第一旋风分离器斜插管筒体划线.开孔，组装及焊接方案 tube opening, assembly and welding program,,,,第一旋风分离器180D-CY1斜插管及筒体的厚度为200mm,同时斜插管与筒体的连接,既是单边相切,又是斜向连接45度,不仅焊缝厚度大,尺寸和角度精度要求高,此条焊缝代表了整个气化炉的加工难度.主要难点为: 1.由于两筒体为45度相交,并且是切向连接,所以焊缝处的空间形状比较特殊. 2.200mm的筒体厚度导致最大的焊缝厚度达到了400mm以上(不包括外壁加强焊缝).焊缝熔敷金属1000kg以上. 3.尺寸偏差在3mm以内,角度偏差0.5度以内.都对划线,开孔,焊接,测量,检验提出了更高的要求.,放样模板,可划出模拟件轨迹,模拟件,分离器筒体,用模拟件划出筒体开孔线,划开孔线等距离偏移动用于测量,开 孔,1.分离器筒体放置在TK6926S数控镗铣床工作平台上,校正相对位置 2.在图示起点钻孔作为起割点 3.开孔程序编入镗铣床数据库中,割刀头沿划线轨迹先走一次,在运行过程中校正，使走的轨迹基本与划线基本一致 4.从起割点开始切割切割方向如图所示切割到A-A’点停止,后面部分在镗床进行机加工。
5.对气割表面进行修磨，打磨至少2mm厚HAZ金属，打磨光洁度平整度应满足焊接的要求 6.坡口表面100%MT检查合格后,开始装配和焊接切割轨迹图,TK6926数控镗铣床机床参数： X轴160000mm， y轴6000mm， z轴1500mm， W轴1500mm， 镗杆直径260mm， 回转工作台4000mm*4500mm，最大承重80吨TK6926数控镗铣床机床参数,,55°± 30',,,,,,,,,,,,——划线:内外壁放样划线并打洋冲标示 (基准线和气割线) Marking: Sampling marking inside and outside of the wall and punch mark ( base line and gas cutting line). ——钻气割孔（试割孔和正式孔） Opening( try opening and official opening) ——在镗铣床机头上装妥斜孔自动开孔工装 并装妥气割喷嘴 Assemble slanting hole auto opening fixture N5092-470 on the head of boring and milling machine and assemble air cutting nozzle ——将产品吊至镗铣床平台上并校调 （0º在最高点，轴线调水平并与机床镗轴垂直）。
Lifting the product on the platform of boring and milling machine and regulate.(0º is the highest point, adjust axis to level and perpendicular with machine boring axis.) ——镗铣床上输入自动走轨迹的程序（分二部分），并校调中 心后按划线试走轨迹，符合要求后才能在产品上气割 Input auto-moving track program on boring and milling machine (separate into 2 parts), and try track according to marking after adjust the center. Gas cutting the product after it complies with requirements. ——装妥隔热装置 (在筒体与镗铣床之间用槽钢制一架子用 石棉布隔热，并且在地面上用石棉布覆盖 Assembly heat insulation device.( Produce one structure which is made of stiffness in between the shell and boring and milling machine. Insulate heat with asbestos cloth. And covered by asbestos cloth on the ground.) ——预热、试割（预先编程） Preheating and try cutting( advance progress) ——预热、正式在产品上气割开孔（分二部分）。
Preheating and official cutting on product( separate to 2 parts) ——去渣并修磨45º斜孔至尺寸 Slag removing and repair grinding 45º slanting hole so that it can reach to required size. ——坡口各尺寸及表面光洁度测量 Groove size and surface cleanness checking. ——45º斜孔坡口MT检查 45º slanting hole groove MT checking.,气割 Gas cutting开孔Opening,,,,,,,装配和检查 Assembly and inspection,,,,,,,A：将筒体吊至装配位置并校调（轴线调水平） Lifting shell in assembly position and adjust it ( Axis shall be in level). B：装焊妥筒体上产品吊轴和二只工装吊耳（在180º方位离 端 口～1000mm）及内壁的定位工装 Assemble and weld product lifting shaft and two lifting lugs on shell(on 180º position and ～1000mm away from end) and inside wall positioning layout . C：对产品进行校调（0º在最高点）。
Adjust product(0º is the highest point). D：斜接管内壁装焊定位块外壁上装焊起吊吊耳（三只）， 在筒体上装焊测量工装 Slanting tube inside wall assemble and weld positioning pieces. Assemble and weld 3 lifting lugs outside wall. E：装配斜接管并校调45º夹角，检查配合 Assemble slanting nozzle and adjust 45º angle and check fit up. F：装妥防变形工装及焊接垫板 Assemble anti-distortion fixture and weld mat plate.,斜管外侧坡口部位打磨 Grind slanting tube groove outside MT检查 MT testing,,葫芦安装（工装） Fixture assembly,,,,,,内壁的定位工装 测量 Positioning fixture measurement,,,,,,,——焊妥防变形工装 （局部预热） Fixture for prevent deformation( Local HT) ——焊妥衬板 Weld scaleboard ——测量角度 Angle measurement,初装加热装置（热电偶）并焊妥 Add thermocouples and welding,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,装焊临时稳固工装 Assemble temporary stable fixture,,,,测量 Measurement,,,,装加热工装（热电偶） Add thermocouples,,,,,,,,,焊接 Welding,焊接工艺 Welding procedure 焊接工艺采用直流埋弧自动焊，局部和外侧加强高采用直流手工电弧焊，有关参数如下： Welding procedure apply direct current SAW, local and outside reinforce. Apply direct current Manual SMAW, related parameter is as follows: 预热温度：200~230℃；层间温度：200~250℃ Pre-heat Tem: 200~230℃；Interpass Tem: 200~250℃ 埋弧焊：焊接电流：500~600A；电弧电压：30~35V；极性：DCEP SAW: Welding current: 500~600A；Arc voltage: 30~35V；Polarity: DCEP 焊接速度：450~550mm/min； Welding speed: 后热规范：300~350℃×4~6h； Post heating specification: 焊接位置：平焊 Welding position: Slip-on welding,,焊机改装和调试 Welding machine debug,,,,,,,,,,,,,,,,,,,,,,,,,,装焊机平台 Assemble welding machine platform 敲测量洋冲眼 Punching 加热 Heating 防变形马脚和塞块焊接 Weld anti-deformation support and plug 装焊机 Assemble welding machine,,,,,,,,,,,,,,,,,,,,,,搭建工作平台 Assemble platform,提升焊机 Lifting welding machine,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,焊剂临时档板 Temporary baffle,,,,,,,,,,,,,,,,,,,,,,,,,,,,,——焊接、测量监控 Welding, measurement check ——焊妥后去氢处理 De-hydrogen treatment after welding ——去氢后不低于200 ℃时割/去除防变形工装和衬垫 After De-hydrogen treatment, Cutting/remove anti-deformation fixture and backing strap when it is about 200 ℃. ——打磨，测量，焊缝MT，RT，UT Grinding, measurement, MT，RT，UT testing the weld ——预热 Preheating ——外侧加强高手工焊焊妥 Manual welding outside reinforcement —— 去氢De-hydrogen —— 打磨Grinding；MT，UT，RT —— 测量Measurement,,,,,,,45,Welding operation technology and sequences: Cleaning before welding: Before assembly and welding, 100%MT to groove surface and its adjacent area according to JB4730. Cleaning after it is accepted, including supports, ark plate etc. Remove foreign matters, such as, surface grease, rust etc. Assembly according to co。