热硫化橡胶衬里工艺规程中英.docx

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