.L-O1灰色底涂0.12kg/,L-02黑色面涂0.17kg /,A. L-01 grey primer coat 0.12kg/m2, L-02 black top coat 0.17kg/m2.B.胶浆：钢件与胶相粘时0.8kg/,胶与胶之间0.4kg/,共计1.2kg/。B. Rubber cement: 0.8kg/m2 between steel workpiece and rubber sheet, 0.4kg/m2 between rubber sheets, totally 1.2kg/m2.C.底涂一开桶后加入底涂总重量10%的甲苯进行稀释，并搅拌15分钟以上。C. After opening the bucket, the primer coating shall be added with proper quantity of methylbenzene, which shall be 10% of the primer coating in weight. 8.7胶板贴衬8.7 Rubber lining operation8.7.1胶板贴衬时未遍胶浆溶剂已完全挥发。8.7.1 When sticking rubber lining, final coat of rubber cement shall have volatized completely.8.7.2胶板贴衬时设备壳体缺陷已用同类胶条填平并已涂刷胶浆。8.7.2 When sticking rubber lining, the defect on housing of equipment shall have been filled with the same kind of rubber strip and rubber cement have been smeared.8.7.3贴衬时胶浆层应保持完整，如被粘掉、擦伤等应重新补刷胶浆晾干后再进行贴衬。8.7.3 When sticking rubber lining, the rubber cement coating shall remain complete. In case of any peeling off or scratch, re-smear rubber cement and stick rubber lining after the rubber cement coating is dried in the air.8.7.4胶板贴衬先后顺序视设备结构而定，并依据下料削口顺序。8.7.4 The sticking order of rubber sheets shall be determined according to the structure of the equipment and the order of the openings cut in blanking process. 8.7.5胶板贴衬时不能使用排气线，特殊情况依据技术部门下达的工艺指令。8.7.5 When sticking rubber lining, exhaust line cant be used, except for special circumstances in which it shall be subject to the instructions issued by Technical Department. 8.7.6胶板贴衬时用垫布卷取铺放，铺放位置应准确，不得起褶或受拉变薄，影响贴衬质量。8.7.6 When sticking rubber lining, use cloth to wind around the rubber sheet and then put it in place. It cant be wrinkled or pulled to be thinner, since such defects will deteriorate the quality of lining. 8.7.7胶板贴衬时必须划线贴衬，确保贴衬边口平直及接缝宽窄一致、平直。8.7.7 When doing rubber lining, draw lines to ensure the edges of the lining are straight and the seams are straight and of the same width.8.7.8胶板辅放完毕后，依次脱开垫布进行辊压。8.7.8 When finishing the placement of rubber sheet, remove the cloth and roll out the sheet in turn.8.7.9辊压时必须先将拐角处用角辊辊压无气孔后再进行拐角边辊压，严禁先压边后辊压拐角造成气孔。8.7.9 When rolling, roll out the corner with an angle roller first and then on the corner edges when there is no air blister. The reversed sequence is forbidden as blisters will occur by so doing.8.7.10辊压时应划线依次辊压，确保粘合紧密，并防止产生气泡。每块胶板贴衬完毕后用窄辊压实接缝边。8.7.10 When rolling, draw lines to roll out the sheet in turn so as to ensure the tight bonding and prevent the occurrence of blisters. After finishing the rubber lining, use a narrow roller to press the edges of seams tightly.8.7.11胶板贴切衬接缝方向遵循下列原则：8.7.11 The direction of seams on the rubber lining should be determined in the following principles:a.接缝方向顺向介质流向；a. the direction of seams follows the flow direction of the medium;b.转动设备接缝方向顺向转动方向。 b. the direction of seams on rotating equipment follows the direction of rotation.8.7.12胶板贴衬接缝宽度及方法：8.7.12 The width of seams and methods for rubber lining单层贴衬时一般采用搭接，接缝宽度25mm；多层贴衬时内层胶一般采用对接，接缝宽度20mm，过搭宽度不大于3mm，面层胶采用搭接，接缝宽度25mm。 Lapped seams are generally applied to the single-layer lining with the width of seams no less than 25mm; butt seams are used often in the multi-layer lining with the width of seams no less than 20mm and the width of overlapped joints no more than 3mm; and lapped seams are also adopted in surface rubber lining with the width of seams no less than 25mm.8.7.13胶板贴衬时接缝应平直，不得采用十字接缝，应采用T字接缝。8.7.13 When doing rubber lining, the seams shall be neat and straight and T-shaped instead of cross-shaped. 8.7.14多层贴衬时，上、下层接缝应错位，一般应不小于100mm，特殊部位最少不少于50mm。8.7.14 When doing multi-layer lining, the seams should be staggered between the upper and lower layers and the width of seams shall be normally no less than 100mm and no less than 50mm in special parts. 8.7.15硫化后需加工部位，胶层厚度应留有加工余量。8.7.15 Machining allowance shall be made related to the bond line thickness in the parts which need to be processed after vulcanization.8.7.16管道贴衬时，涂刷胶浆晾干后，先将胶板根据管道内径粘成圆筒状（略小于管道内径），然后用垫布垫好轻轻拖入管内定位后脱布辊压。8.7.16 When doing pipe lining, wrap the rubber sheet which has been air-dried with rubber cement into a tube with a diameter slightly less the internal diameter of the pipe first, then enclose the tube in the cloth, pull it into the pipe with a slow constant pull, position it, remove the cloth and roll out.8.7.17管道辊压遵循先压里后翻边的原则，法兰边先用同类胶板加厚涂刷胶浆后再翻边。8.7.17 Rolling of the pipe follows the sequence of pressing the inner part first and then arrange flanges. The edges to be flanged shall be painted and thickened with the same kind of rubber cement for the rubber sheet and then be folded.8.7.18多层贴衬时，每层贴衬完毕后必须进行外观质量检查及电火花检测，检测依据GB18241.1-2001标准、HGJ32-90标准中第7条，对缺陷及漏电部位进行修复后才能进行第二层贴衬。8.7.18 With respect to multi-layer lining, surface quality inspection and spark test shall be conducted after each layer of lining is finished in accordance with the GB18241.1-2001 Standard and Article 7 in the HGJ32-90 Standard. The next layer of lining can be conducted only after defective or current leakage areas are repaired.8.7.19胶板厚度大于4mm贴衬时，应对胶板进行预热，预热温度为50-60。8.7.19 When the rubber sheet used for lining is thicker than 4mm, it shall be preheated at a temperature of 50 to 60.8.7.20胶板贴衬全过程中，严禁用烙铁铲剖口或搭边。8.7.20 During the whole process of rubber lining, it is forbidden to use soldering iron shovel to make openings or laps.8.7.21胶板贴衬面层完毕后，进行外观检查及火花检测。并对缺陷进行修复，检测依据GB18241.1-2001标准、HGJ32-90标准中第7条。8.7.21 Upon the completion of outer rubber lining, surface inspection and spark test shall be conducted. Then defective areas shall be repaired. The inspection and test should comply with the GB18241.1-2001 Standard and Article 7 in the HGJ32-90 S