高速线材厂工艺技术规程

高速线材厂工艺技术规程RG/QF-06-1-01版次：A/1高速线材厂工艺技术规程（编号：RG/QF-06-1-01版次A/1）编制：高速线材厂生产技术科审核：批准：2012年月日实施高速线材厂工艺技术规程RG/QF-06-1-01版次：A/1目录1目的················································································2适应范围············································································3定义················································································3.1工艺技术规程·······································································3.2工艺流程总则······································································3.3工艺流程细则·······································································4技术要求及工艺操作··································································4.1加热部分·············································································4.2轧制部分·············································································4.3精整部分·············································································5成品品种、规格及执行标准···························································5.1产品品种·············································································5.2产品规格·············································································5.3执行标准·············································································6产品可追溯性·········································································7打捆·················································································8挂牌·················································································9成品吊运及成品管理··································································10轧辊、辊环和样板···································································11轧辊车削·············································································12轧辊维护·············································································13导卫调整制度········································································14切头与取样···········································································15成品自检制度·········································································高速线材厂工艺技术规程RG/QF-06-1-01版次：A/1高速线材厂工艺技术规程1目的为保证生产作业按规定工艺流程及相应的技术要求,在受控状态下进行。2适应范围本规定适应于高速线材厂。3定义3.1工艺技术规程为保证产品质量达到标准要求，对主要工序的技术条件和工艺质量标准作出明确规定的技术文件。3.2工艺流程总则生产工艺流程加热上料辊道→提升机上料→辊道入炉→蓄热式步进炉加热→出钢辊道出炉→（除磷）→粗轧6架轧制→1#飞剪切头（事故碎断）→中轧6架轧制→2#飞剪切头、尾（事故碎断）→预精轧6架轧制（各架次中间设立活套）→1#水冷箱→3#飞剪切头、尾（事故碎断）→立活套→精轧机10架轧制→水箱冷却→（双模块机组4架轧制）→水箱冷却→夹送辊→吐丝机→散卷控冷→集卷收集→PF链运输→检查质量、取样、剪除头尾→打包→(包装)→称重→卸卷→入库→成品发运。3.3工艺流程细则3.3.1炼钢厂连铸机生产的连铸钢坯通过热送辊道送入高线厂加热车间的加热跨内，由链式提升机提升到安装在标高为+4.5m混凝土平台上的入炉辊道上。3.3.2钢坯由入炉辊道送入蓄热式加热炉内。3.3.3连铸坯在加热炉内加热到规定的轧制温度。3.3.4每支坯料出炉后，根据需要，炉门可以自动关闭以保持炉温稳定。3.3.5坯料轧制前经过除磷机进行氧化铁皮清除处理以保证表面质量。3.3.6输送至轧线，由粗轧机组进行6道次的轧制。3.3.7经过粗轧后的轧件,需要由1#飞剪进行切头操作，以去除轧件头部缺陷部分。3.3.8切头后合格的轧件进入中轧机组轧制6道次。3.3.9由2#飞剪再次切头，合格的轧件进入预精轧机组继续轧制6道次，同时进行切尾操作。3.3.10轧件再由3#飞剪切头后进入精轧机组轧制10道次，必要时进行切尾。高速线材厂工艺技术规程RG/QF-06-1-01版次：A/13.3.11预精轧6架机组间及精轧机组前各设有1个立活套，以实现无张力活套控制轧制，从而保证产品的尺寸精确度。3.3.12通过精轧机的轧件进入双模块机组轧制4道次。3.3.13在预精轧机组、精轧机组和双模块机组后均设有穿水冷却装置，通过调节水箱开闭以及冷却水流量来控制进入精轧机或双模块轧机的轧件温度及线材吐丝温度。3.3.14完成轧制程序的成品由夹送辊及吐丝机的作用形成均匀的螺旋状线圈，并散落到风冷辊道。3.3.15根据不同钢种和产品规格，通过调节辊道速度、保温罩开闭，风机开启数量和风量等操作，以控制线材冷却速度，满足不同钢种产品的性能要求。3.3.16线材经过风冷辊道后平落到集卷筒收集成卷。3.3.17每卷线材收集完整后，收集装置通过芯棒90度的旋转，将盘卷平放到运输小车内，运输小车将盘卷夹紧后继续移送，挂在PF线的C型钩上后，运输小车返回原始位置。3.3.18载有盘卷的C型钩随着运行的PF线轨道前进，并继续进行冷却。此间进行定点成品质量检查、取样和缺陷修剪操作。3.3.19由PF线输送至打包机处，根据各品种、规格的打包要求进行打捆操作。3.3.20根据品种、规格、运输方式及客户要求的不同，进行是捆线防脱落处理及精包装等工作。3.3.21继续输送至称重站，称量出标准重量后，进行重量标识。3.3.22最终到达卸卷站，由吊车运到成品库存放。4技术要求及工艺操作4.1加热部分4.1.1主要设备及技术参数1)连铸坯○1规格:160×160×12000mm重量2334kg○2执行标准:YB/T2011-2004《连续铸钢方坯和矩型坯》。2)加热炉参数1#炉2#炉3#炉炉型侧进侧出蓄热式步进加热炉侧进侧出蓄热式步进加热炉侧进侧出蓄热式步进加热炉高速线材厂工艺技术规程RG/QF-06-1-01版次：A/1燃烧控制段预热段、加热段、均热段加热段、均热段预热段、加热段、均热段有效尺寸19000mm×12800mm13000mm×12800mm19000mm×12800mm燃料高炉、转炉煤气高炉、转炉煤气高炉、转炉煤气最大加热能力热装:160t/h冷装120t/h热装:120t/h热装:160t/h冷装120t/h3)燃烧系统所用介质参数表技术指标单位内容用途空气量Maxm3/h40000助燃高炉、转炉煤气量Maxm3/h50000燃烧烟气生成量Maxm3/h81000满足蓄热室保温需求压缩空气Nm3/h120三通换向阀、摄像头、检测仪表、煤气总管快速切断阀、气动调节阀氮气Nm3/次1000管路吹扫净循环水m3/h≥400冷却水梁、立柱、辊道轴承、风机轴承、炉门、进出料水冷梁、激光检测器等4)加热炉区辊道技术参数辊道名称型式辊距（mm）辊道速度（m/s）单个单机容量装炉辊道单独传动12000.2～1.53KW/辊AC出炉辊道单独传动12000.2～1.53KW/辊AC5)炉门传动装置参数○1气缸拉动链条式升降行程～500mm升降速度0.2m/s6)烟囱参数钢质空烟烟囱直径：1620mm，高度：20米；钢质煤烟烟囱直径：1720mm，高度：20米；数量：3根。7)测温点在均热段的顶部设置3支S型热电偶，在3个加热段的顶部各设置2支S型热电偶，各段两高速线材厂工艺技术规程RG/QF-06-1-01版次：A/1侧下部各安装一支热电偶检测炉子下部温度，温度在CRT上显示，以炉顶热电偶信号为控制该段温度的测量值。4.1.2操作要点1)按标准进行连铸坯的检查和验收，连铸坯长度控制在12000＋40mm以内，且坯料表面不允许有缺陷，不符合标准要求的钢坯严禁装炉；2)严格执行按炉送钢制度；3)严格保证各段炉温、排烟温度、冷却水温度、空煤比、炉压参数；4)严格执行停轧待温制度并相应调整空步；5)严禁因交接班等原因造成各项参数波动；6)注意保持和轧线通讯畅通以保证可控性。4.1.3附:停轧待温制度管理表停轧时间预热段加热段均热段均热段开始升温时间30～60分钟————炉温降低20℃开轧前10～20分钟开始升温60～180分钟——950℃1000℃开轧前30～60分钟开始升温3～8小时熄火900℃950℃开轧前2小时开始升温8～12小时熄火熄火最小流量开轧前2小时开始升温12小时以上熄火熄火最小流量开轧前2小时开始升温4.2轧制部分4.2.1主要设备及工艺参数1)主轧机及电机参数表机组型式设备名称轧辊尺寸速比电机功率转速粗轧机组1HΦ610水平轧机Φ610/Φ550×76066.5500500/10002VΦ610立式轧机Φ610/Φ550×76052.82500500/10003HΦ610水平轧机Φ610/Φ550×76051.447600600/13004VΦ610立式轧机Φ610/Φ550×76048.33550600/13005HΦ610水平轧机Φ610/Φ550×76034.8550600/13006VΦ610立式轧机Φ610/Φ550×76026.318550600/1300中轧机7HΦ430水平轧机Φ430/Φ370×65016.47600600/13008VΦ430水平轧机Φ430/Φ370×65012.79550600/1300高速线材厂