Many boiler demand customers are not familiar with the overall production process of boilers. Today, the editor of Fangkuai Boiler will give you a detailed talk about the overall production process of Fangkuai Boiler.

1. CNC cutting

According to the cutting code automatically generated by the nesting software, it is transmitted to each CNC precision plasma cutting machine equipment, and the equipment automatically recognizes and performs 1:1 cutting on the sheet metal.

2. Roll round

Process the cut or milled pot shells and furnace liner sheets into circular workpieces using a CNC rounding machine.

3. Beside the car

Like the milling process, the workpiece is processed into straight edges and groove shapes using vertical lathes. Therefore, the workpiece is mainly designed for edge bending tube sheets.

4. Drilling and expanding holes

Fix the tube plate on a dedicated platform and use a rocker drilling machine to perform reaming and chamfering on the cut bottom hole.

5. Riveting team

Align the drum, furnace liner, and tube plate according to the two components of the shell assembly and inner liner assembly, and sequentially assemble and weld all internal components of the drum (such as uniform steam orifice plate, diagonal pull rod) and components that require double-sided welding (such as pipe seat, manhole ring, hand hole ring, etc.).

6. Submerged arc welding

After the longitudinal and circumferential seams of the main compressed workpieces (cylinder, tube plate) are assembled and qualified, submerged arc welding is used

The welding machine shall perform welding according to the corresponding welding process card requirements.

7. Tube plate welding

Pipe "refers to seamless pipe, which is defined as smoke pipe or water pipe on the boiler according to its purpose; Plate "refers to a flat steel plate, which corresponds to the front tube plate, rear tube plate, and front and rear tube plates of the combustion chamber on the boiler. The two are combined to form a corner joint, and then mechanically welded under argon protection by using a dedicated tube plate welding machine.

8. Furnace body welding

The welding of the furnace body mainly includes the assembly and welding of components such as the combustion chamber smoke tube, straight rod and tube plate, diagonal rod and tube plate, tube seat and pot shell, furnace body and base, etc., which can meet the conditions for hydrostatic testing. The welding methods involved include electrode arc welding and mixed gas shielded welding.

9. Hydrostatic test

The strength and sealing testing of the boiler after assembly is carried out through the pressure of water.

10. Weld repair

Requirements for weld repair:

Defects that are not allowed to exist on the weld seam should be identified and a feasible repair plan should be developed before repair can be carried out.After grinding, the repaired weld seam should have a smooth transition with the base metal and have the same dimensions as the original weld seam.The welding materials used for repair welding should meet the same welding requirements as the original product.The repair at the junction of the drum ring and longitudinal seam should be carried out by welding the longitudinal seam first and then the circumferential seam.Before repair, defects should be thoroughly removed and repair should not be carried out in contact with water.When repairing pressure components of boilers that have undergone heat treatment, post weld heat treatment should generally be carried out in accordance with the original heat treatment specifications after welding.After weld repair, visual inspection and non-destructive testing should be carried out according to the quality requirements of the original weld. Repairs at the same location shall not exceed two times.After the appearance inspection of the repaired weld seam is qualified, a hydrostatic test shall be conducted again.

11. Production and installation of cigarette boxes

This process includes the production and installation of smoke boxes before and after the boiler. The installation mainly involves assembling and welding the pre made smoke box components with the main body components, laying and curing the insulation layer at their connection parts, and conducting an air tightness test after completion.

12. Production and installation of platform escalators

This process includes the production and installation of boiler platform escalators. The installation mainly involves assembling and welding the pre made platform with the main components, and then assembling the escalator components with the platform and main components, including the pre assembly of guardrails.

This process includes insulation layer, outer panel wrapping, installation of each pipe cap, secondary installation of the platform, installation of electrical circuits, repainting of exposed parts, installation of product nameplates, and wrapping with dust-proof cloth.
14. Energy efficiency testing

This process includes the installation of various pipeline valves, burner debugging and operation according to working conditions, data measurement and analysis, and calculation of operating data.