钢管热镀锌φ生产线技术操作规程

年4月19日钢管热镀锌φ生产线技术操作规程文档仅供参考目录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第一部分生产概况SectiononeGeneraldescriptionoftheproductionline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m2Yearlyyieldbyarea10.5"2.651.227.321100800077040180014400136800020.25"2.651.589.48844800077031"3.252.4414.6454680006283013501080084780041.25"3.253.1418.84424800062851.5"3.253.6121.65368800062862"3.55.130.6261800058210450360026190072.5"3.756.5139.06205800054410450360024480083"4.058.4750.8215780005035225180011452594"4.6512.172.610980004385225180098550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”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)and3004.2.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.Confecttwotanksof17%hydrochloricacidforoneproductionlinebeforestart-up,andaround20tonofhigh-concentrationhydrochloricacidmaybeneeded.Innormalproduction,2(8”)-7(1/24.2.3熔剂的铵锌比按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。Proportionforammoniumandzincinsolventis1.6:1,almost450gperliter.Onetankofsolventneeds4.7tonofammoniumchlorideand2.9tonofzincchloride.4.2.4锌铝合金:含10%的锌铝合金100公斤,在生产过程逐渐加入,锌液中铝含量为50g/吨。添加铝的目的一为防止锌液的氧化,二为增加镀锌管表面的亮度,三为增加镀层表面的均匀性,防止由于锌层表面产生过大晶花而出现鼓棱。Zincandaluminumalloy:100kgofzinc-aluminumalloywith10%ofzincisaddedintosolvent,keepingaluminumcontentof50gpertoninsolvent.Thefunctionofaluminumis:1.preventoxidationtozincsolvent;2.increasebrightnessofgalvanizedpipe’ssurface;3.improveuniformityofgalvanizingcoat;reduceprotuberancecausedbyunevenzincdistribution.铝过多会阻碍合金层的形成而出现漏镀现象。Excessivealuminummayimpedeformofalloycoat,andtheresultisthatthecoatmaynotbeintegral.4.2.5钝化剂的准备:钝化箱一次投放量为350升,其消耗与配制请与供应厂家联系。Preparepassivationadditives:adds350Lofittopassivationcaseforonetime,andconsultsupplierforitsconsumptionandconfectingmethod.4.3.工艺参数processparameters4.3.1产品基本参数与设备运行参数equipmentsandoperationparametersφ114生产线φ114productionline序号规格壁厚mm单重kg/m6m重kg小时产量支/时小时产量公斤/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所用螺旋生产方式10.5"2.651.227.32110080007706.59.2/911.194831491#双管20.25"2.651.589.4884480007708.57/690.8270621641#双管31"3.252.4414.64546800062813.24.55/450.543382732#双管41.25"3.253.1418.844248000628173.5/350.4034303942#双管51.5"3.253.6121.65368800062819.63/300.35302631082#双管62"3.655.1030.6260800055827.72.2/220.2521194623#双管72.5"3.656.5139.06205800055817.63.4/340.434304793#单管83"4.058.4750.821578000503232.6/260.326234804#单管94"4.6512.273.21098000438331.8/180.21181651164#单管114线小磁辊电机114linesmallmagneticrollermotorn=1460rpmi=23r=100mm大磁辊电机largemagneticrollermotorn=1460rpmi=59r=225mm4.3.2温度参数:temperatureparameters4.3.2.1烘干炉温度:120-200℃(热电偶显示)dryingoventemperature:120-200℃(4.3.2.2熔剂温度:70-80℃(温度计人工测量)fluxtemperature:70-80℃(measuredwith4.3.2.3锌液温度:450±5℃(热电偶测量或手持高温温度计人工测量)zincpooltemperature:450±5℃(measuredwithTCor4.3.2.4水冷槽水温:70-80℃(温度计人工测量)temperatureofcoolingwatertank70-80℃(measuredwith4.3.3前处理操作与管理:pre-treatmentandregulation4.3.3.1酸洗液检测制度:rulesoncheckpicklingliquid1)检测内容a)HCl浓度checkitems:a)HCIconcentrationb)铁离子浓度b)ironionconcentration2)检测频度:4小时/次checkfrequency:every4hours3)酸浓度不足可经过添加新酸予以调整以提高酸洗速度。Whenacidconcentrationgetsbelowtherequiredlevel,addsomenewtomaintainacidwashingefficiency.4)铁盐浓度操标时应予排放。Expelpicklingliquidwhenironionexceedrequirements排放标准:铁离子浓度﹥200g/升expelstandard:ironionconcentrationover200g/liter或FeCl2浓度﹥450g/升orFeCl2over450g/literHCl浓度﹤4%HCIconcentrationlessthan4%4.3.3.2酸洗操作:acidwashingoperation酸洗使用天车成捆进行移位与翻动,每个酸槽中均置放有3个梯形石,酸洗时经过天车吊带的收放与梯形石的散捆作用,使钢管表面相互磨擦,促进除锈。在整个酸洗过程,这种吊带收放的操作最少需进行4-5次。Thereare3ladder-shapedstonesineachacid-washingtank,andusecranetomoveandrotatebundlesofpipes.Throughcrane’smotionofraiseanddrop,frictionamongthepipescanhelpfulwithremovingrustonpipes’surface.Duringwholeacidwashingprocess,raise-and-dropmotionshouldbeperformedfor4-5times.钢管表面油污阻碍除锈并造成漏镀,为此钢管的运输移位严禁使用钢丝绳(包括焊管车间),应改用尼龙吊带。Oilstainonpipe’ssurfaceimpederemovingrustandcauseincompletionofgalvanizing,sosteelwireropecannotbeappliedwhentransferringthesteelpipes(includingtheweldingworkshop),onlynylonbeltisacceptable.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,为阻断积存的氧化皮继续消耗盐酸,建议建立倒槽操作制度,每班应进行一次倒槽操作,将槽底积存的含大量氧化铁皮的污泥冲洗干净。Apartfromchemicalreaction,picklingwithHCLcanhavemechanicaleffectonoxidationscale.TopreventstockingoxidationscalecontinuallyconsumeHCL,Troughoperatingsystemshouldberegulated.4.3.3.3漂洗操作:漂洗应在流动的水中进行,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的铁盐含量与游离酸含量进行测控,回用水的盐酸浓度不得高于4g/升,铁盐浓度不得大于3g4.3.3.3Rinsingoperation:rinsingiscarriedoutintheflowingwaterandproceedstwicerinsing.Rinsingwatercanbereusedthroughregeneration.Butprocessingplantcantracktoironsaltandfreeacidofrecycledwater,andtheHCLconcentrationmustlessthan4g/liter,ironsaltconcentrationlessthan3g/liter4.3.3.4熔剂检测制度:1)检测内容:a)游离HCl浓度freeHCLconcentrationb)铁离子浓度ironionconcentrationc)PH值PHvalue2)检测频度:4小时/次4hour/time3)要求:PH值需控制在3.5-4.5范围内,一般情况下,由于酸洗残留物的缘故,熔剂液多少含有游离酸,PH值均较低。PH值大于4.5将引起ZnCl2析出,降低溶剂的效用,应加HCl予以调整;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或加入锌灰予以调整。3)Requirements:PHvaluemustbecontrolledintherangeof3.5-4.5.generallyspeaking,duetopicklingresidueresistance,fluxcontainsuitablefreeacidwhichcausePHinalowvalve,PHvalueismorethan4.5,whichcauseZnCl2saltedout.Inordertolowerfluxinfluence,HCLshouldbeadjustedproperly.PHvaluelessthan3.2orfreeHCLconcentrationmorethan2g/liter,fluxeffectwillbelowerandmoreNH4OHshouldbeaddedoraddzincash.4.3.3.5涂熔剂操作:熔剂须经过连续过滤与加热,过滤机每班最少进行一次反冲清洗,滤芯需定期更新。Fluxneedcontinuallyfilteringandheating,filtershouldbeflushingeachwork,andfiltercoreshouldbechangedregularly熔剂的洁净与否对锌耗有很大的影响,经过试生产应建立一套严格的熔剂管理制度。Thecleanoffluxhaveagreatinfluenceonzincconsumption.Throughtrialproduction,onesetoffluxmanagementregulationshouldbeset.4.4成品质量检验:finishedproductqualityinspection4.4.14.4.2镀层均匀性检验:硫酸铜腐蚀试验。C4.4.3镀层厚度检验:超声测厚仪。Coatingthicknessinspection:ultrasonic4.4.4镀层重量检验:氯化锑置换试验。Coatingweightinspection:butterofantimony4.5.热调试规格:1/2”双管生产(114线);hottestingspecification:1/24”单管生产(114线);4第二部分设备的主要技术性能一．钢管前处理段Pretreatment1.1Hcl酸洗槽5个:HCLpicklingbath5尺寸:长×宽×深=7.6m×1.5m×1.5mDimension:length×width×depth=7.6m×1.5m×1.5m结构:玻璃钢夹层结构,槽壁与槽底用钢结构框架加固,槽低用花岗岩块铺垫。Structure:FRPsandwichstructure,bathwallandbathbasearestrengthenedbyconstructedsteelstructure,andbaseusedinmoonstone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与贮酸罐及排污沟连接,可实现酸洗槽加酸、排污、以及酸槽之间的”倒槽”操作。1.2清洗水槽2个:cleaningwatertank:2尺寸:长×宽×深=7.6m×1.5m×1.5mDimension:length×width×depth=7.6m×1.5m×1.5m结构:与1.1相同。Structure:sameas1.11.3熔剂槽2个:Fluxbath:2尺寸:长×宽×深=7.6m×1.5m×1.5mDimension:length×width×depth=7.6m×1.5m×1.5m结构:与1.1相同。配有熔剂过滤机一台,利用过滤机的泵将熔剂槽的槽液连续抽出、过滤,并经过一个换热面积为3m2的石墨热交换器,将熔剂加热到80℃左右,加热介质为蒸气,温度利用温度调节阀控制。Equippedwith1setfluxfilter,whichdrawoutsolutioninfluxbaththroughpumpoffilter,andthenfliterbygraphiteheatexchangerinexchangeareaof3m2.Whenfluxiswarming-upto80二．烘干炉dryingfurnace尺寸:长×宽=8m×7mDimension:length×width=8m×7m传动:制动电机:YEJ100L——3,n=1500r.p.m,N=3kw;Diving:drivingmotor:YEJ100L——3,n=1500r.p.m,N=3kw;行星摆线减速器:XWEDE3-4P-74-289,I=289,n=5r.p.m;Planetarycycloidreducer:XWEDE3-4P-74-289,I=289,n=5r.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,下部为烘干炉的烟道,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,将烘干炉膛内的空气引入烟道内的换热器,经加热后又喷入炉膛内,以增强钢管的加热效果,烟道入口温度约600℃,出口温度约200℃,烟气量约为1200NM3/h,每小时的供热量约为156500大卡。Dryingfurnacesettingismadeofdoublecastironribbedplateandfluebelowit.ф114pipeheatexchangerinsidethefluewithexchangeareaof20m2.Theworkingprincipleisdryingpipesthroughwastegaseswarmingupstiffenedplates.Exceptforheatexchanger,circulatorwithair-volume6600NM3/h,N=5.5Kwdrawairinthedryingfurnacechamberintoheatexchangerintheflue,andthenpuffintochamberafterheatingtostrengthenheateffectofpipes.Inlettemperatureofflueisabout600℃,and200℃foroutlet,flux1200NM3/h烘干炉的产量最大以8吨/时计,入料温度设为20℃,出料温度设为70℃,其吸热量为:8000×(70-20)×0.111=44400大卡,利用系数为0.28。Themaximumcapacityofdryingfurnaceis8ton/hour,feedingtemperatureis20℃,out-feedingtemperatureis70℃,heat-absorbingis8000×(70-20)×0.111=44400caloric,钢管在烘干炉内的输送依靠链条步进驱动,输送链的移位步距为304.8mm,7m炉长可移动22步,不同规格的钢管在烘干炉内的停留时间为表1-7所示。Thetransmissionofpipeindryingfurnaceisdrivenbystepchain,andtransmissionchaindisplacingstepdistanceis304.8mm,thatisfurnaceof7mlengthdisplace22step.Below1-7areretentiontimeofpipesinthedryingfurnacewithdifferentspecification.烘干炉内钢管的加热时间表1-7Heatingtimeofpipesindryingfurnace规格specification产量output(支/时)节奏(秒)rhythm总加热时间totalheatingtime(秒)烘干炉内容纳钢管的数量为Pipesquantityindryingfurnacen=7000/304.8=220.5″11006.52210.75″8448.52891″54613.24491.25″424175781.5″36819.66662″24514.75002.5″20517.65983″15723506/7824″10933726/1122三．入料辊道feedingroller114入料辊道长28m,辊间距1.43m,共20套辊,输送速度2.78m/s,组合传动,电机N=4Kw,i=3.7t=LengthofRolleris28m,rollerdistance1.43m,andtotal20setsroller.Thetransmissionspeedis2.78m/sandcombineddriving.MotorparametersisN=4Kw,i=3.7t=140mm.辊道连续运行,端部设定位挡板。四．镀锌炉Galvanizingfurnace4.1加热方式:heatingmethod两侧长焰烧嘴加热,两端有循环风机,风机流量约为燃气排出量的10倍左右,形成循环再加热的方式,使炉内温度分布均匀,见图示。Heatbyburner,circulatorinbothendsoffurnacewithairflow10timesisofcombustiongas,whichformscirculationheatingtodistributetemperatureasymmetry.4.2技术数据:(以下所列为一条线的参数)TechnicalData:燃料:煤制气,热值1200-1350Kcal/m3Fuels:coalgas,heatvalue1200-1350Kcal/m3燃气烧嘴:供气压力为1000-1500pa,气量:50万大卡/h2个,25大卡/h2个;Combustiongasburner:Pressure:1000-1500paflowofgas:鼓风机:全风压400-500mm水柱,流量NM3/h,电机11Kw;Blower:windpressuresteam:400-500mmvolume:NM3/hMotor:11kw循环风机:2台,作温度700℃,最高温度800℃。流量:Q=13000NM3/h,全压:30mm水柱,电机:5.5/4Kw双速电机;Circulator:2setworkingtemperature:700℃maxtem:800Flow:Q=13000NM3/hpressure:steam:30mmMotor:5.5/4Kwdouble-speed引风机:一台,流量:Q=2400NM3/h,全压:50mm水柱,电机:2.2kw(变频调速);Draftfun:1set,flow:Q=2400NM3/hpressuresteam:50mm,Motor:2.2kw(VVVF)烟囱:直径ф720,高度18m;Chimney:diameter:ф720Height:18m尾气引风机采用变频调速电机,用于调节炉压,以保证镀锌炉在微负压下工作。ExhaustdraftfunadoptVVVFmotortoadjustfurnacepressuretoensuregalvanizingworkundernegativepressurecondition.4.3镀锌炉的热负荷计算:Thermo-loadcalculation4.3.1最大产量C=8000kg/h。Maxoutput:C=8000kg/h4.3.2加热镀件的热量:每公斤钢升温1℃,需0.111Kcal,钢管入锅温度设为Q1=0.111×400×8000=355200Kcal/hWorksheat:4.3.3熔化锌的热量:每公斤钢大致最多消耗0.085kg锌,锌的比热为0.093Kcal/kg℃锌的熔化潜热为27.17KcQ2=0.085×(0.093×450+27.17)×8000=46934Kcal/h;4.3.4锌液表面的辐射热每平方米的辐射热约为1Kcal/h,锌锅表面积F=7.5×1.5=11.25m2,则Q3=11.25×1=135000Kcal/hRadiationheatpersquaremeterisabout1Kcal/h,surfaceareaofzincpotF=F=7.5×1.5=11.25m2Q3=11.25×4.3.5锌炉表面向车间散热根据经验锌炉表面的温度约为60℃,单位面积的辐射热q=400Kcal/m2hr,炉表面积F约为60m2,则Q4=400×60=24000Kcal/h。Basedonexperience,surfacetemperatureofzincfurnaceisabout60℃,radiationheatperunitareaq=400Kcal/m2hr,surfaceareaF=60m2,thatisQ44.3.6烟气带走的热量heatresultingfromthegas设供气量为A,煤制气的配气量为1.5m3/m3,空气过剩系数α=1.2,煤制气的发热值暂为1300Kcal/kg,尾气温度设为700℃,尾气比热为0.326Kcal/m3。LetairsupplyisA,coalgasis1.5m3/m3,excess-aircoefficientα=1.2,heatvalueofcoalgasis1300Kcal/kg,lettailgastemperatureis700℃andheatcapacity0.326Kcal/m则尾气带走的热气:ThatisheattakingawaybytailgasQ5=(A×1.5×1.2+A)×0.326×680=621×A3.6.3.7热平衡:heatbalanceA×1300=355200+46934+135000+24000+621A561134A==826.41m3/h679当产量为8000kg/h时,煤制气净耗量为826m3/h,停镀保温时的耗气量为100m3/h,Whenoutputis8000kg/h,netconsumptionofcoalgasis826m3/h,gasconsumptionwhenstoppinggalvanizing(heatpreservation4.3.8锌锅热负荷:锌锅传热面积为Fk=(1.6+7.5)×2×2=36.4m2HeattransfersurfaceareaofzincpotFk=(1.6+7.5)×2×2=36.4mQ1+Q2+Q3355200+46934+135000αk==FK36.4=14756Kcal/hr.m2据有关资料介绍,锌锅的最大允许热负荷为30000Kcal/hr.m2αk=14756Kcal/hr.m2是合理的。Accordingtorelevantmaterial,maxthermo-loadofzincpotis30000Kcal/hr.m2五．镀锌锅GalvanizingPot尺寸:长×宽×高×厚度=8000×1600××50,材料:XG08(鞍钢);Dimension:length×width×height×thickness=8000×1600××50Material:XG08(ANSHANIRON)装锌量:BZn=7×8×1.6×(2.0-0.3)=152吨;ZincQuantity:BZn=7×8×1.6×(2.0-0.3)=152吨熔融金属的总装载量为152吨,为最大产量8T/h的19倍。Loadofmoltenmetallicis152tonthatis19timesof8T/h.六．浸锌机构Dippingunit钢管依靠一组三个连续旋转的浸锌螺旋驱动逐根浸入锌液,传动为:行星摆线减速器+蜗轮蜗杆传动。Underthehelpofoneunitcontinuousrotatingspiraldrivingmechanism,immersepipesintozincsolutiononebyone.Transmissionsystemincludeplanetarycycloidreduceandwormgearandwormdrive.Φ114机组使用3套浸锌螺旋,其浸锌存留螺旋节数分别为9.5,7.5,6.5及5.5以适应不同生产节奏下不同浸锌时间的要求。浸锌螺旋转速为1.8～9.2r.p.m变频调速,行星摆线减速器速比为29,蜗轮蜗杆传动速比为10,电机功率为4KW。Φ114pipelineuse3setsdippingscrew,andnumberofscrewisrespectively9.5,7.5,6.5and5.5tomeettherequirementsofdippingtimeinthevariousproductionrhythm.Rotatingspeedofdippingscrewis1.8～9.2r.p.m.Planetarycycloidreducerratiois29,wormgearandwormdriveratio10,motorpower4kw.磁力辊升降电机型号为:Y90L-6-1.1(双出轴)Elevationmotor:Y90L-6-1.1(doublespindle)磁力辊拖动电机型号为:XWDV4-4P-8165-51(变频调速)Draggingmotor:XWDV4-4P-8165-51(VVVF)螺旋下标高约为-980mm,锌锅底标高-mm,锌液面标高-100mm,导轨面标高为-1180mm。Lowerelevationis980mm,vatbottomelevationofmm,solutionlevelelevationof100mm,guidewayfaceelevationof-1180mm。七．拨料机构Kick-outunit由一个ф125×920的气缸驱动三个拨料臂。Itconsistsofoneф125×920pneumaticcylinderandkick-outarm.八．提升机构Elevationunit单钩提升汽缸驱动,气缸为ф160×850,提升钩的行程为1850mm。Hookhoistф160×850pneumaticcylinder,andstrokeis1850mm九．磁力辊magneticrollerφ114机组采用4个双槽磁力辊,磁力辊腰园直径ф430,磁力辊为永磁辊;磁吸力为60kg,4个磁力辊用一台变频电机+行星摆线减速器+链轮—链条驱动,N=4KW,磁力辊转速为30.3～92r.p.m,引出速度为0.21-1.1φ114pipelineusefourdouble-groovemagneticroller,anditsdiameterisф430.Itispermanentmagnetic,andmagneticforceis60kg.Fourrollersaretotallydrivenbyonefrequencyconversionmotortogetherwithplanetarycycloidreducer,gearwheelandchain.Speedofmagneticis30.3～92r.p.m,anddrivenspeedis0.21-1.1m/s.十．外吹Externalblowing外吹环双管使用时,能够单独调压控制气量,结构为球阀+调压阀+压力表+外吹环。单管使用时,将另一侧阀门关闭。两套外吹环单独供气,可同时调节升降。Whendoublepipesaretested,adjustpressureandcontrolgasflowsingly.Adjustmentunitconsistofballvalve,pressuregovernorvalve,pressuregaugeandexternalblowingring.Whensinglepiptested,shutvalve,andtwosetsexternalblowingringsupplyinggasrespectively.十一．磁力辊升降机构Elevationdeviceofmagneticroller改变规格时,磁力辊的标高需加以调整,磁力辊高度调整,电机功率为:N=1.1KW,n=1000r.p.m,蜗轮蜗杆传动比为i=50。磁力辊升降显示设有标尺,调好位置后,应对标尺尺寸做相应的记录。调整丝杆t=6,调整速度U=120mm/min。Whenspecificationismodified,elevationofmagneticshouldbeadjusted,andthattimemotorpowerisN=1.1kw,n=1000r.p.m,wormgearandwormdriveratioisi=50.Elevationofmagneticrollerismeasuredbyscale,andrecorddetailedsizewhenadjustingasuitableposition.十二.曳出辊道Pullingoutroller曳出辊道倾斜17°布置。angleofthetiltofpullingoutrolleris17°φ114机组曳出辊道驱动功率为5.5KW,变频电机+行星摆线减速器+链轮—链条驱动,辊腰圆直径ф175,辊道转速为:74～220r.p.m,速度为0.5-1.5m/s,均为永磁辊防止钢管下滑。Drivenpowerofpullingoutrolleris5.5KW,anddrivenbyfrequencyconversionmotortogetherwithplanetarycycloidreducer,gearwheelandchain.Diameterofrollerisф175,rotatingspeedofrolleris74～220r.p.m,speed0.5-1.5m/s.十三.猫头叉横移机构Fork-shapedtransversemovingdevice采用猫头叉横移机构,横移时钢管平行移动不滚动。Usefork-shapedtransversemovingdevice,andkeeppipesparallelmoving.横移电机N=3KW,n=1450r.p.m,减速器传动比i=59,横移机的回转速度为15r.p.m,步进齿距t=664mmTransversemovingmotorN=N=3KW,n=1450r.p.m,andreducerdriveratioisi=59.Speedoftransversemovedeviceis15r.p.mtoothspacet=664mm.十四.内吹和升降机构Internalblowingandelevationunit14.1φ114机组的内吹装置概况如下:Internalblowingunitisasfollow内吹机构共有四个动作:Internalblowingunitconsistsoffouractions1)夹紧:ф160×400气缸2套驱动,每套夹紧可产生191)Clamping:drivenby2setsф160×400pneumaticcylinder.Generate1900kgclampingforceeachsetclampingunit.2)内吹小车移动汽缸:φ100×300汽缸,最大可产生300kg压紧力以克服内吹后坐力,压紧力可用减压阀调整。2)Movingpneumaticcylinder:Generate300kgsqueezingforceforφ100×300pneumaticcylindertoovercomerecoilforceafterinternalblowing.Squeezingforcecanbeadjustedbypressurereducingvalve.3)DN50/DN80气动球阀各1套:用来提供蒸气。3)DN50/DN80pneumaticballvalve1setrespectivelytosupplysteam.4)内吹箱消音罩启闭气缸:φ125×520,内吹时,罩体下降,将钢管尾部封闭在罩内,然后进行内吹,可达到降低噪音的作用。4)Mufflercoverofinternalblowingbox:Wheninternalblowing,coverfalldownandencloseendofpipeinit,andthenbegintoblowtoreducenoise.14.2升降机构:摆动梁用一个φ160×880的汽缸驱动摆动,当摆动梁处于上位时,摆动梁处于一条17°倾斜线上,正好与步进机的停位标高一致,摆动梁移到下位时,转为水平位置滚入冷却水槽。Swayingbeamisdrivenbyoneφ160×880pneumaticcylinder.Whenbeamisintheupperposition,andjustlyitkeepidenticalwithpositionelevationofsteppingmachine.Totheopposite,beamchangestohorizontaltorolltocoolingwatertank.冷却水槽为钢板结构件,可贮水17t,槽内有3条步进运动的链条可将槽内钢管逐根捞出。Coolingwatertankissteelplatestructureandrefillwater17t.Thereare3chainstodragoutonebyone.114线链条驱动电机N=4KW,n=1450,行星摆线减速器i=59,链节距t=100,步进距离l=300mm,链轮齿数Z=9,完成一个步进动作所需时间为1.2秒。Drivingmotorby114chainN=4kw,n=1450,planetarycycloidreducei=59,chainpitcht=100,stepspacingl=300mm,gearwheeltoothZ=9.Finishingonestepactiononlyspends1.2second.冷却水槽的三根链条倾斜布置高差为70mm,使钢管以倾斜状态引出,以利排水。冷却水利用蒸汽吹管加热,待水温达80℃后可投入利用,在生产过程中水温增高,热水经过溢流口,自流排至车间外的热水池,用泵引至冷却塔,将水温降至76℃左右,引至冷水池,再用泵引回冷却水槽,继续使用。Coolingwateriswarmupbysteam.Whentempreach80℃,andthenputintouse.Intheprocessofproduction,tempincrease产量8吨/时,热管入槽温度估为300℃,温降220℃,钢比热为0.111大卡/℃.Kg冷却热量为200,000大卡。如采用冷却塔,且冷却塔温降为7℃,则循环水的流量Q=30t/h。十六.检查台架Checktable检查台架入口有气动挡板将冷却水槽倾斜引出的钢管挡住,待钢管排齐后,挡板放下,钢管下滚。检查台架的中部有一气动闸板,闸板落下,正品钢管继续下滚,闸板抬起,次品管落入台架下的次品小车。十七.钝化辊道:PassivationRoller114线钝化辊道长16m,辊间距1.5m,共12套辊,输送速度1.6m/s,组合传动,电机N=4Kw,端部设定位挡板,电动快速无返回式拨料,拨料时间不得超出0.5秒。Lengthofpassivationrolleris16m,space1.5m,total12setsroller.Transmissionspeedis1.6m/s,driven十八.钝化喷淋站Sprayingstationforpassivation.喷淋吹环依管径设计,喷淋操作在一密闭箱内进行,钝化液用一台泵循环使用。泵参数:Q=44.7m3/hr,H=10m,N=2.2Kw。出口配外吹环。Spraystationisdesignedaccordingtopipediameter.Sprayoperationisworkinaclosedcase.Andsprayliquidisstoredinonepumpandusedinacycle.十九.烘干台架Dryingtable(skid)台架长4.5m,1#线可存管20(8”)-40(3”)支,烘干时间1900-920秒;2#线可存管160(1/2”)-35支),烘干时间520(1/2Lengthofskidis4.5m,1#storepipe0(8”)-40(3”)pieces,anddryingtime1900-920seconds,2#storepipes160(1/2”)-35,anddryingtime520(1/2”二十.打印辊道StampRoller114线打印辊道与钝化辊道完全相同,打印辊道为双线布置,共11套辊道。Stamprolleristhesameaspassivationroller.Stamprollerisdouble-linedeployed.Total11setsroller.二一.打印机Stampmachine胶轮气动打印机,全长打印,114线配备2台打印机。二二.六角打包设备PackagingEquipment由4套设备组成,consistsof4setsequipments出料台架,配有人工滚印色带装置;outletskidisequippedwithribbondevice六角包收集槽;六角包的上半部由人工码放;collectingtank:upperpartsispiledbymanual气动推齐设备;pneumaticpushingequipment两台气动打包机、平衡机及其悬挂吊架。每包重约3吨,每小时按打3个包能力配置。Consistoftwosetpneumaticpackingmachine,balancingmachineandsuspendingdevice.二三.除尘器Cleaner采用布袋除尘器,过滤面积200m2Usebagfilterwithfilterareaof200m2,conveyerspiralautomaticallydischargeash,andthencompressedairpulse有暖风机向除尘箱供应暖风,降低结露危害。Fanheaterblowingwarmairtocleaningtrunktolowerhazard温度监控,超温报警,紧急情况下水喷淋降温。Temperaturegoverning,givingalarmingwhentemperatureexcursion,andsprayingtocooldowninemergencycircumstances.顶部配备压差变送器。Equippedwithpressure