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The supervision of HAECO steel structure parts is to supervise and inspect the whole process of steel structure parts manufacturing. Its goal is that the manufacturing quality of steel structure parts must meet the quality standards agreed in advance by both parties to ensure the quality of the whole machine.
1 The technical supervision of HAECO's steel structure supervision is based on inspection, and inspection is to compare the manufacturing process and results of the steel structure with the requirements to be achieved, so as to make a judgment of whether it is qualified or not. The requirements to be met by these regulations are the technical basis for manufacturing supervision.
The technical basis for the supervision of HAECO's steel structure parts is roughly as follows: the order contract and the attached technical specifications; the construction drawings that have been reviewed and approved; the plan review minutes and the documents between the supply and demand parties; relevant international and domestic technologies Standards and specifications; relevant process documents of the manufacturer; relevant enterprise standards of the manufacturer.
The manufacture of steel structural parts involves materials, structures, welding, non-destructive testing, painting and other specialties. The technical information is quite rich. The supervisors should try to collect, familiarize and use these materials proficiently in the process of supervision.
2 Principles of Manufacturing Port Machinery Steel Structure Process Route The beams and door legs of large port machinery are usually box-shaped structures, which are the main force-bearing components of the equipment and are relatively complicated to manufacture. This article focuses on the supervision of box beams.
To do a good job of supervision, it is necessary to be familiar with the manufacturing process of steel structure parts in order to track and inspect them. Different manufacturers, due to differences in technical level, design drawings, production facilities, process equipment capabilities, etc., will have different manufacturing processes for steel structures, but the principle of the process is basically the same. The following is the principle process route of box beam manufacturing for a large domestic port machinery manufacturing enterprise: raw materials storage ※ pretreatment of steel plates and steel sections, blanking diaphragms, wing plates, web panels—the assembly of diaphragms and lower wing panels (Two-sided forming) * Assembly of left and right webs and lower wing panels (three-sided forming) * Assembly of upper wing panels (four-sided forming) ※ Pre-assembly of bridge frame ※ Secondary rust removal and surface cleaning coating ※ Assembly of 3 Port Machinery Steel Structure Process supervision 3.1 Raw materials are stored in two materials (equivalent to 16Mn). Among them, Q235 is used for components with less stress and Q345 is used for main components.
The main points of the process inspection are as follows: steel grade, model, specification, executive standard, batch number, and factory material certificate; appearance quality of steel: surface flatness, waveiness, pitting, flaking, interlayer (should meet the relevant steel standards ) Material storage re-inspection report: Although steel suppliers have attached material quality certification documents when supplying steel, HAECO generally carries out material re-inspection when materials are in storage, especially for the risk of fracture Steel plate of the part (FCM component). The purpose of re-inspection is to verify whether each steel plate meets the mechanical performance indicators specified in the material standards. Because the material certificate of the batch number provided by the steel supplier only proves the quality of the batch of steel represented by the batch number.
Each HAECO manufacturing company has its own regulations regarding the re-inspection of raw materials in storage. The supervisors must supervise the manufacturing enterprises to conduct re-inspection according to the re-inspection requirements agreed upon by the supply and demand parties in advance. The unqualified steel plates cannot be used in products. Manufacturing.
3.2 Pretreatment of steel plates and section steels The pretreatment of steel plates and section steels is to level, straighten and apply temporary anti-rust paint (workshop primer) on the surface of steel. The processing line can be used for the integration treatment of leveling, rust removal, and workshop primer coating on steel plates above 6mm (including 6mm). For the section steel, sandblasting and rust removal, and spray shop primer treatment are used.
The main points of the process inspection are as follows: (1) The brand, brand, and production date of the shop primer: The owner generally does not make regulations on the shop primer, but must understand the performance of the shop primer used during supervision, especially whether it can be used with the owner ’s selected The rust primer is integrated, because part of the steel surface coated with the shop primer will be coated with anti-rust primer (such as the inner surface of the box beam).
Quality level and surface roughness achieved by rust removal: These two indicators are generally prescribed by the owner. For the steel plate, since the assembly line is closed, it cannot be detected. In actual inspection, it can be carried out from two aspects: first, according to the certified process parameters of the assembly line, it can be judged by the reading of the instrument installed in the equipment. Second, check the coating quality of the off-line steel plate. For section steel, first check the sandblasting rust removal level and surface roughness, and then check the coating quality.
Dry film thickness of shop primer: The shop primer is only used for temporary rust prevention. Most of it will be removed in the future manufacturing process, but as mentioned before, some will also be retained. The thickness of the shop primer is recorded here, just to prepare for the correct measurement of the thickness of the anti-rust primer in the future.
Transplantation of steel furnace batch number and serial number for re-inspection of storage.
3.3 Lofting and blanking The manufacture of modern steel structural parts uses CNC cutting for a certain number of parts with complex shapes. Even in a few cases where CNC cutting is not used, magnetic guide rails must be used for semi-automatic cutting or compass cutting. Quasi-freehand cutting.
The main points of the process inspection are as follows: for steel plates with a thickness of more than 60mm, 45 steel and rail steel, they must be preheated before cutting; whether the parts comply with the specified materials and specifications; whether the main dimensions of the parts have a specified margin; the cut is flat The roughness of the parts does not exceed 25Mm. Part number, part number, material grade, batch number and re-inspection serial number of the storage.
3.4 Diaphragm, wing plate, web panel wing plate and web plate are larger in size, and are generally formed by splicing several steel plates. In order to increase the strength and rigidity of the members, angle steel reinforcing ribs are longitudinally welded on the inside of the wing and web. If this beam has a flange connecting other beams or door legs, a node hinge plate shall be welded at the near-end portions of the web.
The splicing seams of the wing, web, flange and web are double-sided welding seams, which are made by manual arc welding + automatic submerged arc welding.
The diaphragm has a zigzag shape, although the size is not large, but in order to save materials, it is also spliced ​​from double-sided welding seams. It is also used for manual arc welding and automatic submerged arc welding.
The main points of the process inspection (hereinafter referred to as the process 4 inspection points) are as follows: part drawing number, part number, material grade, and batch number; the size of the transition slope when the thin plate and the thick plate are spliced; Whether the board meets the process requirements; weld size and appearance quality: smooth welds, clear weld lines, no undercuts, no weld lumps, no slag, no porosity, no cracks, high weld reinforcement, high weld angle and welding The throat height meets the standard requirements, and there is no spatter near the weld; the base metal flaw detection report and the weld flaw detection report: the base metal flaw detection is to check the steel interlayer (layered defects), because the interlayer is generally not judged by the naked eye, most cases are in It can only be found when hot cutting is performed. Therefore, for the type and + type joints with a thickness of 13mm or more, when the Z direction has a higher stress, the base material at the joint should be ultrasonically probed.) For the splicing weld of the diaphragm, it is generally 10 % UT, for splicing welds of wings and webs, it is generally 100% UT + 10% RT (ray inspection) qualification of non-destructive testing personnel and the validity period of the verification of related equipment; parts dimensional accuracy, flatness, joint hinge plate center distance: Dimensional accuracy and flatness of the separator shape is an important condition to ensure the box girder, attention should be paid.
The assembling of the diaphragm and the lower wing plate (two-sided forming) The assembling of the diaphragm and the lower wing plate is carried out on the horizontal tire frame (the curved box beam is on the tire frame with arch). The lower wing board horse is fixed on the tire frame, and the transverse partition is assembled on it. The assembly surface of the lower wing is marked with a center reference line, a diaphragm assembly line, and a detection line; a central positioning line is drawn on the diaphragm. During assembly, the center positioning line of the diaphragm and the center reference line of the lower wing plate should be aligned and positioned. The assembly of the diaphragm and the lower wing is the basis for the box beam to be formed on all four sides.
The inspection points of this process are as follows: Tack welding qualification: The assembly of the diaphragm and the lower wing plate is only used for tack welding. All welding will be carried out when the three sides are formed; tack welding must be performed by a qualified welder; tack welding Length and spacing (positioning welds are part of formal welds, and the requirements are the same as those of formal welds); the assembly of left and right webs and lower wing plates (three-sided forming) is based on two-sided forming, and the left and right webs are assembled, that is, three-sided forming . When assembling the webs, the assembly lines on both sides of the lower wing are positioned, and the positioning welding is performed perpendicular to the lower wing (for a box beam with a rectangular cross section).
After positioning, the diaphragm and the lower wing plate, one side web and the lower wing plate, the diaphragm and the two side webs are welded successively, but H / 4 is left at the opening (H is the box beam (Height of cross-section) The position is not welded, but welded properly when forming on three sides.
Welding adopts manual arc welding or C2 protection arc welding. After the three sides are formed, an inspection is required. A comprehensive inspection should be conducted at this stage, especially inside the beam, including surface defects of the steel plate and surface defects of the weld. Because after the fourth surface (upper wing) is installed, the inside is inconvenient to walk, the light is dark, and the defects are not easy to see.
The main points of this process inspection are as follows: dimensional accuracy and flatness of each plate; base metal flaw detection report and weld flaw detection report: carried out according to the flaw detection requirements and evaluation standards stated in the drawings and process documents. The fillet welds of the web and the lower wing are usually Conduct 10% magnetic particle inspection (MT); temporary rust prevention measures for welds.
3.7 Assembling the upper wing panel (four-sided forming) After the three-sided forming is qualified, the upper wing panel can be assembled, that is, forming on four sides. The upper wing plate is positioned with the upper edge of the left and right webs by its own assembly line for positioning welding. If this beam has a flange connecting other beams or door legs, install the flange, align and position the center line of the flange with the center line of the node hinge plate on the left and right webs, and perform position welding. Here the flanges are paired, that is, their own flanges will be connected to the flange on the other beam or leg with high-strength process bolts. This treatment not only strengthens the rigidity of the flange and is not easy to deform during welding, but also ensures the accuracy of the alignment of the beam and the beam or the beam and the leg after assembly.
After the positioning is completed, the diaphragm and the left and right webs (4 positions), the upper wing and the diaphragm, and the upper wing and the left and right webs are welded successively. Welding adopts manual arc welding or C2 protection arc welding.
After the four sides are formed, the in-field production of the structure is basically completed.
Four-sided forming is an important node in the production of steel structural parts. It should be thoroughly and seriously inspected. If it is missed, it will be difficult to handle in the future and often affect the quality of the product.
The main points of the process inspection are as follows: base material flaw detection report and weld flaw detection report: carried out according to the flaw detection requirements and evaluation standards stated in the drawings and process documents. The fillet weld of the upper wing plate and the web is usually 10% MT, and the joint hinge plate The welding seam with the flange is usually 100% UT + 10% RT; the tightening degree of the bolt connection of the paired flange (this item is checked before the welding of the paired flange) the groove size and the carbon on the back of the flange welding place Rooting quality; completion inspection of the component: mainly inspect the integrity and geometry of the component, that is, the flatness of each surface, the straightness (or side bending) of the beam twist, and the bending of the bending beam. If the geometry does not meet the requirements, it is allowed to be corrected by mechanical pressure or flame heating (sometimes supplemented by external forces), but any correction process is not allowed to cause the steel plate to sag or reduce its mechanical properties due to thermal effects.
3.8 Pre-assembly of the bridge frame The box beams participating in the pre-assembly of the bridge frame must be inspected and qualified. The pre-assembly of the bridge is the positioning assembly before the final assembly of the whole machine, and some components need to be pre-assembled multiple times. After assembly, the components will be disassembled, and then transferred to sandblasting, painting, electrical installation in the beam and other processes.
The pre-assembly of the bridge is the assembly of beams and beams or beams and legs. During the pre-assembly of the bridge, the assembly center line of each beam is used as the positioning line, and the laser instrument is used to align it. It needs to be repeated many times to obtain accurate assembly. After assembling and positioning, weld the end of the beam or leg to the flange.
The flange and beam (or leg) are welded by manual arc welding.
The inspection points of this process are as follows: the reference center line of the beam and beam or beam and leg to be assembled should be on the same horizontal line, and the cross section of each beam and leg is vertical; the beam (or leg) and the flange assembly line should be aligned Quasi, check the center distance between 2 beams or 2 legs at the same time; the tightening of the pair of flange process bolts; the welding place between the beam (or leg) and the flange is cut to reserve a margin, the cut is smooth, and the slope The size of the mouth is correct, and the roots are cleaned by carbon planing on the reverse side. Weld flaw detection report: carried out according to the flaw detection requirements and evaluation standards stated in the drawings and process documents. The welding seam of the beam (or leg) and flange is usually 100% UT + 10% MT; Before disassembly, mark the alignment on the pair of flanges.
3.9 After the second removal of the pound and the surface cleaning of the pre-treated steel component, there is always a part of the workshop primer on the surface of the steel that is damaged due to cutting, processing, welding, assembly, handling or natural reasons, causing the steel surface to corrode again. Before these components are officially painted, a surface treatment is required, which is called secondary descaling in the HAECO coating project.
Secondary rust removal usually uses sandblasting or power tool polishing. The former has high processing efficiency and good effect. For the box-shaped beam, the outer surface is sandblasted, and the inner surface is not easy to be sandblasted due to the small space, so it can only be polished by power tools.
The purpose of surface cleaning of structural parts is to improve the cleanliness of the coated surface of the structural parts. Its main work content is to remove water, dust, salt, grease and other debris and dirt.
Surface cleaning usually uses cloth wiping, water rinse, solvent (a small amount) light wiping and high-pressure air blowing. On the already painted surface, before recoating, it is necessary to polish the original coating with fine sandpaper to properly improve the roughness of the original coating and strengthen the adhesion between the coatings.
The main points of the inspection of the process are as follows: the integrity of the components: the structural parts entering the derusting paint stage should have the maximum integrity, except for the parts that need to be positioned and welded during installation, they should be assembled and welded to reduce the future welding on the coating Damage; environmental conditions, including lighting and illuminance, temperature and humidity, cleanliness of air, good ventilation, etc .; after rust removal, anti-rust primer should be applied as soon as possible (generally no more than 4h); rust removal of power tools 2, namely St2, St3; one flame descaling, namely F1. The derusting of steel structure parts of Port Machinery is commonly used in Sa2.5 and St3. The specific requirements should meet the agreement between the supply and demand parties.
The evaluation method of the rust removal quality grade is to compare the surface of the steel to be evaluated with the color photographs of the rust removal grade attached to the standard.
Surface roughness: Various anti-rust primers have different requirements on the roughness of the surface to be coated, which is specified in the coating specification; the surface roughness can be measured with a magnetic thickness meter or a portable roughness meter, or with a roughness standard Compare the sample blocks; the structural parts that have been derusted and cleaned should be primed as soon as possible, because the environmental conditions on the site will often re-contaminate or rust the structural parts.
The application of large-scale port machinery steel structure parts generally requires 1 primer, 1 intermediate paint and 2 topcoats. Usually only 1 primer, 1 intermediate paint and 1 topcoat are applied to the structural parts, the second The top coat is left at the final assembly of the equipment. For the inner surface of the sealed box beam, there is only one primer. How many paints are applied to each part of the steel structure, what is the thickness of the paint film, and what brand, what brand, color, origin, coating method, etc. are used for each paint, the owner has the regulations when ordering, monitoring The manufacturing personnel must carry out inspection and check according to the requirements of the owner.
Paint brand, brand, color, origin, production date; dew point management: In order to ensure that the coated surface is dry, it is usually specified that the temperature of the coated surface must be 3 * C higher than the air dew point (environmental dew point can be checked with a dew point slide rule and calculation table ); Coating formulation, dilution, mixing and curing (according to the coating instructions); the integrity of the coating equipment and tools: the large-scale port machinery is generally applied by airless spray, and roller coating is only used in places where the components are not easy to spray. And brushing; coating appearance quality: the surface quality of the coating requires the color to be consistent with the regulations, and the color is uniform, no shades, no spray particles, no missing coating, sagging, brush marks, pinholes, wrinkles, Cracks and other defects; dry film thickness of the coating: the thickness of the coating should be uniform, usually controlled at more than two 90%, that is, the film thickness measured at more than 90% of the measurement points must reach the specified value, and must not exceed the specified value of 120 % The film thickness measured at the remaining less than 10% of the measuring points must not be less than 90% of the specified value; the coating thickness can be directly measured on the coating with a paint film thickness meter; coating performance testing: many coating performance indicators , Conventional Test items include coating film adhesion, coating film hardness, coating film flexibility, coating film impact resistance, coating film water resistance, coating film glossiness, coating film stickiness, coating film weather resistance, coating film wear resistance, coating Membrane aging, etc. These properties should pass the product appraisal and finalization in the paint manufacturing plant, and should meet the standards, but the quality of the paint used for the owner's products and their construction can be subject to random inspections of certain items depending on the situation.
Coating interval: The coating has its specified two paint overcoating intervals. If it is not as specified, it will affect the quality of the coating.
Flange surface of high-strength bolt connection: Because high-strength bolt connection is transmitted by friction of the contact surface of the flange, the greater the friction coefficient of the contact surface, the better. Therefore, the flange surface of high-strength bolt connection is the best Sandblasted state, or apply a rust-preventive primer (thickness about 30, um) to seal the airtightness of the box beam (this test is usually carried out when the steel structure is formed).
4Working methods for the supervision and manufacturing of steel structure parts of HAECO The supervision and manufacture of steel structure parts of HAECO is a work involving many professions, arduous and meticulous work. To be competent and do this work, you should pay attention to the following points: Engineering and technical personnel with professional basic theoretical knowledge, richer practical experience, strong sense of responsibility, and certain organizational and coordination capabilities are responsible for manufacturing supervision.
The staffing should be able to cover all kinds of majors involved in the steel structure. In order to streamline the supervision and production team, the supervision and supervision staff should be multi-functional and professional.
Before factory supervision, make full technical preparations, including collecting data; familiar with the equipment order contract and technical specifications; familiar with the relevant drawings and documents at the drawing review stage; familiar with the equipment, especially the standards used for the selection of steel structural parts 3. Norms; if possible, it is best to consult the supervisors who have supervised the manufacture of similar products before paying attention to supervisory precautions.
After staying in the factory, you should be familiar with the working environment as soon as possible, understand the factory's production organization, technical management, quality assurance system, quality inspection, etc., and be aware of it.
After staying in the factory, the construction drawings, process documents, production plans and other relevant materials should be collected as soon as possible, and the relevant items of the manufacturer and the content and format of the quality inspection report should be agreed with the relevant departments of the manufacturer.
Manufacturing supervisors should closely work with the project supervisors of the design, process, production, quality inspection and other departments of the manufacturer, and communicate and exchange frequently to improve work efficiency.
It is necessary to pay attention to the role of the three-level inspection system of the manufacturer's self-inspection, mutual inspection, and special inspection, and supervise and remind the three-level inspection system to implement it.
Supervisors should promote diligent, strict, detailed and practical work styles. Not only must they adhere to the inspection projects, the side stations of important quality control points and actual measurement inspections, but they must also often go deep into the construction site for inspections.
Practice has proved that quality problems are often found inadvertently.
For important quality issues, it should be promptly written to the manufacturer in the form of a memorandum, and require rectification within a time limit.
After the supervision is over, various materials in the supervision work should be sorted in time, including the supervision work log, inspection records, memoranda, business contact list with the manufacturer, etc., and transferred to the archive.
Zhou Jinde: 315040 Beilun, Ningbo City, Zhejiang Province, Ningbo Port Authority Beilun Second Port Company 8 instrument standards and verification procedures passed the expert review of the Ministry of Transport. This newsletter was published by the Institute of Water Transport Science of the Ministry of Transport, Nanjing Institute of Water Resources, Tianjin Water Transport Ministry of Transport The sub-project of the Ministry of Communications' Science and Technology Project on the Development of Highway Water Transportation Engineering and the Development of Metrological Verification Regulations jointly undertaken by the Engineering Science Research Institute was approved by the Ministry of Communications experts on November 13, 2003 Will be reviewed. The People's Republic of China Transportation Industry Standard "Port Machinery Load Sensor Secondary Meter" "Port Machinery Digital Lifting Moment Limiter", Ministry of Communications of the People's Republic of China Metrology Verification Regulations "Port Machinery Load Sensor Secondary Meter" "Port Machinery Digital The results of eight instrument standards and verification procedures, such as Lifting Moment Limiter, have been evaluated as reaching international and domestic advanced levels, respectively.
Three Gorges University is one of the cooperative units invited to participate. The units in charge of the standards issued by the Ministry and the verification procedures issued by the Ministry are the Science and Technology Education Department of the Ministry of Communications and the Technical Committee of Metrology of the Transportation Industry. The drafting units are the Institute of Water Transportation Science of the Ministry of Communications and the Three Gorges University.
Relevant leaders from the Department of Science, Technology and Education of the Ministry of Transport and the Water Transport Department of the Ministry of Transport, as well as experts from national research institutes of transportation and water transportation industry and port machinery manufacturers attended the expert review meeting.
(Wang Shanqiao)
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