卧式油罐制作方案

100m3常压卧式油罐

制

作

方

案

一、单位工程概况 ··········································································

1、工程概况 ·············································································

2、油罐制作现场排版图： (1)

二、施工方案 ················································································

1.施工前准备·············································································

2.油罐制作················································································

3.组对拼装 ···············································································

4.制造过程质量控制····································································

5.焊接检验 ···············································································

6.试验·····················································································

7.油罐的防腐·············································································三．验收 ······················································································四、油罐吊装方案 ··········································································

1．油罐概况 ·············································································

2.施工准备 ···············································································

3.吊装·····················································································

一、单位工程概况

1、工程概况

1.1、本工程为10×100m3罐组，现场制作工程量为20台。原设计图纸油罐仅有外形尺寸，外径φ3216mm，总长度12800mm，需要深化设计。建设单位要求：油罐封头厚度δ=10mm，筒体板厚8mm，钢板材质为

Q235-A，人孔为DN600，高800mm。

2、油罐制作现场排版图：

二、施工方案

1.施工前准备

1.1该油罐采用普通碳素结构钢Q235-A焊制，符合GB T709-2006 《热轧钢板和钢带的尺寸、外形、重量及允许偏差》及钢板质量应符合GB700—88《碳素结构钢》。焊接材料为E4303，其质量应符合GB/T5117-1995《碳钢焊条》。

1.2所有材料必须具备材料出厂质量证明书。到货后要按材料质量证明书进行验收，对有怀疑的项目，要进行复检，不合格材料不得使用。

2.油罐制作

2.1制作程序：

封头不在现场制作，委托加工厂制作。

2.3筒节的卷制

2.3.1 卷板机应在设备精度和卷板能力范围内使用。

2.3.2 工量夹具有钢卷尺、钢直角尺、角磨砂轮、圆弧样板、校正用夹具及组对装置等。钢卷尺、钢直角尺、圆弧样板须定期检定。

2.3.3 卷制前准备

2.3.3.1 卷制前操作者应熟悉有关图样、标准和工艺文件。

2.3.3.2卷制前操作者应了解图纸中的有关要求并对钢板进行检查。材质标记应放在外侧。

2.3.3.3筒体钢板的下料长度尺寸可按下列公式确定：L=πDp+δ1+δ2+δ3-δ4

式中：L —筒体钢板的下料长度尺寸，Dp —筒体的平均直径，mm；δ1—气割加工余量，mm；δ2—机械加工余量，mm；δ3—预弯直段余量，mm；δ4—冷卷伸长量，一般2～5mm。注：有预弯直段要求时才考虑及δ1、δ2及δ3。一般当钢板厚度δ≥20mm时，如在卷板机上预弯，每端预弯直段余量不小于2δ；当δ＜20mm时，可不考虑预弯直段余量。本工程筒节钢

板δ=8mm，不考虑预弯直段余量。

2.3.3.4 筒体的下料长度尺寸应与之相配的封头冲压成形后的尺寸相适应，以保证筒体和封头环缝对接的质量。

2.3.3.5 钢板卷制前，应保证钢板的长、宽尺寸偏差和对角线长度之差，且符合图样有关规定，检查合格后方可转入冷卷工序。

2.3.3.6 被卷钢板以气割作为板料最终加工手段时，必须清除气割毛刺及金属飞溅物，钢板表面及边缘必须光洁、平整，对接口（或坡口）端面及两侧不小于20mm范围内必须清除油污、铁绣、氧化皮等。需再机加工时，修磨清理应在机械加工后进行。

2.3.3.7 钢板卷制前开动卷板机进行空车运转检查。各转动部分运转正常，方才进行卷制。

2.4 卷制过程

2.4.1 本工程筒节使用三辊卷板机卷制，在三辊卷板机上卷制时，钢板两端一般应预弯。预弯如在压力机上进行，应采用专用的预弯模具压制，预弯的长度应大于三辊卷板机两个下辊中心距尺寸的二分之一。在预弯长度内，预弯圆弧与检查样板（检查样板曲率半径的公称尺寸宜比图样名义尺寸小

0.5~1mm）。间隙h小于或等于1mm。下图所示。

2.4.2 预弯时应随时用样板检查预弯圆弧，局部有凸起或凹进的地方，可用钢板条作衬垫来校正。

2.4.3对于有预弯直段余量的钢板应在钢板两端预弯后将余量切除。焊接端面及两侧不小于20mm范围内清除油污、铁绣、氧化皮。

2.4.4 被卷制钢板应放在轴辊长度方向的中间位置，并对钢板位置进行校正。