The largest workload in today's pressure vessel manufacturing is welding (50% to 60%), especially for the welding of ring welds. Therefore, as long as the elimination of thick-ring welds can improve the technical and economic indicators of pressure vessels and increase productivity, the new flat-wound pressure vessel is effectively solving this problem.
1) Cylinder raw material: The cylinder of the new flat-wound pressure vessel is composed of a flat steel strip with an inner cylinder and an outer wall interlaced, and the inner cylinder is thin, and can be manufactured by general steel coil welding. A large number of raw materials are flat steel strips with simple rolling type, low price, reliable material and wide source. It has good mechanical properties, can be supplied in rolls, and has a very high utilization rate (its overall performance and cost are lower than any thick plate and sheet).
2) Machining: Only the outer wall of the inner cylinder needs to be ground, and the multi-layer structure of the cylindrical part of the container greatly reduces the processing amount in the rough machining process, and the metal utilization rate is high and simple.
3) Welding: Only the inner cylinder and the ends of the winding are welded, which greatly reduces the welding amount.
4) Quality inspection: the wall is easy to weld, the quality is easy to be guaranteed, easy to inspect, only the inner cylinder needs non-destructive testing, and the quality of the container is reliable.
5) Heat treatment: only the inner cylinder needs heat treatment, and no large heat treatment facilities are needed.
6) Manufacturing equipment: The large-scale simple winding machine is not the only special equipment in the manufacturing process of the new flat-wound pressure vessel. It is a simple winding device that supports the container to realize the rotation and the belt movement without the bed. Assembled steel such as channel steel or I-beam. It can be designed as a detachable structure, easy to operate, and high in winding efficiency, which provides favorable conditions for on-site winding of large-sized wound-type pressure vessels. In the manufacture of the new flat-wound container, only the inner cylinder is hoisted on the winding machine, and the flat winding is mechanized and automatically wound on the outside of the thin inner cylinder until the required thickness is required, and the container needs to be removed. The inner diameter of the wound container, the length of the barrel, the thickness of the wall and the weight can vary over a wide range. It not only ensures the winding quality of the steel strip, but also enables the steel strip to be wound with high efficiency.
7) Manufacturing cost: The manufacturing cost can be reduced by 30% to 50%, which is much lower than other multi-layer pressure vessels, and has significant economic benefits.
8) Manufacturing process technology: The winding machine tool is simple and easy to operate. According to the stress level of the layer under the working condition of the container, the initial winding data of each layer of steel strip can be calculated. The winding requirement can be achieved by a very simple winding machine. There is no “fastening†accuracy requirement between the winding layers of the steel strip, and it is not necessary to strictly control the interference between the interlayer bonding surfaces.
9) Production efficiency: It takes only 100 hours to 200 hours to wind a large container. The process is small and the cycle is short, which can double the work efficiency.
10) Safety and reliability: The barrel has no thick ring seam, and the intertwined steel belt layer has the function of “breathingâ€. The belt layer can withstand high pressure and protect the inner cylinder made of high-strength steel. effect. Even if there is a defect in the inner cylinder, the container will not be brittle and broken due to the prestressed winding of the belt layer; even if the inner cylinder is broken under various working pressures under the working pressure, it will “leak only to suppress explosionâ€, and the use is safe and reliable. No additional explosion-proof housing is required.
11) Thickness of the cylinder: The thickness of the inner cylinder is only 1/4 to 1/6 of the total thickness.
12) Stress distribution of inner cylinder: multi-layer combination, because the steel strip is pre-tensioned and wound, the axial stress of the container is small, and the structure of “low stress inner cylinder†can be made, so that the diameter and hoop stress distribution of the container under working condition Evenly.
13) Production management: very simple.
14) Others: The new flat-wound pressure vessel is light in weight and saves 80% in energy consumption during manufacturing.
According to the above introduction, the new flat-wound pressure vessel can not only ensure the most favorable manufacturing process conditions, but also improve the strength, and has the safety feature of “leak-proof and explosion-proofâ€; and since the steel strip is subjected to variable pre-stress winding, It can be adapted to normal temperature, low temperature, high temperature and strong corrosion. Therefore, it is a multi-layer pressure vessel structure with excellent structure, low manufacturing cost, higher operational safety and reliability than the existing similar forms of the container, and strong adaptability. It will be more widely used in petroleum, chemical, metallurgy, light industry, heavy machinery, food, gas, nuclear station, aviation and other fields, and has broad development prospects.
1) Cylinder raw material: The cylinder of the new flat-wound pressure vessel is composed of a flat steel strip with an inner cylinder and an outer wall interlaced, and the inner cylinder is thin, and can be manufactured by general steel coil welding. A large number of raw materials are flat steel strips with simple rolling type, low price, reliable material and wide source. It has good mechanical properties, can be supplied in rolls, and has a very high utilization rate (its overall performance and cost are lower than any thick plate and sheet).
2) Machining: Only the outer wall of the inner cylinder needs to be ground, and the multi-layer structure of the cylindrical part of the container greatly reduces the processing amount in the rough machining process, and the metal utilization rate is high and simple.
3) Welding: Only the inner cylinder and the ends of the winding are welded, which greatly reduces the welding amount.
4) Quality inspection: the wall is easy to weld, the quality is easy to be guaranteed, easy to inspect, only the inner cylinder needs non-destructive testing, and the quality of the container is reliable.
5) Heat treatment: only the inner cylinder needs heat treatment, and no large heat treatment facilities are needed.
6) Manufacturing equipment: The large-scale simple winding machine is not the only special equipment in the manufacturing process of the new flat-wound pressure vessel. It is a simple winding device that supports the container to realize the rotation and the belt movement without the bed. Assembled steel such as channel steel or I-beam. It can be designed as a detachable structure, easy to operate, and high in winding efficiency, which provides favorable conditions for on-site winding of large-sized wound-type pressure vessels. In the manufacture of the new flat-wound container, only the inner cylinder is hoisted on the winding machine, and the flat winding is mechanized and automatically wound on the outside of the thin inner cylinder until the required thickness is required, and the container needs to be removed. The inner diameter of the wound container, the length of the barrel, the thickness of the wall and the weight can vary over a wide range. It not only ensures the winding quality of the steel strip, but also enables the steel strip to be wound with high efficiency.
7) Manufacturing cost: The manufacturing cost can be reduced by 30% to 50%, which is much lower than other multi-layer pressure vessels, and has significant economic benefits.
8) Manufacturing process technology: The winding machine tool is simple and easy to operate. According to the stress level of the layer under the working condition of the container, the initial winding data of each layer of steel strip can be calculated. The winding requirement can be achieved by a very simple winding machine. There is no “fastening†accuracy requirement between the winding layers of the steel strip, and it is not necessary to strictly control the interference between the interlayer bonding surfaces.
9) Production efficiency: It takes only 100 hours to 200 hours to wind a large container. The process is small and the cycle is short, which can double the work efficiency.
10) Safety and reliability: The barrel has no thick ring seam, and the intertwined steel belt layer has the function of “breathingâ€. The belt layer can withstand high pressure and protect the inner cylinder made of high-strength steel. effect. Even if there is a defect in the inner cylinder, the container will not be brittle and broken due to the prestressed winding of the belt layer; even if the inner cylinder is broken under various working pressures under the working pressure, it will “leak only to suppress explosionâ€, and the use is safe and reliable. No additional explosion-proof housing is required.
11) Thickness of the cylinder: The thickness of the inner cylinder is only 1/4 to 1/6 of the total thickness.
12) Stress distribution of inner cylinder: multi-layer combination, because the steel strip is pre-tensioned and wound, the axial stress of the container is small, and the structure of “low stress inner cylinder†can be made, so that the diameter and hoop stress distribution of the container under working condition Evenly.
13) Production management: very simple.
14) Others: The new flat-wound pressure vessel is light in weight and saves 80% in energy consumption during manufacturing.
According to the above introduction, the new flat-wound pressure vessel can not only ensure the most favorable manufacturing process conditions, but also improve the strength, and has the safety feature of “leak-proof and explosion-proofâ€; and since the steel strip is subjected to variable pre-stress winding, It can be adapted to normal temperature, low temperature, high temperature and strong corrosion. Therefore, it is a multi-layer pressure vessel structure with excellent structure, low manufacturing cost, higher operational safety and reliability than the existing similar forms of the container, and strong adaptability. It will be more widely used in petroleum, chemical, metallurgy, light industry, heavy machinery, food, gas, nuclear station, aviation and other fields, and has broad development prospects.
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