Manufacturing method of radiation waste boiler for recovering waste heat of coal gasification synthesis gas

Abstract

The present application provides a method for manufacturing a radiation waste boiler for recovering waste heat from coal gasification synthesis gas. The manufacturing method includes the following steps: manufacturing of a water-cooling jacket assembly; manufacturing of a water-cooling screen assembly; manufacturing of auxiliary components; and overall assembly. The method mainly focuses on the two important main components of the radiation waste boiler, the water-cooling jacket and the water-cooling screen. Each of them is first disassembled and manufactured, and then the workbench uses tooling to position, assemble, and connect the two major components as a main line, and interspersed with the installation of accessories to complete the manufacture of the main body of the equipment. During the assembly process, the alternating coordination of the positioning and supporting tooling in the upper and lower half circles is used to reasonably arrange the assembly sequence of the upper and lower parts of the water-cooling screen and the water-cooling jacket. The present application specifically proposes a special process solution to solve the difficulties, and manufactures experience data based on actual conditions, which has important reference value for on-site assembly and welding of similar equipment.

Description

Technical Field

[0001] The present application generally relates to the technical field of radiation waste boiler manufacturing, and more specifically to a method for manufacturing a radiation waste boiler for recovering waste heat from coal gasification synthesis gas. Background Art

[0002] The radiation waste boiler is installed in the water-coal slurry water-cooled wall gasifier through ear connection, absorbing the heat in the synthesis gas coming down from the gasifier combustion chamber to generate high-temperature and high-pressure saturated steam, with high energy utilization; at the same time, since the temperature of the raw synthesis gas entering the quenching chamber is low, the amount of quenching water and ash water circulation is reduced, which is energy-saving and environmentally friendly.

[0003] Radiation waste boilers are characterized by numerous connecting pipes, complex winding arrangements, limited assembly space, long lengths, and easily deformed pipes. Manufacturing of these devices requires numerous technical details and high assembly precision. Therefore, to effectively ensure the required precision after fabrication and provide a high-quality product for subsequent installation, an optimized and rational manufacturing method is required. This method provides a more scientific process layout and facilitates process control. This method provides valuable guidance for quality assurance in the production, assembly, and overall assembly of these devices. Summary of the Invention

[0004] This application aims to meet the high manufacturing precision requirements of radiation waste boilers and provides a method for manufacturing a radiation waste boiler for recovering waste heat from coal gasification synthesis gas. The method includes the following steps:

[0005] Manufacturing of water cooling jacket assemblies;

[0006] Manufacturing of water cooling panel components;

[0007] Manufacturing of auxiliary components; and

[0008] Overall assembly;

[0009] The water-cooling jacket assembly includes a water-cooling jacket straight tube panel, an upper annular header, a lower annular header and a water-cooling jacket special-shaped convection tube; the water-cooling screen assembly includes a water-cooling screen straight tube panel and a water-cooling screen horizontal collecting header; the auxiliary components include a water-cooling screen lower convection elbow, a water-cooling screen lower vertical header, a water-cooling screen upper connecting pipe, a radiation waste boiler water inlet pipe, a radiation waste boiler water outlet pipe, a radiation waste boiler sewage pipe, an external reinforcement ring and a radiation waste boiler mounting ear seat; the tooling used in the overall assembly includes a stand workbench, an end positioning tooling, an internal positioning support tooling, an external support tooling and a tooling for an upper turntable.

[0010] Optionally, the steps of manufacturing the water cooling jacket assembly specifically include:

[0011] a. Manufacturing of water cooling jacket straight tube screen:

[0012] ①. Comprehensively consider the welding shrinkage reserve and processing allowance to determine the pipe cutting length, and use the pipe beveling machine to process the bevel at one end of the pipe, and clean and blow clean the inside and outside of the pipe;

[0013] ②Use the automatic tube panel welding system to assemble and weld the tubes and fins into a four-tube five-flat steel tube panel. Align the other end of the tubes according to the length shown in the drawing, clean them, and seal them with tube caps for protection.

[0014] b. Manufacturing of the upper annular header and the lower annular header of the water cooling jacket:

[0015] ①. Considering the forming allowance and processing allowance, determine the blanking length, and form the header into two pieces;

[0016] ②. Lay out on the platform, calculate the theoretical arc length of the header half ring pipe and add the process allowance to mark the cutting line, cut along the cutting line using gas cutting method, and clean the cutting slag;

[0017] ③. Process the end face groove of the half-ring tube on the boring and milling machine, remove the burrs, assemble the two half-ring tubes into an integral header on the platform, and weld the interface according to the welding process;

[0018] ④. Draw the cross azimuth reference lines of 0°, 90°, 180°, and 270° on the platform. Draw the assembly position lines of the convection pipe, radiation waste boiler water inlet pipe, radiation waste boiler water outlet pipe, radiation waste boiler sewage pipe, and the connecting pipe on the water cooling panel according to the reference lines, and make proofs and marks.

[0019] ⑤. Use drilling machines and boring and milling machines to process each pipe hole. After processing, clean and blow the inside of the header, and seal the pipe holes;

[0020] c. Manufacturing of special-shaped convection tubes of water cooling jackets:

[0021] ①. Consider the forming process allowance and assembly allowance to determine the blanking length, and use the bending tool to cold bend the pipe;

[0022] ② Use a grinding machine to cut the allowance and grind the pipe end bevel, clean the burrs, and seal the pipe cap;

[0023] The manufacturing steps of the water cooling screen assembly specifically include:

[0024] a. Manufacturing of water-cooled straight tube screen:

[0025] ①. Comprehensively consider the welding shrinkage reserve and processing allowance to determine the pipe cutting length, clean and blow clean the inside and outside of the pipe;

[0026] ②Use the automatic tube panel assembly and welding system to assemble and weld the tubes and fins into an eight-tube, seven-flat steel tube panel, clean it, and seal it with tube caps for protection;

[0027] b. Manufacturing of horizontal collection box of water-cooled panel:

[0028] ① Leave some end surface machining allowance for cutting;

[0029] ②. Process the flat end surface and the bevel at both ends on a lathe;

[0030] ③. Use a drilling machine and a wire cutting machine to process the convection pipe holes and the connecting pipe holes on the water cooling screen respectively, clean and blow clean the inside and outside, and perform sealing protection;

[0031] c. Assembly of water cooling screen components:

[0032] ① Assemble and weld the horizontal header of the water-cooling panel to one end of the straight tube panel of the water-cooling panel;

[0033] ②. Process the bevel at the other end of the water-cooling panel straight tube panel, clean it and blow it clean, and seal it with a pipe cap for protection;

[0034] The steps of manufacturing auxiliary components specifically include:

[0035] a. Manufacturing of the convection elbow at the bottom of the water-cooling panel and the radiation waste boiler drain pipe:

[0036] ①. Consider the forming process allowance and assembly allowance to determine the blanking length, and use the bending tool to cold bend the pipe;

[0037] ② Use a grinding wheel to cut the allowance and grind the pipe end bevel, clean the burrs, and use a pipe cap for sealing protection;

[0038] b. Manufacturing of the vertical header at the bottom of the water-cooling panel:

[0039] ①. Consider the forming process allowance, machining allowance and assembly allowance to determine the blanking length;

[0040] ②. Process the groove on one end on a lathe and remove burrs;

[0041] ③. Use medium frequency pipe bending machine to simmer and shape;

[0042] ④. Process the convection pipe holes on the drilling machine, clean and blow clean the inside and outside, and perform sealing protection;

[0043] c. Manufacturing of connecting pipes on water cooling screen:

[0044] ①. Consider the machining allowance and assembly allowance to determine the cutting length;

[0045] ② Use a wire cutting machine to process one end into a 45° V-shaped groove, grind the groove, and clean it;

[0046] d. Manufacturing of radiation waste boiler water inlet pipe and radiation waste boiler water outlet pipe:

[0047] ①. Consider the forming process allowance and assembly allowance to determine the blanking length;

[0048] ②, Use medium frequency pipe bending machine to simmer and shape;

[0049] The overall assembly steps specifically include:

[0050] ①, Stand: Place the annular header under the water cooling jacket, the lower half of the outer support fixture, and the end positioning fixture on the stand workbench in sequence, align and center them, and fix them with channel steel after passing the inspection;

[0051] ②Assemble the lower half of the water-cooling jacket straight tube panel: Start assembling the lower half of the water-cooling jacket straight tube panel from the 6 o'clock position until it reaches the 3 o'clock and 9 o'clock positions respectively. When assembling, adjust the tube panel gap appropriately to ensure the overall assembly requirements. After passing the requirements, fix them by spot welding.

[0052] ③. Assemble the lower half of the inner positioning support fixture: The tube panel groove on the inner positioning support fixture falls vertically on the center of the tube of the water-cooling jacket straight tube panel. The fixture is centered and aligned, and the inner positioning support fixture is firmly spot-welded to the fins of the water-cooling jacket straight tube panel using flat steel bars. The upper half and part of the lower half of the inner positioning support fixture are marked and cut off, leaving half of the tube panel groove open upward to position the water-cooling panel assembly for subsequent assembly.

[0053] ④. Assemble the lower half of the water-cooling panel assembly: Starting from the 6 o'clock position, assemble the water-cooling panel assembly according to the tube panel slot position on the lower half of the inner positioning support tooling until reaching the 3 o'clock and 9 o'clock positions respectively. Use wooden supports to reinforce the space between the two water-cooling panel assemblies.

[0054] ⑤. Install and weld the upper half circle of the inner positioning support tooling: restore the upper half circle of the inner positioning support tooling to a full circle of the inner positioning support tooling according to the marked serial number;

[0055] ⑥. Assemble the upper half of the water-cooling panel assembly and the upper half of the water-cooling jacket straight tube panel: assemble the upper half of the water-cooling panel assembly and the upper half of the water-cooling jacket straight tube panel from the 3 o'clock and 9 o'clock positions respectively, until the 12 o'clock position. After passing the test, fix them by spot welding according to the welding process requirements;

[0056] ⑦. The entire circle of water-cooling casing straight tube panel ends are smoothed and beveled;

[0057] ⑧. Assemble the upper annular header of the water cooling jacket: align and assemble the lower annular header of the water cooling jacket and the end positioning tooling according to the dimensions of the design drawing, and then fix it;

[0058] ⑨. Install and weld the upper connecting pipe of the water-cooling panel: The upper connecting pipe of the water-cooling panel is used to connect the horizontal collecting box of the water-cooling panel in the water-cooling panel assembly and the upper annular box of the water-cooling jacket in the water-cooling jacket assembly. It is cut according to the actual length, remove the installation allowance, and grind the groove for matching;

[0059] ⑩. Assemble the special-shaped convection tube of the water cooling jacket: measure the actual length between the annular header and the straight tube screen of the water cooling jacket, and make and weld the special-shaped convection tube of the water cooling jacket;

[0060] Unloading and loading onto the turntable: Unloading and loading each component from the vertical workbench, moving it onto the turntable using the upper turntable tooling, and welding them to the outside of the external reinforcement ring;

[0061] Reinstalling fins: Install and weld fins between each group of special-shaped convection tubes of the water-cooling jacket, between each group of straight tube panels of the water-cooling jacket, between the straight tube panels of the water-cooling jacket and the lower annular header of the water-cooling jacket, and between the water-cooling panel assemblies and the water-cooling jacket assemblies on the turntable;

[0062] Install and weld the lower vertical header of the water-cooling panel and arrange the pipes: The lower vertical header of the water-cooling panel is installed and welded to the outside of the annular header under the water-cooling jacket, and passes through the pipe-allowing position of the straight tube panel of the water-cooling jacket to install and weld the lower convection elbow of the water-cooling panel between the lower vertical header of the water-cooling panel and the straight tube panel of the water-cooling panel. The installation and welding of the lower convection elbow of the water-cooling panel is carried out on site in the order of actual measurement, arrangement and welding;

[0063] Install and weld the radiation waste boiler water inlet pipe and radiation waste boiler water outlet pipe: install and weld the radiation waste boiler water outlet pipe joint on the water cooling jacket annular header, and install and weld the radiation waste boiler water inlet pipe elbow and water inlet connecting pipe on the water cooling jacket lower annular header; clean the inside of the pipe, and install and weld the radiation waste boiler water inlet pipe and radiation waste boiler water outlet pipe pressure test blind cover;

[0064] Welding pins: Welding pins are installed on the upper conical section inside the water cooling jacket assembly;

[0065] Overall heat treatment: After passing the inspection and non-destructive testing, the overall stress relief heat treatment is carried out in a gas furnace;

[0066] Welding the radiation waste pot mounting lugs made of austenitic stainless steel and the thermocouple base made of nickel-based material;

[0067] Hydrostatic test of the inner cavity of the radiation waste boiler;

[0068] Water pressure test inside the tube of the radioactive waste boiler;

[0069] Anti-corrosion treatment and nitrogen filling protection: The inner cavity of the radiation waste boiler is sprayed with high-temperature resistant anti-corrosion paint, and the outer surface is sprayed with silicone heat-resistant primer; 0.05MPa nitrogen is filled in the pipe for anti-corrosion protection.

[0070] Optionally, the water-cooling jacket assembly and the water-cooling screen assembly are made of 12Cr1MoV material. The 12Cr1MoV materials are preheated to 150°C to 200°C before welding, and the preheating range is not less than 100mm on both sides of the groove. Dehydrogenation treatment is performed immediately after welding: heating to 350°C and keeping warm for 2 hours.

[0071] Optionally, the butt-welded joints of the pipes shall be subjected to 100% RT testing 24 hours after welding and shall be qualified according to Level II in NB / T47013.2-2015; all butt joints, Class D joints, elbows and 100mm straight pipe sections on both sides shall be subjected to 100% PT testing and shall be qualified according to Level I in NB / T47013.5-2015; the fillet welds between the pipes and fins shall be subjected to 100% PT testing and shall be qualified according to Level I in NB / T47013.5-2015.

[0072] Optionally, the water-cooling jacket special-shaped convection tubes connected between the water-cooling jacket upper annular header and the water-cooling jacket straight tube panel, the water-cooling panel upper connecting pipes connected between the water-cooling panel horizontal collecting header and the water-cooling jacket upper annular header, and the water-cooling panel lower convection elbows between the water-cooling panel lower vertical header and the water-cooling panel straight tube panel are all made according to the actual measured dimensions with assembly process allowances reserved according to assembly requirements.

[0073] Optionally, after the water-cooling jacket straight tube panel and water-cooling panel straight tube panel are manufactured, the center distance tolerance of adjacent tubes is ±0.5mm; the center line tolerance of the fin and the center line of the tube is ≤1.5mm; the lateral bending tolerance of the water-cooling jacket straight tube panel is ≤4mm; the bidirectional lateral bending tolerance is ≤5mm, and the unidirectional lateral bending tolerance is ≤3mm.

[0074] Optionally, the roundness tolerance of the annular tube of the water-cooling jacket upper annular header and the water-cooling jacket lower annular header after forming is ≤5mm; the flatness tolerance of the entire annular tube is ≤3mm; and the roundness tolerance of the tube after forming is ≤2mm.

[0075] Optionally, after assembly is completed, the tolerance of the total length of the radiation waste pot is 0 to 6 mm; the tolerance of the coaxiality of the upper annular header of the water cooling jacket and the lower annular header of the water cooling jacket is ≤4 mm; the tolerance of the parallelism of the upper annular header of the water cooling jacket and the lower annular header of the water cooling jacket is ≤3 mm.

[0076] Optionally, the steps in the overall assembly Specifically including: assembling the inner cavity water pressure test tooling, and conducting a water pressure test on the inner cavity at a pressure of 0.5MPa.

[0077] Optionally, the steps in the overall assembly Specifically include: installing a pressure test blind plate, conducting a water pressure test in the pipe, the water temperature must not be lower than 15°C, and after filling with water, when the equipment wall temperature is close to the water temperature, slowly increase the pressure to the design pressure of 7.7MPa, and after confirming that there is no leakage, continue to increase the pressure to the test pressure of 10.5MPa, and maintain the pressure for not less than 30min; then reduce the pressure to 7.7MPa, maintain the pressure for a sufficient time for inspection, and pass the test if there is no leakage, no visible deformation, and no abnormal sound; after the test is completed, remove water stains and blow dry with compressed air.

[0078] Compared with the prior art, the present application has the following beneficial effects: in the manufacturing method of the radiation waste boiler for recovering waste heat from coal gasification synthesis gas provided in the present application, the main processes include the manufacturing of the water-cooling jacket assembly; the manufacturing of the water-cooling screen assembly; the manufacturing of auxiliary components; and the overall assembly. The method mainly focuses on the two important main components of the radiation waste boiler, the water-cooling jacket and the water-cooling screen. Each of them is first disassembled and manufactured. Then, the workbench uses the tooling to position, assemble, and connect the two major components as a main line, and the accessories are installed interspersed to complete the manufacturing of the main body of the equipment. During the assembly process, the alternating coordination of the positioning and supporting tooling in the upper and lower half circles is used to reasonably arrange the assembly sequence of the upper and lower parts of the water-cooling screen and the water-cooling jacket. The present manufacturing method fully analyzes the difficulties in equipment manufacturing, proposes special process solutions to solve the difficulties in a targeted manner, and manufactures experience data based on actual conditions. It has important reference value for the manufacture of similar equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] Figure 1 is a schematic structural diagram of a radiation waste cooker provided according to an exemplary embodiment of the present application;

[0080] Figure 2 Schematic diagram of the structure of the drilling tool used in step ③ of manufacturing the horizontal header of the water-cooled panel provided in accordance with an exemplary embodiment of the present application;

[0081] Figure 3 This is a schematic structural diagram of the end positioning tool used in the stand in step ① of the overall assembly steps provided in accordance with an exemplary embodiment of the present application;

[0082] Figure 4 is a structural schematic diagram of the internal positioning support tooling used for positioning the water-cooled screen assembly in steps ③ and ⑤ of the overall assembly according to the exemplary embodiment of the present application; and

[0083] Figure 5 It is a structural schematic diagram of the external support tooling used in the stand in step ① of the overall assembly steps provided in the exemplary embodiment of the present application.

[0084] In the figure: 1 is the water cooling jacket assembly, 2 is the water cooling screen assembly, 3 is the positioning plate, 4 is the water cooling screen horizontal collection box, 5 is the top plate, 6 is the bottom plate, 7 is the support plate, 8 is the vertical plate, 9 is the baffle, 10 is the pull rod, and 11 is the nut. DETAILED DESCRIPTION

[0085] The present application provides a method for manufacturing a radiation waste boiler for recovering waste heat from coal gasification synthesis gas. The method includes the following steps: manufacturing of a water-cooling jacket assembly; manufacturing of a water-cooling screen assembly; manufacturing of auxiliary components; and overall assembly; wherein the water-cooling jacket assembly includes a water-cooling jacket straight tube screen, an upper annular header for a water-cooling jacket, a lower annular header for a water-cooling jacket, and a water-cooling jacket special-shaped convection tube; the water-cooling screen assembly includes a water-cooling screen straight tube screen and a water-cooling screen horizontal collecting header; the auxiliary components include a water-cooling screen lower convection bend, a water-cooling screen lower vertical header, a water-cooling screen upper connecting pipe, a radiation waste boiler water inlet pipe, a radiation waste boiler water outlet pipe, a radiation waste boiler sewage pipe, an external reinforcement ring, and a radiation waste boiler mounting ear seat; the tooling used in the overall assembly step includes a stand workbench, an end positioning tooling, an internal positioning support tooling, an external support tooling, and a tooling for an upper turntable. Reference Figure 1 The figure is a schematic diagram of the structure of a radiation waste boiler provided according to an exemplary embodiment of the present application. The radiation waste boiler is installed in a water-coal slurry water-cooled wall gasifier through an ear seat connection, and absorbs heat from the synthesis gas coming down from the gasifier combustion chamber to generate high-temperature and high-pressure saturated steam. The main components of the radiation waste boiler are a water-cooling jacket assembly 1 and a water-cooling screen assembly 2.

[0086] In a preferred embodiment of the present application, the steps of manufacturing the water cooling jacket assembly specifically include:

[0087] a. Manufacturing of water cooling jacket straight tube screen (multiple groups):

[0088] ①. Comprehensively consider the welding shrinkage reserve and processing allowance to determine the pipe cutting length, and use the pipe beveling machine to process the bevel at one end of the pipe, and clean and blow clean the inside and outside of the pipe;

[0089] ②Use the automatic tube panel welding system to assemble and weld the tubes and fins into a four-tube five-flat steel tube panel. Align the other end of the tubes according to the length shown in the drawing, clean them, and seal them with tube caps for protection.

[0090] b. Manufacturing of the upper annular header and the lower annular header of the water cooling jacket:

[0091] ①. Considering the forming allowance and processing allowance, determine the blanking length, and form the header into two pieces;

[0092] ②. Lay out on the platform, calculate the theoretical arc length of the header half ring pipe and add the process allowance to mark the cutting line, cut along the cutting line using gas cutting method, and clean the cutting slag;

[0093] ③. Process the end face groove of the half-ring tube on the boring and milling machine, remove the burrs, assemble the two half-ring tubes into an integral header on the platform, and weld the interface according to the welding process;

[0094] ④. Draw the cross azimuth reference lines of 0°, 90°, 180°, and 270° on the platform. Draw the assembly position lines of the convection pipe, radiation waste boiler water inlet pipe, radiation waste boiler water outlet pipe, radiation waste boiler sewage pipe, and the connecting pipe on the water cooling panel according to the reference lines, and make proofs and marks.

[0095] ⑤. Use drilling machines and boring and milling machines to process each pipe hole. After processing, clean and blow the inside of the header, and seal the pipe holes;

[0096] c. Manufacturing of special-shaped convection tubes (multiple groups) of water cooling jackets:

[0097] ①. Consider the forming process allowance and assembly allowance to determine the blanking length, and use the bending tool to cold bend the pipe;

[0098] ② Use a grinding machine to cut the allowance and grind the pipe end bevel, clean the burrs, and seal the pipe cap;

[0099] The manufacturing steps of the water cooling screen assembly specifically include:

[0100] a. Manufacturing of water-cooled straight tube panels (multiple groups):

[0101] ①. Comprehensively consider the welding shrinkage reserve and processing allowance to determine the pipe cutting length, clean and blow clean the inside and outside of the pipe;

[0102] ②Use the automatic tube panel assembly and welding system to assemble and weld the tubes and fins into an eight-tube, seven-flat steel tube panel, clean it, and seal it with tube caps for protection;

[0103] b. Manufacturing of horizontal headers for water-cooled panels (multiple groups, the same number as the number of straight tube panels for water-cooled panels):

[0104] ① Leave some end surface machining allowance for cutting;

[0105] ②. Process the flat end surface and the bevel at both ends on a lathe;

[0106] ③. Use drilling machine and wire cutting machine to process convection pipe holes and connecting pipe holes on water cooling screen respectively, clean and blow clean inside and outside, and perform sealing protection; Figure 2 , Figure 2 is a schematic diagram of the structure of an exemplary drilling tool used in this step; Figure 2 As shown, the drilling tool includes a positioning plate 3, a top plate 5, a bottom plate 6, a support plate 7, a vertical plate 8, a baffle 9, a pull rod 10 and a nut 11.

[0107] c. Assembly of water cooling screen components:

[0108] ① Assemble and weld the horizontal header of the water-cooling panel to one end of the straight tube panel of the water-cooling panel;

[0109] ②. Process the bevel at the other end of the water-cooling panel straight tube panel, clean it and blow it clean, and seal it with a pipe cap for protection;

[0110] The steps of manufacturing auxiliary components specifically include:

[0111] a. Manufacturing of convection elbows (multiple pieces) at the bottom of the water-cooling panel and waste water pipes for radiation waste boilers:

[0112] ①. Consider the forming process allowance and assembly allowance to determine the blanking length, and use the bending tool to cold bend the pipe;

[0113] ② Use a grinding wheel to cut the allowance and grind the pipe end bevel, clean the burrs, and use a pipe cap for sealing protection;

[0114] b. Manufacturing of vertical headers at the bottom of the water-cooling panel (multiple groups, the same number as the straight tube panels of the water-cooling panel):

[0115] ①. Consider the forming process allowance, machining allowance and assembly allowance to determine the blanking length;

[0116] ②. Process the groove on one end on a lathe and remove burrs;

[0117] ③. Use medium frequency pipe bending machine to simmer and shape;

[0118] ④. Process the convection pipe holes on the drilling machine, clean and blow clean the inside and outside, and perform sealing protection;

[0119] c. Manufacturing of connecting pipes on the water-cooling panel (multiple groups, the same number as the straight tube panels of the water-cooling panel):

[0120] ①. Consider the machining allowance and assembly allowance to determine the cutting length;

[0121] ② Use a wire cutting machine to process one end into a 45° V-shaped groove, grind the groove, and clean it;

[0122] d. Manufacturing of radiation waste boiler water inlet pipes (multiple sets) and radiation waste boiler water outlet pipes (multiple sets):

[0123] ①. Consider the forming process allowance and assembly allowance to determine the blanking length;

[0124] ②, Use medium frequency pipe bending machine to simmer and shape;

[0125] The overall assembly steps specifically include:

[0126] ①, Stand: Place the annular header under the water cooling jacket, the lower half of the outer support fixture, and the end positioning fixture on the stand workbench in sequence, align and position them, and fix them with channel steel after inspection. Figure 3 and Figure 5 , Figure 3 is a schematic structural diagram of an exemplary end positioning tool, Figure 5 is a schematic structural diagram of an exemplary external support tooling;

[0127] ②Assemble the lower half of the water-cooling jacket straight tube panel: Start assembling the lower half of the water-cooling jacket straight tube panel from the 6 o'clock position until it reaches the 3 o'clock and 9 o'clock positions respectively. When assembling, adjust the tube panel gap appropriately to ensure the overall assembly requirements. After passing the requirements, fix them by spot welding.

[0128] ③. Assemble the lower half of the inner positioning support tooling: The tube panel groove on the inner positioning support tooling falls vertically on the center of the tube of the water-cooling jacket straight tube panel. The tooling is centered and aligned, and the inner positioning support tooling is firmly spot-welded to the fins of the water-cooling jacket straight tube panel using flat steel bars. The upper half of the inner positioning support tooling and part of the lower half are marked and cut off, leaving half of the tube panel groove open upwards to position the water-cooling panel assembly for subsequent assembly. Figure 4 , Figure 4 is a schematic structural diagram of an exemplary internal positioning support tooling;

[0129] ④. Assemble the lower half of the water-cooling panel assembly: Starting from the 6 o'clock position, assemble the water-cooling panel assembly according to the tube panel slot position on the lower half of the inner positioning support tooling until reaching the 3 o'clock and 9 o'clock positions respectively. Use wooden supports to reinforce the space between the two water-cooling panel assemblies.

[0130] ⑤. Install and weld the upper half circle of the inner positioning support tooling: restore the upper half circle of the inner positioning support tooling to a full circle of the inner positioning support tooling according to the marked serial number;

[0131] ⑥. Assemble the upper half of the water-cooling panel assembly and the upper half of the water-cooling jacket straight tube panel: assemble the upper half of the water-cooling panel assembly and the upper half of the water-cooling jacket straight tube panel from the 3 o'clock and 9 o'clock positions respectively, until the 12 o'clock position. After passing the test, fix them by spot welding according to the welding process requirements;

[0132] ⑦. The entire circle of water-cooling casing straight tube panel ends are smoothed and beveled;

[0133] ⑧. Assemble the upper annular header of the water cooling jacket: align and assemble the lower annular header of the water cooling jacket and the end positioning tooling according to the dimensions of the design drawing, and then fix it;

[0134] ⑨. Install and weld the upper connecting pipe of the water-cooling panel: The upper connecting pipe of the water-cooling panel is used to connect the horizontal collecting box of the water-cooling panel in the water-cooling panel assembly and the upper annular box of the water-cooling jacket in the water-cooling jacket assembly. It is cut according to the actual length, remove the installation allowance, and grind the groove for matching;

[0135] ⑩. Assemble the special-shaped convection tube of the water cooling jacket: measure the actual length between the annular header and the straight tube screen of the water cooling jacket, and make and weld the special-shaped convection tube of the water cooling jacket;

[0136] Unloading and loading onto the turntable: Unloading and loading the components from the vertical workbench, moving them onto the turntable using the upper turntable tooling, and welding them to the outside of the external reinforcement ring;

[0137] Reinstalling fins: Install and weld fins between each group of special-shaped convection tubes of the water-cooling jacket, between each group of straight tube panels of the water-cooling jacket, between the straight tube panels of the water-cooling jacket and the lower annular header of the water-cooling jacket, and between the water-cooling panel assemblies and the water-cooling jacket assemblies on the turntable;

[0138] Install and weld the lower vertical header of the water-cooling panel and arrange the pipes: The lower vertical header of the water-cooling panel is installed and welded to the outside of the annular header under the water-cooling jacket, and passes through the pipe-allowing position of the straight tube panel of the water-cooling jacket to install and weld the lower convection elbow of the water-cooling panel between the lower vertical header of the water-cooling panel and the straight tube panel of the water-cooling panel. The installation and welding of the lower convection elbow of the water-cooling panel is carried out on site in the order of actual measurement, arrangement and welding;

[0139] Install and weld the radiation waste boiler water inlet pipe and radiation waste boiler water outlet pipe: install and weld the radiation waste boiler water outlet pipe joint on the water cooling jacket annular header, and install and weld the radiation waste boiler water inlet pipe elbow and water inlet connecting pipe on the water cooling jacket lower annular header; clean the inside of the pipe, and install and weld the radiation waste boiler water inlet pipe and radiation waste boiler water outlet pipe pressure test blind cover;

[0140] Welding pins: Welding pins are installed on the upper conical section inside the water cooling jacket assembly;

[0141] Overall heat treatment: After passing the inspection and non-destructive testing, the overall stress relief heat treatment is carried out in a gas furnace;

[0142] Welding the radiation waste pot mounting lugs made of austenitic stainless steel and the thermocouple base made of nickel-based material;

[0143] Hydrostatic test of the inner cavity of the radiation waste boiler;

[0144] Water pressure test inside the tube of the radioactive waste boiler;

[0145] Anti-corrosion treatment and nitrogen filling protection: The inner cavity of the radiation waste boiler is sprayed with high-temperature resistant anti-corrosion paint, and the outer surface is sprayed with silicone heat-resistant primer; 0.05MPa nitrogen is filled in the pipe for anti-corrosion protection.

[0146] In a preferred embodiment of the present application, the water-cooling jacket assembly and the water-cooling screen assembly are made of 12Cr1MoV material. The 12Cr1MoV materials are preheated to 150°C to 200°C before welding, and the preheating range is not less than 100mm on both sides of the groove; dehydrogenation treatment is performed immediately after welding: heating to 350°C and keeping warm for 2 hours.

[0147] In a preferred embodiment of this application, butt-welded pipe joints undergo 100% RT testing 24 hours after welding, passing Level II in accordance with NB / T47013.2-2015. All butt joints, Class D joints, bends, and the 100mm straight pipe sections on both sides undergo 100% PT testing, passing Level I in accordance with NB / T47013.5-2015. Fillet welds between pipes and fins undergo 100% PT testing, passing Level I in accordance with NB / T47013.5-2015. In a preferred embodiment of this application, the weld groove surface and the area within 50mm on both sides must be cleaned of oil, dirt, and rust. The groove surface must be free of defects such as delamination, cracks, and inclusions. The groove surface undergoes 100% MT testing, passing Level I in accordance with NB / T47013.4-2015.

[0148] In a preferred embodiment of the present application, the water-cooling jacket special-shaped convection tubes connected between the water-cooling jacket upper annular header and the water-cooling jacket straight tube panel, the water-cooling panel upper connecting pipes connected between the water-cooling panel horizontal collecting header and the water-cooling jacket upper annular header, and the water-cooling panel lower convection bends between the water-cooling panel lower vertical header and the water-cooling panel straight tube panel are all made according to the actual measured dimensions with assembly process margins reserved according to assembly requirements. In a preferred embodiment of the present application, the header butt joints, water inlet pipe butt joints, and water outlet pipe butt joints are primed with argon arc welding to ensure full penetration, and are then filled and covered with arc welding; the water-cooling jacket straight tube screen, water-cooling screen, and sewage pipe butt joints are welded by manual argon arc welding to ensure full penetration; the sewage pipe and annular header, the water inlet pipe and annular header, the water outlet pipe and annular header, the water-cooling screen convection tube and the horizontal collecting header, and the vertical header are placed in the type D welded joints by argon arc welding to ensure full penetration, and are then filled and covered with arc welding; the inserted type D welded joints between the water-cooling jacket convection tube and the upper and lower annular headers are welded by manual welding; the water-cooling jacket screen and the water-cooling screen are positioned and welded on the automatic tube screen welding machine using mixed gas shielded automatic welding to ensure full penetration and the required weld leg height; the special-shaped fins and the manufacturing process require the fins to be added at the end, and the convection tube welding is performed by mixed gas shielded manual welding to ensure full penetration and the required weld leg height.

[0149] In a preferred embodiment of the present application, after the water-cooling jacket straight tube panel and the water-cooling panel straight tube panel are manufactured, the center distance tolerance of adjacent tubes is ±0.5mm; the center line tolerance of the fin and the center line of the tube is ≤1.5mm; the lateral bending tolerance of the water-cooling jacket straight tube panel is ≤4mm; the bidirectional lateral bending tolerance is ≤5mm, and the unidirectional lateral bending tolerance is ≤3mm.

[0150] In a preferred embodiment of the present application, the roundness tolerance of the annular tube of the water-cooling jacket upper annular header and the water-cooling jacket lower annular header after forming is ≤5mm; the flatness tolerance of the entire annular tube is ≤3mm; and the roundness tolerance of the tube after forming is ≤2mm.

[0151] In a preferred embodiment of the present application, after assembly is completed, the tolerance of the total length of the radiation waste boiler is 0 to 6 mm; the coaxiality tolerance of the upper annular header of the water cooling jacket and the lower annular header of the water cooling jacket is ≤4 mm; the parallelism tolerance of the upper annular header of the water cooling jacket and the lower annular header of the water cooling jacket is ≤3 mm.

[0152] In a preferred embodiment of the present application, the steps in the overall assembly are Specifically including: assembling the inner cavity water pressure test tooling, and conducting a water pressure test on the inner cavity at a pressure of 0.5MPa.

[0153] In a preferred embodiment of the present application, the steps in the overall assembly are Specifically include: installing a pressure test blind plate, conducting a water pressure test in the pipe, the water temperature must not be lower than 15°C, and after filling with water, when the equipment wall temperature is close to the water temperature, slowly increase the pressure to the design pressure of 7.7MPa, and after confirming that there is no leakage, continue to increase the pressure to the test pressure of 10.5MPa, and maintain the pressure for not less than 30min; then reduce the pressure to 7.7MPa, maintain the pressure for a sufficient time for inspection, and pass the test if there is no leakage, no visible deformation, and no abnormal sound; after the test is completed, remove water stains and blow dry with compressed air.

[0154] In a preferred embodiment of the present application, the pin and pipe legs are welded using stud welding. The following key points should be noted: the weld surface should be free of defects or excessive roughness and should be clean, free of excessive oil stains, grease (liquid), rust, and scale. Before formally welding the pin, a trial weld should be performed on the pipe edge material to check that the inner wall of the pipe to which the pin is welded has no burn-through, the inner wall indentation does not exceed 1mm, and the weld has no undercut. Only after passing the test can welding be carried out. The stud must be placed and the welding gun must be operated so that the stud axis is perpendicular to the workpiece surface. This is key to ensuring complete fusion of the joint. During welding, the welding gun must not shake, and the entire bottom surface of the pin must be welded to the pipe. After welding is completed, a visual inspection should be performed. The weld should form an annular edge with no undercut, and there should be no cracks in the weld and heat-affected zone. The diameter of the pores on each pin surface should not exceed 1mm and should not exceed two. The perpendicularity between the pin and the pipe should be ±5° along the pipe axis and ±10° along the pipe circumference. Use a small hammer to tap lightly along the top of the pin to check for compliance; 24 hours after welding, conduct 100% PT inspection on the joint surface, and it must be qualified according to Level I in NB / T47013.5-2015.

[0155] In a preferred embodiment of the present application, relevant welding construction records are kept in a timely manner, and the welding position of each welder is marked on the layout drawing to ensure that each pressure-bearing weld is traceable.

[0156] In a preferred embodiment of the present application, after the gasifier is started up, the radiation waste boiler absorbs heat from the syngas flowing down from the gasifier combustion chamber to produce high-temperature, high-pressure saturated steam. If foreign matter accumulates in a convection tube of the radiation waste boiler, causing a blockage, the water-deficient section of the tube will quickly become corroded by high-temperature steam, causing the tube to leak or burst, resulting in gasifier shutdown or other safety incidents. Therefore, during the manufacturing process of the radiation waste boiler, special attention must be paid to details such as cleaning and protection. These details include:

[0157] ⑴ Inspection of the internal cleaning process of controlled parts. After cutting and processing controlled parts (including straight pipes, annular headers, pipe screens, water inlet pipes, water outlet pipes, flow guides, special-shaped pipes, elbows, collection headers and pipe screen connecting pipes, etc.), burrs and chips should be removed consciously. After cleaning and self-inspection, they can be handed over for inspection and transferred to the next step for pairing. The ends that are not yet paired should be sealed with pipe caps in time;

[0158] (2) Inspection stop point of the water-cooling screen component cleaning process. After the production of a single water-cooling screen component of the radiation waste boiler is completed, the interior should be cleaned and purged, and after passing the inspection, it should be sealed in time with a pipe cap or blind cover;

[0159] ⑶ Check the cleanliness of the control parts before assembly. Before assembly, check, clean and blow out the pipes and pipe holes. Clean each pair of pipes and then clean the next pair after assembly. It is not allowed to completely disassemble the pipe openings to prevent debris from falling into the pipes during the production process. After assembly, the exposed openings should be sealed with pipe caps in a timely manner.

[0160] (4) Cleaning, purging and protection after the water pressure test. After the water pressure test is passed, use an angle grinder to cut off the blind plate of the sewage pipe, open the water inlet pipe stop valve, clean the water stains, blow them dry with compressed air, and perform nitrogen filling protection in time;

[0161] ⑸ Removal of blind plates at the water inlet and outlet and port protection at the installation site. Before assembling the radiation waste boiler, a horizontal nitrogen-filled blind plate should be removed to prevent cutting slag from entering the equipment during the cutting process. After the cutting is completed, the cut mouth and pipe end should be inspected immediately to remove impurities and grind the bevel. If qualified, the pipe cap should be used to seal the pipe immediately. During the subsequent piping, one blind cover should be removed and the pipe should be cleaned before piping the next interface.

[0162] After the radiation waste pot is completed and passes the dimensional inspection and non-destructive testing, it is subjected to stress relief heat treatment in a gas heat treatment furnace. The heat treatment parameters are shown in Table 1:

[0163] Table 1 Overall heat treatment parameters of radiant waste boiler

[0164]

[0165]

[0166] A large number of specific examples are provided in the embodiments provided herein, and it should be understood that these examples are only for the purpose of elaborating on the embodiments of the present application and are not intended to limit the present application. The embodiments in the present application can be practiced without these specific examples. In some embodiments, structures and / or technologies well known to those skilled in the art are not shown in detail so as not to obscure the understanding of the present application.

[0167] Although preferred embodiments of the present application have been shown and described herein, it will be readily understood by those skilled in the art that these embodiments are provided by way of example only. Those skilled in the art will now appreciate multiple variations, changes, and substitutions without departing from the present application. It should be understood that the various alternatives to the embodiments of the present application described herein are optionally used to implement the present application. It is intended that the scope of the present application be defined by the claims, and that methods, structures, and their equivalents within the scope of these claims be encompassed thereby.

Claims

1. A method for manufacturing a radiation waste boiler for recovering waste heat from coal gasification synthesis gas, characterized in that: The following steps are involved: Manufacturing of water cooling jacket assemblies; Manufacturing of water cooling panel components; Manufacturing of auxiliary components; as well as Overall assembly; The water-cooling jacket assembly includes a water-cooling jacket straight tube panel, an upper annular header, a lower annular header, and a water-cooling jacket special-shaped convection tube; the water-cooling jacket assembly includes a water-cooling jacket straight tube panel and a water-cooling jacket horizontal collecting header; and the auxiliary components include a water-cooling jacket lower convection elbow, a water-cooling jacket lower vertical header, a water-cooling jacket upper connecting pipe, a radiation waste boiler water inlet pipe, a radiation waste boiler water outlet pipe, a radiation waste boiler sewage pipe, an external reinforcement ring, and a radiation waste boiler mounting ear seat; the tooling used in the overall assembly includes a stand workbench, an end positioning tooling, an internal positioning support tooling, an external support tooling, and a tooling for an upper turntable; The manufacturing of the water cooling jacket assembly specifically includes: a. Manufacturing of the water cooling jacket straight tube panel: ①. Comprehensively consider the welding shrinkage reserve and processing allowance to determine the pipe cutting length, and use the pipe beveling machine to process the bevel at one end of the pipe, and clean and blow clean the inside and outside of the pipe; ②Use the automatic tube panel welding system to assemble and weld the tubes and fins into a four-tube five-flat steel tube panel. Align the other end of the tubes according to the length shown in the drawing, clean them, and seal them with tube caps for protection. b. Manufacturing of the upper annular header of the water cooling jacket and the lower annular header of the water cooling jacket: ①. Considering the forming allowance and processing allowance, determine the blanking length, and form the header into two pieces; ②. Lay out on the platform, calculate the theoretical arc length of the header half ring pipe and add the process allowance to mark the cutting line, cut along the cutting line using gas cutting method, and clean the cutting slag; ③. Process the end face groove of the half-ring tube on the boring and milling machine, remove the burrs, assemble the two half-ring tubes into an integral header on the platform, and weld the interface according to the welding process; ④. Draw cross-azimuth reference lines of 0°, 90°, 180°, and 270° on the platform. Draw the assembly position lines of the convection pipe, the radiation waste boiler water inlet pipe, the radiation waste boiler water outlet pipe, the radiation waste boiler sewage pipe, and the connecting pipe on the water cooling panel according to the reference lines, and make proofs and marks. ⑤. Use drilling machines and boring and milling machines to process each pipe hole. After processing, clean and blow the inside of the header, and seal the pipe holes; c. Manufacturing of the special-shaped convection tube of the water cooling jacket: ①. Consider the forming process allowance and assembly allowance to determine the blanking length, and use the bending tool to cold bend the pipe; ② Use a grinding machine to cut the allowance and grind the pipe end bevel, clean the burrs, and seal the pipe cap; The manufacturing of the water cooling screen assembly specifically includes: a. Manufacturing of the water-cooled straight tube panel: ①. Comprehensively consider the welding shrinkage reserve and processing allowance to determine the pipe cutting length, clean and blow clean the inside and outside of the pipe; ②Use the automatic tube panel assembly and welding system to assemble and weld the tubes and fins into an eight-tube, seven-flat steel tube panel, clean it, and seal it with tube caps for protection; b. Manufacturing of the water-cooled panel horizontal collection box: ① Leave some end surface machining allowance for cutting; ②. Process the flat end surface and the bevel at both ends on a lathe; ③. Use a drilling machine and a wire cutting machine to process the convection pipe holes and the pipe holes of the connecting pipes on the water cooling screen respectively, clean and blow clean the inside and outside, and perform sealing protection; c. Assembly of the water cooling screen assembly: ① Assemble and weld the horizontal collecting header of the water-cooling panel to one end of the straight tube panel of the water-cooling panel; ②. Process the bevel at the other end of the water-cooling panel straight tube panel, clean it and blow it clean, and seal it with a pipe cap for protection; The manufacturing of the auxiliary component specifically includes: a. Manufacturing of the convection elbow at the lower part of the water-cooling panel and the radiation waste boiler drain pipe: ①. Consider the forming process allowance and assembly allowance to determine the blanking length, and use the bending tool to cold bend the pipe; ② Use a grinding wheel to cut the allowance and grind the pipe end bevel, clean the burrs, and use a pipe cap for sealing protection; b. Manufacturing of the vertical header at the bottom of the water-cooling panel: ①. Consider the forming process allowance, machining allowance and assembly allowance to determine the blanking length; ②. Process the groove on one end on a lathe and remove burrs; ③. Use medium frequency pipe bending machine to simmer and shape; ④. Process the convection pipe holes on the drilling machine, clean and blow clean the inside and outside, and perform sealing protection; c. Manufacturing of the connecting pipe on the water cooling panel: ①. Consider the machining allowance and assembly allowance to determine the cutting length; ② Use a wire cutting machine to process one end into a 45° V-shaped groove, grind the groove, and clean it; d. Manufacturing of the radiation waste boiler water inlet pipe and the radiation waste boiler water outlet pipe: ①. Consider the forming process allowance and assembly allowance to determine the blanking length; ②, Use medium frequency pipe bending machine to simmer and shape; The overall assembly specifically includes: ①, Stand: Sequentially center and align the lower annular header of the water cooling jacket, the lower half of the outer support fixture, and the end positioning fixture on the stand workbench. After inspection, secure them with channel steel. ② Assemble the lower half of the water-cooling jacket straight tube panel: Start assembling the lower half of the water-cooling jacket straight tube panel from the 6 o'clock position until reaching the 3 o'clock and 9 o'clock positions respectively. During assembly, adjust the tube panel gap appropriately to ensure the overall assembly requirements. After passing the requirements, fix them by spot welding. ③. Assemble the lower half of the inner positioning support fixture: The tube panel slot on the inner positioning support fixture is vertically positioned at the center of the tube of the water-cooling jacket straight tube panel. The fixture is centered and aligned, and the inner positioning support fixture is firmly spot-welded to the fins of the water-cooling jacket straight tube panel using flat steel bars. The upper half and part of the lower half of the inner positioning support fixture are marked and then cut off, leaving half of the tube panel slot open upward to facilitate positioning of the water-cooling panel assembly to be assembled later. ④. Assemble the lower half of the water-cooling panel assembly: Starting from the 6 o'clock position, assemble the water-cooling panel assembly according to the tube panel slot position on the lower half of the inner positioning support tooling until reaching the 3 o'clock and 9 o'clock positions respectively. Use wooden supports to reinforce the space between the two water-cooling panel assemblies. ⑤. Assemble and weld the upper half circle of the inner positioning support tooling: restore the upper half circle of the inner positioning support tooling to a full circle of the inner positioning support tooling according to the marked serial number; ⑥. Assemble the upper half of the water-cooling panel assembly and the upper half of the water-cooling jacket straight tube panel: Assemble the upper half of the water-cooling panel assembly and the upper half of the water-cooling jacket straight tube panel from the 3 o'clock and 9 o'clock positions respectively, and continue until the 12 o'clock position. After passing the test, fix them by spot welding according to the welding process requirements; ⑦. Smooth and groove the ends of the straight tube panels of the water cooling jacket in the entire circle; ⑧. Assemble the upper annular header of the water cooling jacket: align and assemble the upper annular header of the water cooling jacket with the lower annular header of the water cooling jacket and the end positioning tool according to the dimensions of the design drawing, and then fix it; ⑨. Install and weld the water-cooling panel upper connecting pipe: The water-cooling panel upper connecting pipe is used to connect the water-cooling panel horizontal collecting header in the water-cooling panel assembly and the water-cooling jacket upper annular header in the water-cooling jacket assembly. It is cut according to the actual length, remove the installation allowance, and grind the groove for matching; ⑩. Assembling the special-shaped convection tube of the water-cooling jacket: measuring the actual length between the annular header on the water-cooling jacket and the straight tube panel of the water-cooling jacket, and fitting and welding the special-shaped convection tube of the water-cooling jacket; Unloading and placing on the turntable: The components are unloaded from the vertical workbench, moved to the turntable using the upper turntable tooling, and assembled and welded to the outer side of the external reinforcement ring; Replacing fins: installing and welding fins between each group of the water-cooling jacket special-shaped convection tubes, between each group of the water-cooling jacket straight tube panels, between the water-cooling jacket straight tube panels and the water-cooling jacket lower annular header, and between the water-cooling jacket assemblies on the turntable; Installation and welding of the lower vertical header of the water-cooling panel and piping: The lower vertical header of the water-cooling panel is installed and welded to the outside of the lower annular header of the water-cooling jacket, and the lower convection elbow of the water-cooling panel is installed and welded between the lower vertical header of the water-cooling panel and the straight tube panel of the water-cooling jacket through the pipe-allowing position of the straight tube panel of the water-cooling jacket. The installation and welding of the lower convection elbow of the water-cooling panel is carried out on site in the order of actual measurement, fitting and welding; Install and weld the radiation waste boiler water inlet pipe and the radiation waste boiler water outlet pipe: install and weld the joint of the radiation waste boiler water outlet pipe to the upper annular header of the water cooling jacket, and install and weld the elbow and water inlet connecting pipe of the radiation waste boiler water inlet pipe to the lower annular header of the water cooling jacket; clean the inside of the pipe, and install and weld the pressure test blind covers of the radiation waste boiler water inlet pipe and the radiation waste boiler water outlet pipe; Welding pins: Welding pins are installed on the upper conical section inside the water cooling jacket assembly; Overall heat treatment: After passing the inspection and non-destructive testing, the overall stress relief heat treatment is carried out in a gas furnace; Welding the radiation waste pot mounting lugs made of austenitic stainless steel and the thermocouple base made of nickel-based material; A water pressure test on the inner cavity of the radiation waste boiler; Water pressure test inside the tube of the radiation waste boiler; Anti-corrosion treatment and nitrogen filling protection: the inner cavity of the radiation waste boiler is sprayed with high-temperature resistant anti-corrosion paint, and the outer surface is sprayed with organic silicon heat-resistant primer; 0.05MPa nitrogen is filled in the pipe for anti-corrosion protection.

2. The manufacturing method according to claim 1, characterized in that The water-cooling jacket assembly and the water-cooling screen assembly are made of 12Cr1MoV material. The 12Cr1MoV materials are preheated to 150°C to 200°C before welding, and the preheating range is not less than 100mm on both sides of the groove. Dehydrogenation treatment is performed immediately after welding: heating to 350°C and keeping warm for 2 hours.

3. The manufacturing method according to claim 1, characterized in that The butt-welded joints of pipes are subjected to 100% RT testing 24 hours after welding and are qualified according to Level II in NB / T47013.2-2015; all butt joints, Class D joints, elbows and 100mm straight pipe sections on both sides are subjected to 100% PT testing and are qualified according to Level I in NB / T47013.5-2015; the fillet welds between pipes and fins are subjected to 100% PT testing and are qualified according to Level I in NB / T47013.5-2015.

4. The manufacturing method according to claim 1, characterized in that The water-cooling jacket special-shaped convection tubes connected between the water-cooling jacket upper annular header and the water-cooling jacket straight tube panel, the water-cooling panel upper connecting tubes connected between the water-cooling panel horizontal collecting header and the water-cooling jacket upper annular header, and the water-cooling panel lower convection bends between the water-cooling panel lower vertical header and the water-cooling panel straight tube panel are all made according to the actual measured dimensions with assembly process margins reserved according to assembly requirements.

5. The manufacturing method according to claim 1, characterized in that After the water-cooling jacket straight tube panel and the water-cooling panel straight tube panel are manufactured, the center distance tolerance of adjacent tubes is ±0.5mm; the center line tolerance of the fin and the center line of the tube is ≤1.5mm; the lateral bending tolerance of the water-cooling jacket straight tube panel is ≤4mm; the bidirectional lateral bending tolerance is ≤5mm, and the unidirectional lateral bending tolerance is ≤3mm.

6. The manufacturing method according to claim 1, characterized in that The roundness tolerance of the annular tubes after forming the upper annular header of the water cooling jacket and the lower annular header of the water cooling jacket is ≤5mm; the flatness tolerance of the entire annular tube is ≤3mm; and the roundness tolerance of the tubes after forming is ≤2mm.

7. The manufacturing method according to claim 1, characterized in that After assembly, the total length tolerance of the radiation waste boiler is 0-6 mm; the coaxiality tolerance of the water-cooling jacket upper annular header and the water-cooling jacket lower annular header is ≤4 mm; the parallelism tolerance of the water-cooling jacket upper annular header and the water-cooling jacket lower annular header is ≤3 mm.

8. The manufacturing method according to claim 1, characterized in that Steps in the overall assembly Specifically including: assembling the inner cavity water pressure test tooling, and conducting a water pressure test on the inner cavity at a pressure of 0.5MPa.

9. The manufacturing method according to claim 1, characterized in that Steps in the overall assembly Specifically include: installing a pressure test blind plate, conducting a water pressure test in the pipe, the water temperature must not be lower than 15°C, and after filling with water, when the equipment wall temperature is close to the water temperature, slowly increase the pressure to the design pressure of 7.7MPa, and after confirming that there is no leakage, continue to increase the pressure to the test pressure of 10.5MPa, and maintain the pressure for not less than 30min; then reduce the pressure to 7.7MPa, maintain the pressure for a sufficient time for inspection, and pass the test if there is no leakage, no visible deformation, and no abnormal sound; after the test is completed, remove water stains and blow dry with compressed air.

Images