Changling hydrogenation reactor manufacturing, creating three domestic first

On March 17, the refinery reactor of Sinopec Changling Branch with a total weight of 432 tons was manufactured by Shanghai Tianyi Petrochemical Heavy Equipment Manufacturing Co., Ltd. (a mechanical manufacturing company owned by Ningbo Engineering Co., Ltd.) and Shanghai Machinery Manufacturing Plant. The contract is scheduled to be delivered on schedule and shipped to the construction site of the Sinopec Changling Branch's oil quality upgrade and reconstruction project.
The first hydrogenation reactor using domestic plates instead of imported materials is the core equipment of the 2.4 million tonne/year gasoline and diesel hydrogenation unit of the Sinopec Changling branch's oil quality upgrading project. The total length is 22.1 meters and the total weight is 432. Tons, maximum wall thickness 124 mm, design working temperature 410 °C.
"This hydrogenation reactor has created three domestic firsts and its cylinder diameter reaches 4.2 meters. It is currently the largest diameter hydrogenated reactor for plate welding in China." Ningbo Tianyi Shanghai Machinery Manufacturing Factory Song Shaohua introduced.
Due to the working condition of the hydrogenation reactor, it is required to have high strength, good high temperature creep resistance, and resistance to temper embrittlement in the long-term high temperature, high pressure, and hydrogen-prone conditions. Previously, hydrogenation reactors were manufactured. The plates need to be imported.
“With the increase in the level of smelting at domestic iron and steel plants, domestic steel plates can now meet the design conditions and material requirements for hydrogenation reactors. The hydrogenation reactors we manufactured at this time in Changling Branch are made of domestic steel plates.” Xu Yirong, chief engineer of Tianyi Shanghai Machinery Manufacturing Plant, said.
“This hydrogenation reactor is the third reactor we manufacture and process. In 2007, when we first built two hydrogenation reactors for Hebang Chemical, we had organized a technical breakthrough. A simulation loop was conducted to simulate the manufacturing process of the annular seam, longitudinal seam, and pipe-joint reactors, this time on the basis of the successful manufacture of the Hobang chemical reactor, and the overall manufacturing of the hydrogenation reactor of Changling Branch was determined. Xu Rong said that in the manufacturing process, Ningbo Tianyi Shanghai Machinery Manufacturing Factory first started with the “entry clearance” of holding materials. After the main steel plates and forgings arrived at the factory, they checked the size specifications of the plates one by one. The sample of the sheet is extracted for ultrasonic flaw detection and the performance of the sheet is checked to ensure that the internal and external qualities of the sheet meet the relevant criteria and technical conditions of the hydrogenation reactor.
At the same time, based on the technical standards, design drawings, reactor manufacturing and acceptance technical conditions, combined with the actual situation of the material plate and manufacturing equipment, site, etc., they formulated the cylinder typesetting and molding process, and refined the cylindrical body into In 25 processes, the manufacturing of the spherical head was refined into 14 processes, and the manufacturing of the boss was refined to 21 to process. According to the requirements of the welding procedure, the welding procedure was refined into 17 processes.
For the first time, a spherical head was used for the weld head replacement equipment, which was generally formed by pressing a whole sheet of sheet metal. Due to the larger diameter of the cylinder of the hydrogenation reactor of Changling Branch, its upper and lower two spherical heads cannot be pressed and formed with the entire sheet metal, and only three steel plates can be used for the welding. In this way, the head is thermoformed, its strength and performance will be significantly reduced, and it can not meet the requirements.
For this reason, they have specially developed a replacement process for the original patchwork metal. After the welding of the sheets was completed, they made obvious weld position marks on both sides of the patch. After the hot stamping of the spherical heads, they used carbon arc gouging, first planed to open the original weld bead inside the head, and then re-welding, and then used the same method to replace the bead metal of the outer bead of the ball head.
“In order to clean up the original weld metal, we have 3 mm more on each side of the weld.” Xu Weirong said, “At the same time, we implemented the internal and external weld passes in three stages. The lower transition section of the skirt of the equipment is also used for the replacement of the original weld metal to better control the welding distortion caused by re-welding."
Three “warm-up” eliminations of equipment stress Chang Ling’s hydrogenation reactor is difficult to implement due to its “big physique” elimination of its welding stress. In order to guarantee the construction period, they combined the existing heat treatment conditions, and on the basis of pre-heating before welding, they used the method of heating by heating furnace and electric heating, respectively, followed by the hydrogen-removal heat treatment of the weld bead and the intermediate local heat treatment. The final overall furnace heat treatment.
Strict manufacturing process control has also yielded good results. After 100% ray inspection of the device's body weld bead, 910 shots were made, and the qualified rate of welding once reached 97.3%. After the final heat treatment was completed, 100% of the test was conducted again. The results showed that the reactors were in line with the Class I standard in JB/T4730-2005.

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