Assembly and welding technology of buffer tank for separation of water from gas

Contents

Introduction

Section 1 Process Part

1.1 General requirements

1.2 Technical Requirements and Specifications

1.3 Constructability Analysis

1.4 Calculation and design of welded structure

1.4.1 Define the shape and size of the structure

1.5 Selection of article main materials

1.5.1 Evaluation of weldability of main structural materials

1.6 Calculation of structural elements

1.6.1 Design and calculation of welded joints

1.7 Development of article assembly and welding technology

1.7.1 Development of product manufacturing process diagram

1.8 Selection of workpiece production method

1.8.1 Characteristics of procurement operations

1.8.2 Characteristics of procurement operations equipment

1.8.3 Selection and justification of methods of article assembly and welding

1.8.4 Selection of welding materials

1.8.5 Selection of welding equipment

1.8.6 Calculation of welding modes parameters

1.8.7 Evaluation of mechanical properties of welded joints

1.8.8 Article assembly and welding technique and technology

1.8.9 Technical rationing

1.8.10 Quality control of welded joints

Section 2 Design Part

2.1 Engineering of technological equipment

2.2 Development of assembly and welding shop plan

Section 3 Calculation and Planning of Main Technical and Economic Parameters of Welded Structure Production

3.1 Organization of work planning in the welding area

3.2 Areas of improvement of welding production efficiency

3.3 Procedure for organization of welding production repair and maintenance

3.4 Measures to create and ensure prevention of safe working conditions in welding areas

3.5 Calculation and planning of cost of welded structure based on standards of process modes, labor and material costs

3.5.1 Calculation of cost of basic and auxiliary materials

3.5.2 Calculation of process power cost

3.5.3. Calculation of basic wages of production workers

3.5.4 Calculation of additional wages and social contributions

3.5.5 Calculation of depreciation deductions for operation of equipment and mechanization facilities

3.5.6 Calculation of overhead costs of welding production

3.5.7 Planning the cost of the welded structure unit

3.6 Calculation of the plant selling price for welded structure

3.7 Planning of main parameters of welded structure production and implementation

3.7.1 Planning of annual production volume

3.7.2 Planning revenue from sales and cost of annual output

3.7.3 Profit and profitability planning

Section 4 Safety of Assembly-Welding Process

4.1 Analysis of hazardous and harmful factors arising during execution

electric welding works and ways of their elimination

4.2. Development of engineering solutions for impact reduction

identified hazardous and harmful factors on workers and the environment

Conclusion

List of sources used

Appendix A Roadmap

Appendix B Assembly-Welding Routines

Appendix B Specification

Introduction

The basis of the diploma design is the choice of the main parameters of the technological process of manufacturing the welded structure, primarily procurement and assembly and welding. An important task is also to acquire skills in the practical development of a set of knowledge obtained when studying other special subjects in the specialty "equipment and technology of welding production," the ability to use reference literature and regulatory and technical documentation.

Welding is one of the leading technological processes in mechanical engineering. Metals of any thickness can be welded. The strength of welded joints in most cases is not inferior to the strength of the base metal. According to the type of energy introduced into the product, all welding processes can be divided into three groups (GOST 1952174): thermal, thermomechanical and mechanical. Thermal processes combine all methods of melting welding.

Electric arc welding of metals was created by the outstanding Russian inventor Nikolai Nikolaevich Benardos (18421905) in 1882. In his invention N.N. Benardos used the idea laid down in the works of the Russian physicist Vasily Vladimirovich Petrov (17611834), who in 1802 discovered the phenomenon of an electric arc and pointed out the possibility of its use for melting metals. N.N. Benardos focused on the development of a method of welding with a non-consumable electrode. Such welding is called welding according to the Benardos method. The essence of the method was that current was passed between the welded article and the carbon rod (electrode) from the accumulator battery and an electric arc arose. The arc melted the edges to be welded, and additional metal in the form of a rod was introduced into the arc and, melting in it, filled the gap.

Further development of arc welding is associated with its mechanization . Already in

In the early 20s. in various countries, special mechanisms of automatic welding and surfacing were created. A new stage in the development of automatic arc welding began in the late 30s, when, under the leadership of E.O. Paton, automatic welding under a flux layer was developed in its modern form. The initial idea of ​ ​ welding under flux was proposed by N.G. Slavyanov, but as any idea that overtakes its time, it did not receive recognition and development during the life of the inventor.

In the late 40s. received industrial use of the method of arc welding in protective gases. The idea of ​ ​ using gases to protect the welding zone was put forward by N.N. Benardos, and was first carried out by the American scientist Alexander in 1928. However, in those years this welding method did not receive industrial use due to the difficulty of producing protective gas.

An outstanding achievement of welding technology was the development at the IES named after E.O. Paton in collaboration with a number of industrial enterprises in 1949 of a fundamentally new type of welding, called electric slag welding. The use of electric slag welding has introduced fundamental changes in the technology of producing drums, boilers, heavy presses, shafts of large hydraulic turbines and other large-sized products.

The development of welding technology is associated with the emergence of new sources of heat for melting metals. One such source is the concentrated electron flow in vacuum, on the basis of which in the late 50s. the name of electron-beam welding. Electron beam welding is used to connect refractory chemically active metals and alloys and special parts.

A great contribution to the development of the scientific foundations of melting welding technology was made by Soviet and Russian scientists of the Baton Institute of Electric Welding, Moscow State Technical University (MVTU) named after N.N. Bauman, IMET named after A.A. Baykova, USTU (UPI), Leningrad School of Welders and other technical countries.

Section 1 Process Part

1.1 General requirements

The degassing buffer is designed to separate water from gas at a given pressure, as well as to capture "floating oil." It is used in process units gas, oil, oil processing and petrochemical industries.

The design of the degassing buffer is a pressure vessel and must be technological, reliable during the service life stipulated by the technical documentation, ensure safety during manufacture, installation and operation, provide for the possibility of inspection (including the internal surface), cleaning, washing, blowing and repair.

When designing a degassing buffer, the requirements of the "Rules for the carriage of goods by rail, water and road" are taken into account.

Strength calculation of the apparatus and its elements is carried out in accordance with the current regulatory and technical documentation. GOST 1424989; GOST 2475589.

The degassing buffer is transported in assembled form, has sling devices (gripping devices) for loading and unloading operations, lifting and installation of vessels in the design position.

It is allowed to use process nozzles and necks, ledges, beads and other structural elements of the apparatus in place of sling devices in agreement with the installation organization.

Sling devices (gripping devices) designed for slinging, structural elements of the product are designed for mounting weight and loads depending on the installation method.

The degassing buffer is equipped with hatches providing inspection, cleaning, safety of corrosion protection works (for corrosion protection), installation and dismantling of developed internal devices, repair and control of vessels.

All blind parts of assembly units and elements of internal devices are provided with drainage holes, located in the lowest places of these assembly units and elements, to ensure complete drain of liquid in case of device shutdown.

1.3 Constructability Analysis

The basic version provides for all welds by welding in the environment of protective gases, which makes it possible to reduce the cost of construction due to the cost effectiveness of this welding method. The welding process takes place at several welding stations with different welding devices, but in one workshop, which allows to minimize the loss of time for transportation. Given that capacitive devices in the petrochemical industry are the most numerous, in the case of the introduction into production of a better-modified technological process for the manufacture of this design, this will have a significant economic effect for the enterprise.

The designed design is technological from the position of the material capacity; manual labor costs are minimized by using mechanized technological equipment, as well as mechanized welding method. The main welding time is reduced by the small length of welds and the use of a productive welding method. The auxiliary time is larger than the main time. There is a need for manual climbing and regulation during assembly, as well as numerous cantering of the assembly unit. In general, the design has acceptable processability indicators, taking into account the refinement of the technological process, they can be increased.

1.4 Calculation and design of welded structure

1.4.1 Define the shape and size of the structure

The shapes and dimensions of the buffer-degasser structures are determined by the corresponding regulatory technical documentation.

1.7 Development of article assembly and welding technology

Features of assembly and welding. After the workpiece, the parts of the welded structures are delivered to the assembly. An assembly is a process of sequentially connecting parts to each other in the order provided for by the process and drawing, for subsequent welding.

Depending on the type of production, design features and process conditions, assembly can be carried out in various ways: by marking, by templates or the first product, by assembly holes, in devices (universal, specialized and special), assembly by marking is carried out without devices.

The highest assembly accuracy at minimum labor consumption can be ensured when using assembly and assembly welding equipment.

The main purpose of the assembly process is to determine the most advantageous sequence of assembly of individual parts, ensuring that the technical requirements for the manufacture of this product are met at the minimum cost of labor, time and auxiliary materials. Prior to assembly, the assembler visually verifies that parts meet drawing and process plan requirements.

Mating surfaces and adjacent areas of assembled parts with a width of at least 20 mm shall be thoroughly cleaned from rust, oil, dirt, scale and moisture in order to avoid the appearance of pores and other defects in the weld metal.

When assembling welded structures, the parts of the assembled welded assembly are arranged in such a way that they are located in the finished assembly. Assembly clearances shall be strictly in accordance with the drawing. Exceeding the edge of one of the butt joint elements above the other, if it is not provided and is not specified specifically in the drawing, it is allowed over the entire length of the weld not more than 0.2 of the element thickness (up to 4 mm) and 0.15 of the element thickness (over 4 mm, but not less than 1.5 mm).

Local edge excesses are monitored prior to welding.

When assembling welded structures, parts are connected to each other by means of tacks, which are placed at the locations of future welds. Tacks are made with coated electrodes, in protective gases or under flux. The cross-sectional area of the grips shall not exceed 2/3 of the cross-sectional area of the future seam and shall not exceed 2530 mm2. The length of each tack must be equal to 4-5 thicknesses of the parts to be connected, but not less than 30 mm and not more than 17 mm. The smaller the thickness of the parts to be welded, the smaller the distance between the tacks.

It is allowed to apply tacks outside the places of joints for temporary fastening of the part. These tacks are removed after performing their purpose, and their places of placement are cleaned. It is rational to replace tacks with a continuous seam of a small section (process seam). Assembly tacks are made with welding materials of the same grades as during welding of this structure.

The requirements for the quality of tacks are the same as for welding seams. Tacks and process seams are digested during welding of the main seam.

When welding longitudinal seams to insert the electrode into the seam and remove it from the seam outside the article, at the end of welding, the lead and lead bars must be welded to the edges. The shape of the strip preparation shall correspond to the preparation of the edges of the main seam.

Depending on the type of production, design features and process conditions, the assembly can be carried out in various ways: by marking, by templates or the first product, by assembly holes, in devices (universal, specialized and special),

assembly by marking is carried out without accessories.

The highest assembly accuracy at minimum labor consumption can be ensured when using assembly and assembly welding equipment.

1.8 Selection of workpiece production method

1.8.1 Characteristics of procurement operations

Blanks can be cast, forged, stamped and rolled. The process of procuring rolled stock parts can include editing, marking, edge machining, bending, and cleaning.

Edit. As a rule, it is produced in a cold state by creating local plastic deformation. In order to avoid significant loss of plastic properties, the extent of elongation of the most deformed fibers is usually limited by the pour point.

For steel 09G2C, Δ is allowed with cold straightening up to 1% and with cold bending up to 2%. Based on this, the stroke of the pusher during straightening on presses and the radius of the roll during straightening in rollers are limited. The sheet-adjusting rolls may be 411 rolls or more. Straightening is achieved by bending and stretching by repeatedly passing sheets between the upper and lower rows of rolls.

Markup. Individual marking is time consuming. Mapping is more productive, however, the production of special mapping templates is useful only for mass production or for repeated single-production designs.

Edge cutting and machining. To cut sheet material, guillotine scissors and press scissors are used. Cut sheet is turned between lower and upper knives until stop, clamped by clamping and pressing of upper knife is performed by chipping. Support means in the form of rollers or ball supports are often used to facilitate the supply of sheet material to the scissors. Sheets from 3 to 25mm thick can be cut with disk scissors. Sometimes, to obtain parallel edges of the sheet, the disc knives are located directly on the rolls of regular rollers.

Oxygen separation is extremely widely used.

cutting. Manual and puluautomatic cutting is usually made according to markings ,

automatic - using copy devices.

Preparation of edges for welding. Stitching or milling of edges on machines is usually done in the following cases: 1) to form chamfers that have a complex shape; 2) if the specification requires edge treatment after cutting with scissors; 3) to ensure accurate dimensions of the part; 4) to improve the surface of some steels of increased strength after manual gas cutting. When stitching long edges of sheets of large size, edge-building machines are used, and end-cutters are used for processing.

Flexible. The most common works include rolling. In cold rolling, the ratio of bend radius to metal thickness must be at least 25 (for low alloy steels).

With a lower ratio, it is usually recommended to roll in a hot state. When folded in the rolls, the end portion of the sheet remains almost flat. In three-roll rollers, the width of this section can be 150200 mm. When the sheets are bent in the four roll rolls, this portion is from S to 2S depending on the length of the edge to be bent. After this operation, the sheet is installed in the rolls, the shaft axis and the sheet edge are aligned, and folding begins at the middle of the sheet.

Cleaning for welding. It is carried out manually with abrasive circles or brushes, on sandblasting plants, on shot blasting plants, by chemical means and with the help of ultra-sound. Cleaning with shaped circles and brushes is not productive. Cleaning at the sandblasting plant is more productive and widely used, but it has a significant drawback - it contaminates the air of the workshop. Shot blasting plants using metal sand from bleached cast iron are no less productive than plants using dry quartz sand;

pollution occurs to a much lesser extent.

During hydraulic jet cleaning, pulp is performed (mixture of sand and

water) directed to the part by compressed air, no contamination occurs.

1.8.3 Selection and justification of methods of article assembly and welding

Welding in protective gases.

Inert (argon, helium) and active (carbon dioxide) gases are used as protective ones, as well as various mixtures of inert or active gases and inert gases with active ones. This welding method has a number of significant advantages over those discussed above. It can be used to combine metals of a wide range of thicknesses - from tenths of fractions to tens of millimeters.

The use of inert gases significantly increases the stability of the arc. A significant difference in the thermophysical properties of protective gases and the use of their mixtures, changing the thermal efficiency of the arc and the conditions for introducing heat into the welded edges, significantly expand the technological capabilities of the arc. When welding in protective gases, the possibilities of changing the chemical composition of the weld metal are more limited compared to other welding methods and are possible due to changing the composition of the welding (additive) wire or changing the share of the main metal in the formation of the weld metal (welding mode), when the compositions of the main and electrode metals differ significantly.

Welding with melting electrode is performed in inert, active gases or their mixtures. The absence of spattering and associated corrosion sites is favorable when welding corrosion-resistant and heat-resistant steels. However, jet transfer is possible at currents above the critical one, in which burning during welding of sheet metal is possible. Addition to argon up to 3... 5% oxygen reduces the critical current. In addition, the creation of an oxidizing atmosphere in the arc zone also reduces the probability of formation of pores caused by hydrogen. The latter is achieved by using a mixture of argon with 15... 20% carbon dioxide. This reduces the consumption of expensive and scarce argon. However, with these gas additions, the carbon monoxide of the alloying elements increases, and with the addition of carbon dioxide, carburization of the seam metal is also possible. Addition to argon 5... 10% nitrogen can be increased in the weld metal. Nitrogen, being a strong austenizer, allows you to change the structure of the weld metal.

When low-carbon high-alloy steels are welded in carbon dioxide using low-carbon welding wires, if the initial carbon concentration in the welding bath is less than 0.10%, the metal is carburized by 0.02... 0,04 %. This is sufficient to dramatically reduce the resistance of the weld metal to intercrystalline corrosion. At the same time, the oxidizing atmosphere created in the arc due to the dissociation of carbon dioxide contributes to the burning of up to 50% of titanium and aluminum.

Manganese, silicon, etc., burn out slightly less. Therefore, when welding corrosion-resistant steels in carbon dioxide, welding wires containing deoxidizing and carbide-forming elements (aluminum, titanium and niobium) are used.

Special emulsions applied to the edges prior to welding should be used to reduce the possibility of sticking to the base splash metal. The use of pulse welding also allows a slight reduction in spattering. The presence of a difficult-to-remove oxide film on the surface of the seams makes welding of multi-pass seams in carbon dioxide almost impossible. Welding with melting electrode in protective gases is carried out semi-automatically or automatically at direct current of reverse polarity.

Flux welding.

This is one of the main methods of welding high alloyed steels with a thickness of 3... 50 mm has a great advantage over manual arc welding with coated electrodes due to the stability of the composition and properties of the metal along the entire length of the weld when welded with and without edge preparation.

Good formation of the surface of joints with fine flakiness and smooth transition to the base metal, the absence of splashes on the surface of the product significantly increases the corrosion resistance of welded joints. With this method, the labor intensity of preparatory work is reduced, since edge preparation is carried out on metal with a thickness of more than 12 mm (with manual welding over 3... 5 mm). Possible welding with increased clearance and without cutting steel edges up to 30... 40 mm. Reduction of losses on carbon monoxide, spraying and baking of electrodes by 10... 20% reduces the consumption of expensive welding wire.

Alloying through the wire is more preferred because it provides increased stability of the weld metal composition. During welding, non-oxidizing low-silicon fluoride and high-base fluxes are used, which create non-oxidizing or low-oxidizing mediums in the welding zone, which contribute to minimum fading of alloying elements. Residues of slag and flux on the surface of the joints, which can serve as corrosion points for welded joints on corrosive and heat resistant steels, must be carefully removed. The type of flux determines the preferred use for reverse polarity DC welding. At the same time increased depth of penetration is achieved.

1.8.10 Quality control of welded joints

The quality control of welding works begins even before the welder has begun welding the product. At the same time, the quality of the main metal, welding materials (electrodes, welding wire, flux, etc.), blanks entering the assembly, the state of the welding equipment and the quality of the assembly, as well as the qualification of welders are checked. All these activities are called pre-inspection .

In the process of welding, the appearance of the seam, its geometric dimensions are checked, the article is measured, continuous monitoring of the serviceability of the welding equipment is carried out, and the execution of the technological process is monitored. These operations constitute monitoring.

The last check step is to check the welding quality of the finished product. For this purpose, there are the following types of control: external inspection and measurement of welded joints, density testing, X-ray or gamma-ray transmission, ultrasound control, magnetic control methods, luminescent control method, metallographic studies, mechanical tests.

The type of quality control of the finished product is chosen depending on the purpose of the product and the requirements that are imposed on this product by the specifications or GOST.

Section 3 Calculation and Planning of Main Technical and Economic Parameters of Welded Structure Production

3.1 Organization of work planning in the welding area

Technical preparation of welding production is a set of measures for designing and mastering the production of new and improving manufactured welded structures and products, developing progressive technological processes of procurement, assembly and welding and equipping them on the basis of scientific achievements of technology and advanced production experience.

The tasks of technical preparation of welding production at the machine-building enterprise are:

- creation of the most advanced welded structures and products;

- development of new and improvement of existing technological processes of assembly and welding, provision of production with technological documentation;

- design and manufacture of technological equipment in the form of assembly and welding devices, conductors, etc.; - development of technical standards of labour intensity, consumption standards of main and auxiliary materials ;

- creation of prerequisites for cost-effective and rhythmic operation of assembly and welding shops and sections and the whole enterprise ;

- introduction of technologies and achievements of production methods, mechanization and automation of production processes, which provide growth of labor productivity, reduction of production cost and improvement of its quality in accordance with AETD, ESKD, AETPP systems ;

- Field process debugging.

As a result of technical preparation of production, all workshops of enterprises receive; a variety of technical documentation and technological equipment. The productions given technical training such as technically reasonable norms, specifications of materials and purchased semi-finished products, preparations and details, are widely used for the organization of production and compensation, in-plant planning, technical inspection, logistics, etc. of logistics, etc.

The organizational stage of the technical preparation of production includes the planning of equipment, calculation of its load, identification of the need for materials, semi-finished products of purchased products, the formation of contractual relations with customers and suppliers, etc.

One of the conditions for rational technological preparation of production is the correct choice of process options. This is due to the fact that modern technology allows you to produce the same products in different ways and with different economic efficiency. Thus, machine parts are manufactured by casting, forging and hot forging with subsequent machining. These processes are successfully replaced by cold stamping in combination with welding (stamped, welded, welded-cast parts, etc.). Choosing from several - possible options the most acceptable.

the technologist must find the optimal solution. For this, economic analysis of technological solutions is used.

To determine the Cost Effectiveness of the selected process variant, you can limit yourself to calculating the so-called process cost. It is a monetary expression of the amount of material and labor costs necessary to perform the work due to this process, without the cost of control and maintenance of production. The comparison of process costs with different technology options gives an idea of ​ ​ the cost-effectiveness of each of them.

3.2 Areas of improvement of welding production efficiency

Welding is one of the leading technological processes of creating the material basis of modern civilization.

More than half of the national product of industrialized countries is produced through welding and related technologies. In many cases, welding is the most efficient way to create permanent joints of structural materials.

In protective gases (MIG/MAG, TIG), contact welding (friction, diffusion), laser welding, electron beam, hybrid methods (MAG + laser ).

Arc and contact welding will remain the dominant method of metal bonding.

Solving Welding Problems

Option one. Hire more unskilled labor from neighboring countries.

Option two. Leave everything as it is, constantly repair equipment manufactured at the end of the last century, rely on experienced welders. Going this way, you should not count on high performance, product quality and customer respect.

Option three. Civilized. Update the welding equipment fleet, send welders and engineers to advanced training courses, introduce an effective quality management system, begin the introduction of new welding technologies, without forgetting about ensuring normal working conditions - ventilation, heating, lighting

Key Terms and Definitions

Equipment Maintenance and Repair System - A set of interconnected tools, maintenance and repair documentation and executors necessary to maintain and restore the quality of products included in this system.

Welding Equipment Maintenance (Preventive Maintenance, Technical Care) - Set of operations to maintain equipment serviceability.

Repair - A set of operations to restore the serviceability or operability of products.

Maintenance (Repair) Periodicity - The time interval or operating time between this type of maintenance (repair) and the subsequent one of the same type or other of greater complexity. (Note: the type of maintenance (repair) means maintenance (repair) allocated by one of the characteristics: stage of existence, periodicity, scope of work, operating conditions, regulation, etc.).

Periodic Maintenance - Maintenance performed at operating time or time intervals specified in the operating documentation.

Regulated maintenance - Maintenance provided for in the regulatory and technical or operational documentation and performed with a periodicity and in the scope established in it, regardless of the technical condition of the product at the time of the start of maintenance.

Scheduled Maintenance - Maintenance to be performed in accordance with the requirements of the regulatory and technical or operational documentation.

Overhaul - Repair performed to restore the serviceability of a complete or close to complete restoration of the product resource with the replacement or restoration of any of its parts, including basic ones .

Medium repair - Repair performed to restore serviceability or partial restoration of the product life with replacement or restoration of components of a limited nomenclature and control of the technical condition of components.

Medium repair - Repair performed to restore serviceability or partial restoration of the product life with replacement or restoration of components of a limited nomenclature and control of the technical condition of components.

Scheduled repair - Repair, installation on which is carried out in accordance with the requirements of regulatory and technical documentation

3.3 Procedure for organization of welding production repair and maintenance

Operation of welding equipment shall be carried out in accordance with the requirements of the "Rules for Technical Operation of Electrical Installations of Consumers" (PTE).

Requirements of the Rules for technical operation of electrical installations of consumers:

Item 1.2.3 In order to perform the duties for the organization of electrical installations operation, the manager appoints the person responsible for the electrical facilities of the organization;

Item 3.1.21 The plant shall have a system for maintenance and repair of CO (plants), designed and implemented taking into account PTE, JI operating instructions, manufacturer's instructions and local conditions;

Item 3.1.22 Insulation resistance is measured at least once every 6 months, as well as in case of long interruptions in operation and mechanical damage;

Item 1.6.10 Installed equipment shall be provided with spare parts and materials. Condition, conditions of supply, storage is controlled by the responsible for the energy industry

The welding equipment maintenance and repair system in the organization includes:

the presence of a person responsible for the electric farm, who is obliged to provide timely and high-quality maintenance and preventive maintenance (P.1.2.6. PTE);

availability of welding equipment B, which is responsible for operation, as per para 3.1.23 of PTE in case of Gl service. the welder is responsible to him, who "Heads the development of schedules for the scheduled preventive and overhaul of welding equipment";

availability of the PPM schedules drawn up by the Energy Manager approved by the Technical Head of the Consumer (item 1.6.3. PTE)

PPM schedules shall provide for ongoing repairs (maintenance), medium and capital. Thus, for general industrial sources, the following sequence of scheduled repairs is recommended: start-up (K) - T - C - T - C - T - C - T - K. At the same time, the period between repairs is set depending on the complexity of the equipment, operating conditions, and work intensity. T - from 3 to 6 months, C- from 1-3 years, K- 3-6 years. So between the repair cycle from one overhaul to another is the service life of the welder, which, as a rule, is 6 years. Certificates for individual equipment grades indicate maintenance periods and scope of work, for example, for VDU 506 once a month, dust is cleaned and contact condition is checked, once every 3 months, control units are checked.

After a quality repair or creation of an iron masterpiece, you need to finish the work correctly:

Power off, stop gas supply;

Clean the generator of the remaining carbide;

Collect, put together tools;

Run the cable;

Wear a protective cap on the bottle;

Remove the work area;

Change clothes, spread work uniforms and protective tools in places;

All malfunctions report to management for proper resolution.

3.4 Measures to create and ensure prevention of safe working conditions in welding areas

Occupational safety in an emergency

The accident can occur, both due to the fault of the welder and with outside help. Failure to comply with the guidelines for the electric gas welder may affect the occurrence of fire, explosion or electric shock. Knowing the rules of conduct in emergency situations, it is possible to avoid and mitigate the consequences.

Actions required:

Inform management;

Inform specialized services to correct the problem;

Disconnect the electricity;

In case of fire, try to independently eliminate the problem using a fire extinguisher, water or sand, remove all flammable substances, turn off ventilation;

Provide first aid if there are victims;

In difficult situations, evacuate people.

The application of labor protection for welders, disciplines employees, increases the overall safety of the facility. Repetition of the briefing, reminds of possible consequences, thereby increasing responsibility in the performance of work. Not knowing the safety rules, does not remove responsibility for what is happening.

Safety of pressure vessel welding process by automatic welding under flux layer.

Safety and industrial sanitation regulations and regulations must be observed in the design and operation of industrial equipment. Safety regulations GOST 12.0.002 - 80 contain technical requirements aimed at protecting working personnel from the effects of objects and means of labor, safe operation of equipment and tools.

Arc welding of products in the environment of protective gases, under the flux layer, requires compliance with a certain set of safety and safety rules, which must be reflected in the process charts and strictly observed during welding. These rules are fixed in GOST 12.3.00386 Electric welding works. Safety requirements: I-1-VIII-89 changes.

In this work, studies were carried out on the influence of the main parameters of the electric arc welding mode (current strength, voltage value, welding speed) on the formation of the weld metal.

4.1 Analysis of hazardous and harmful factors arising during electric welding works and ways of their elimination

For this smelting method, there is a possibility of hazardous effects on the welder due to the following factors:

1) electric shock when a person touches the current-carrying parts of the electric circuit;

2) damage by the rays of the electric arch of the eyes and the open surface of the skin;

3) burns from metal drops and slag during welding;

4) poisoning with harmful gases emitted during welding and during contamination of premises with dust and evaporation of various substances;

5) explosions due to improper handling of compressed gas cylinders, either due to welding in flammable substances tanks, or welding near flammable and explosive substances;

6) fires from molten metal and slag during welding;

7) injuries of various mechanical nature during preparation of heavy articles for welding and during welding.

Conclusion

In accordance with the initial data - the design drawing, technical requirements for the welded structure, the production program, work was carried out on the technology of assembly and welding of the apparatus and the requirements for reliability and service life of the structure, the main materials for welding were selected; to ensure the equal strength of welds with the main material, appropriate welding materials were selected, methods for producing an undisturbed joint were chosen, and the equipment necessary for welding the structure; welding modes are calculated, information on methods for inspection of welded joints is given.

To increase productivity and improve working conditions for workers, as well as improve the quality of welds, mechanized welding in the environment of protective gas was replaced by automatic welding under a flux layer, thereby saving material resources due to the use of less qualified personnel

During welding of welded structure elements: bottoms to shell housing, the following technical and economic parameters can be provided:

- stability of production;

- quality of welds;

- reduction of material costs;

The proposed welding technology ensures cost-effectiveness when it is introduced into production.

The economic effect is 230,850 rubles/year.