钢管热镀锌φ114生产线技术操作规程
目录 Contents
第一部分生产概况…………………………………………………
(2)
Section one General description of the production line
一、生产工艺流程图…………………………………………………
(2)
Process flow diagram
二、工艺平面布置示意图…………………………………………………
(2)
Layout sketch
三、原料规格及执行标准…………………………………………………
(2)
Specification of material and its criteria
四、试生产说明 (3)
Starting-up illustration
第二部分设备的主要技术性能…………………………………………………
(5)
Section two Main technical characteristics of the equipments
一、钢管前处理段…………………………………………………
(4)
Pre-treatment of steel pipes
二、烘干炉…………………………………………………
(5)
Drying oven
三、入料辊道…………………………………………………
(6)
Feeding rollers
四、镀锌炉…………………………………………………
(6)
Galvanizing furnace
五、镀锌锅…………………………………………………
(8)
Galvanizing vat
六、浸锌机构…………………………………………………
(8)
Dipping unit
七、拨料机构…………………………………………………
(8)
Kick out unit
八、提升机构…………………………………………………
(8)
Lifting unit
九、磁力辊…………………………………………………
(8)
Magnetic roller
十、外吹…………………………………………………
(8)
External blowing
十一、磁力辊升降机构…………………………………………………
(9)
Elevation device of magnetic roller
十二、曳出辊道…………………………………………………
(9)
Pulling out roller
十三、猫头叉横移机构…………………………………………………
(9)
Fork-shaped transverse moving device
十四、内吹和升降机构…………………………………………………
(9)
Internal blowing and elevation device
十五、冷却水
槽…………………………………………………
(9)
Cooling water tank
十六、检查台架…………………………………………………
(10)
Check table
十七、钝化辊道…………………………………………………
(10)
Passivation roller
十八、钝化喷淋站…………………………………………………
(10)
Spraying station for passivation
十九、烘干台架…………………………………………………
(10)
Drying table
二十、打印辊道…………………………………………………
(10)
Stamp roller
二一、打印机…………………………………………………
(10)
Stamp machine
二二、六角打包设备…………………………………………………
(10)
Packaging tools
二三、除尘器…………………………………………………
(10)
Cleaner
二四、电器设备…………………………………………………
(10)
Electrical device
第三部分镀锌车间技术操作规程…………………………………………………
(11)
Section three Operating instruction of galvanizing workshop
一、目的…………………………………………………
(11)
Purposes
二、使用范围…………………………………………………
(11)
Applying scope
三、工作程序…………………………………………………
(11)
Working procedures
3.1、酸洗工序…………………………………………………
(11)
Acid cleaning
3.2、火炕工序 (11)
Heating
3.3、锌锅工序…………………………………………………
(11)
Dipping
3.4、内外吹工序 (12)
Blowing
3.5、钝化水洗工序 (12)
Passivation and wash
3.6、检验工序 (12)
Check
3.7、司炉工 (12)
Operators
修订状况记录…………………………………………………
(12)
Record of revision
(12)
第一部分生产概况Section one General
description of the production line 一．生产工艺流程图Process flow diagram
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。Steel pipe hot-dip galvanizing line is the automatic equipments to produce resistant and smooth layer on the surface of raw pipes after cleaning.
二．工艺平面布置示意图（附）Layout sketch (enclosed)三．原料规格及执行标准Specification of material and its criteria
φ114生产线产品大纲main parameters of φ114 production line
criteria (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: statistics of single pipe weight and yield based on raw pipes. Because consumption of acid, solvent
and zinc is related to and calculated by pipe’s
surface area, production data should include
both weight yield and area yield.
四．试生产说明Starting-up illustration
4.1镀锌炉的点火与升温Galvanizing furnace
ignition and heating up
4.1.1 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。Piled zinc and lead ingots, and use a piece
of rubber tube and 1.5 meter long steel pipe
as a auxiliary burning device to ignite the
main fire, because blast-furnace gas has low
calorific value and is hard to light up.
点火前应准备8套燃烧器对8套烧嘴同时进行强迫点火。Prepare 8 sets of burning
device to light 8 burners simultaneously.
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。The furnace might have been contacted with water and got dry after 4-5 months exposure to air. But still for sake of safety, laggard and placid heating speed is recommended, elongate time at temperature of 110℃(flowing water evaporation) and 300℃(crystal water evaporation).
4.2.试生产用料准备Raw pipes preparation for
start-up
4.2.1炉料furnace material: 1#锌锭155吨
zinc ingot 155 ton
铅锭15吨lead ingot 15 ton
4.2.2.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. Hydrochloric aid: its solution of 37% concentration has specific gravity of 1.19. Confect two tanks of 17% hydrochloric acid for one production
line before start-up, and around 20 ton of high-concentration hydrochloric acid may be needed. In normal production, 2(8”)-7(1/2”) ton of 37% acid are consumed per day, so some stock of it is necessary to maintain continuous production with respect to delivery and production plan.
4.2.3 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。Proportion for ammonium and zinc
in solvent is 1.6:1, almost 450g per liter. One tank of solvent needs 4.7 ton of ammonium chloride and 2.9 ton of zinc chloride.
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。Zinc and aluminum alloy: 100kg of zinc-aluminum alloy with 10% of zinc is added into solvent, keeping aluminum content of 50g per ton in solvent.
The function of aluminum is: 1. prevent oxidation to zinc solvent; 2. increase brightness of galvanized pipe’s surface; 3.
improve uniformity of galvanizing coat;
reduce protuberance caused by uneven zinc distribution.
铝过多会阻碍合金层的形成而出现漏镀现象。Excessive aluminum may impede form of alloy coat, and the result is that the coat may not be integral.
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。Prepare passivation additives: adds 350L of it to passivation case for one time, and consult supplier for its consumption and confecting method.
4.3.工艺参数process parameters
4.3.1 产品基本参数与设备运行参数
equipments and operation parameters
4.3.2 温度参数：temperature parameters
4.3.2.1 烘干炉温度：120-200℃（热电偶显示）
drying oven temperature: 120-200℃(measured with TC)
4.3.2.2 熔剂温度：70-80℃（温度计人工测量）
flux temperature: 70-80℃(measured with
thermometer manually)
4.3.2.3 锌液温度：450±5℃（热电偶测量或手
持高温温度计人工测量）zinc pool temperature: 450±5℃(measured with TC or thermometer manually)
4.3.2.4 水冷槽水温：70-80℃（温度计人工测量）
temperature of cooling water tank 70-80℃（measured with thermometer）
4.3.3 前处理操作与管理：pre-treatment and
regulation
4.3.3.1 酸洗液检测制度：rules on check
pickling liquid
1）检测内容a)HCl 浓度check items: a) HCI concentration
b)铁离子浓度b) iron
ion concentration
2）检测频度：4小时/次check frequency: every 4 hours
3）酸浓度不足可通过添加新酸予以调整以提高酸洗速度。When acid concentration gets below the required level, add some new to maintain acid washing efficiency.
4）铁盐浓度操标时应予排放。Expel pickling liquid when iron ion exceed requirements
排放标准：铁离子浓度﹥200g/升expel standard: iron ion concentration over 200g/liter
或FeCl2浓度﹥450g/升or FeCl2 over 450g/liter
HCl浓度﹤4% HCI concentration less than 4%
4.3.3.2 酸洗操作：acid washing operation
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，酸洗时通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。There are 3 ladder-shaped stones in each acid-washing tank, and use crane to move and rotate bundles of pipes. Through crane’s motion of raise and drop, friction among the pipes can helpful with removing rust on pipes’ surface. During whole acid washing process,
raise-and-drop motion should be performed for 4-5 times.
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。Oil stain on pipe’s surface impede removing rust and cause incompletion of galvanizing, so steel wire rope can not be applied when transferring the steel pipes(including the welding workshop), only nylon belt is acceptable.
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。Apart from chemical reaction, pickling with HCL can have mechanical effect on oxidation scale. To prevent stocking oxidation scale continually consume HCL, Trough operating system should be regulated.
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，漂洗水可通过再生处理