Industrial autoclave. Construction Industry Autoclave Types, Main Parameters and Dimensions

The original analogue of the autoclave appeared back in 1795 in France. There was even a prize given to whoever invents reliable remedy for food preservation. It is connected with the fact that in those days the issue of food and human survival was in the first place. One confectioner under the name of Upper François won. He put food in a special container and boiled it in ordinary water. Thus, the first autoclave for home (domestic) use was obtained.

In 1880, another Frenchman, Charles Chamberland, created a real autoclave, in which the necessary pressure was created when temperature regime. The use of this invention was limited, and became widespread only among chemists and physicians, who were faced with the issue of sterilizing instruments.

In 1953 (only two hundred years later) the autoclave received further development. Lagarde has developed a unique autoclave for use in the textile industry - using the device to dye fabrics. And in 1978, Lagarde released the first professional autoclave for sterilizing food.

The USSR made a significant contribution to the development of autoclaves - a device was developed at the Institute of Petrochemical Synthesis high pressure. This gave impetus to the appearance of resin, polymer materials and synthetic oils.

At this time, there is a division of autoclaves into several branches - industrial devices, household (home) and medical devices appeared.

A few years later, literally in 1988, an autoclave for home canning appeared, which worked with the help of electrical energy. That is, absolutely anyone could connect the autoclave to the mains and cook food accordingly right at home.

A modern autoclave is an apparatus that is made in the form of a sealed chamber and is used to process material under pressure above atmospheric pressure. Under such conditions, the reaction is accelerated and a higher quality product is obtained.

When used in medicine, high-pressure autoclaves are used to sterilize instruments. If the device works without pressurization, then it is called drying cabinet or sterilizer.
For chemical reactions use special devices called chemical reactors. But in its essence and principle of operation, it is still the same autoclave.
The autoclave is widely used at home - with its help it is possible to both prepare canned food and sterilize food. And by installing a distiller, you will get purified water for cooling systems Vehicle and battery charge.

Design features

At present, autoclaves are made from especially strong alloyed steels of various grades: and 20K, 06KhN28, 16GS, 12Kh18N9T, 09G2S. The hull is constructed by welding or riveting links with convex bottoms. Special openings (lids) are made in the case through which it is convenient to load materials. Steam is supplied through the fitting to the pipe, and condensate is removed using a drain valve.

A modern industrial autoclave is equipped with a wide variety of devices: remote, external and internal heat exchangers, electric heaters, various other heating components, mixing devices (pneumatic, electromagnetic or mechanical), various devices regulation and measurement of pressure and temperature, other control and measuring sensors.

Main characteristics

in diameter this device, as a rule, varies from 1.2 meters to 8 meters. In length it can reach large sizes - from 2 to 40 meters! It is mounted on special supports that allow the metal to lengthen (expand) when heated. To avoid heat loss, the casing is made of special thermal insulation. Inside the autoclave there are rails with trolleys - this is the way products for sterilization are fed.

Changing the temperature regime and pressure occurs with the help of copper or platinum thermal resistance transducers.

In general, an industrial high pressure autoclave is a complex technological device.

Design differences

The main parameters of industrial autoclaves can be different: the capacity varies from a few centimeters to hundreds of meters, it is possible to work under pressure up to 150 MN / m2 and temperatures up to 500 degrees Celsius. The differences are due to the fact that such devices are used in a wide variety of industries:

construction- production and release building materials;
food- sterilization and food preparation;
chemical- production of various dyes, herbicides;
rubber- vulcanization of products;
metallurgy- recovery of precious and non-ferrous metals.

Different autoclaves are used for each individual process. For example, tunnel and dead-end units are involved in construction. They are a pipe three to six meters long and fifteen to twenty meters in diameter. Tunnel systems are closed with a lid on both sides, and dead-end systems - only on one side.

In the field of chemistry - glandless installations that do not require additional sealing. Such devices are equipped with a unique shielded electric motor. The rotor is protected by a screen made of a special non-magnetic material.

And in Food Industry there are a wide variety of models in size, principle of operation, both horizontal and vertical installation. IN horizontal installations it is possible to sterilize products not only in rigid containers, but also in semi-rigid or even soft ones. This is due to the fact that back pressure is created inside the unit in relation to each specific product package.

Recent developments are equipped with multi-level protection systems, systems automatic shutdown and locks. A special “protective jacket” is used, which reliably protects the seams and body materials from the influence of the coolant.

Additional equipment

Autoclaves are produced in any size and configuration, both in conventional and explosion-proof versions. Parameters are selected according to the wishes and requirements of the customer. There is also non-standard equipment for the chemical and oil industries.

The units are equipped with the following equipment:

ventilation system;
heating blocks;
vacuum pumps;
other systems for the regulation and control of vacuum, pressure, temperature and time.

The sale of industrial autoclaves today is carried out in a wide range choice - the needs of absolutely any customer will be satisfied.

The principle of operation of the device

After selecting a sterilization cycle, a vacuum is created inside the chamber with periodic heating. Thus, air is completely removed from the working chamber along with condensate. In accordance with the specified parameters, the operator creates the necessary indicators of temperature and pressure. This is the so-called sterilization phase.

IN normal conditions when the water temperature reaches 100 degrees Celsius, it stops heating further. If the water boils for a long time, then the moisture is transformed into steam. The process of intense evaporation begins. Steam is the same gas that creates overpressure in the chamber. In this case, the heat has an increased penetrating power, and therefore completely penetrates the structure of microorganisms, destroying them.

Modern industrial autoclaves use a vacuum function, which means removing oxygen in several cycles. Thanks to this technique, the sterilization process is many times faster with the preservation of all useful properties substances.

The pressure is then released and the drying phase begins. Remaining moisture quickly evaporates high temperatures. The sterilization cycle is fully automated by the machine, so there is no human error.

But the sterilization cycle can be controlled using the electronic touch screen. It also displays the parameters of the current program. Using the display, it is possible not only to select the autoclave cycle, but also to transfer the unit to the “standby” mode.

Achievements of scientific progress make it possible to manufacture industrial autoclaves of a wide variety of models, but the principle of operation of some differs little from others. In industry, autoclaves are used, both water-cooled and air-cooled.

Air cooling means cooling with a jet of cold air.
Water cooling It consists in the action of water, which circulates in the system with the help of a pump.

Autoclave operation

cameras high blood pressure and temperatures are actively used in hydrometallurgy, chemical, rubber, light, construction industries, and medicine. Especially when creating products from carbon fiber.

But autoclaves have been actively used in the food industry. Such devices are equipped with reliable multi-level protection and a special “jacket” that protects the main (external) material from the effects of a thermal carrier.

Around the world, about 1.5-2 million industrial autoclaves are constantly in operation.

Unit advantages:

automation and modernization production processes;
ensuring perfect sterility - microorganisms and infections are completely destroyed;
saving electrical energy;
possibility of operation in various fields and with a wide variety of materials;
high quality and reliability of sterilization;
autonomy and safety of the process.

It is for these reasons that autoclaves have become so widespread.

Variety of autoclaves

An autoclave is either a fully enclosed vessel or with a lid, designed to carry out technical processes that are necessary for the processing of materials by pressure and high temperature. Optionally, it can be equipped with pneumatic, electromagnetic or mechanical agitators. If necessary, it is equipped with remote, external or internal heat exchangers and other devices for measuring liquid level, pressure, temperature, and so on.

Industrial autoclaves are classified according to design features, type of heating, purpose, volume, pressure, lid design.

By design type

All autoclaves can be divided into two large blocks - vertical units, horizontal, rotating, swinging and column. Each of these types has its own obvious benefits and some shortcomings.

Vertical. The water medium is heated with the help of special heating elements. heating elements located inside the camera at the bottom of the device. Characterized compact structure. It has been widely used in the laboratory.
Horizontal. Most commonly used gas heating, which is characterized by a minimum heating time and greater flexibility in operation. This unit is usually used in industry for processing composite materials. Of the advantages of gas horizontal autoclave It should be emphasized the ease of installation, small dimensions, there is no need to equip a diathermal heating system. The costs of an electric autoclave are slightly higher. However, technology does not stand still - it already exists horizontal systems with a spiral energy-saving heat exchanger. At a price, a spiral heat exchanger will cost several times more than its gas counterpart. Payback periods are much higher.
Rotating. Suitable for working with suspended solids or mushy, namely for the leaching of mineral concentrates of various metals and ores. It looks like a sealed vessel with a removable lid. The latter is attached to the body with a sealing gasket and studs. Mounted on the outside of the cover stop valve with multilayer filter.
rocking. These devices allow the mixing of substances in such packages, for which sterilization in conventional autoclaves is considered unacceptable.
columnar. Commonly used to create alumina from bauxite. This unit allows you to simplify the labor and time costs in such a process.

By working volume

There are construction and chemical units with a capacity of hundreds cubic meters. For example, such high-pressure systems are used to produce bricks. There are also food (capacity - 5-100 liters) and laboratory autoclaves (0.25-5 liters).

By pressure

High and low pressure devices are available. The former include industrial autoclaves, while the latter include medical and food devices.

By arrangement of lids

Materials are loaded through special hatches, which are closed with lids. Tunnel autoclaves use two lids, and dead end autoclaves use one. The latter option is more widely used due to its structural simplicity.

By appointment

According to their purpose, industrial autoclaves can be divided into the following types:

food- used for food processing and canning.
Chemical- they usually work with a nominal pressure of 15-25 atmospheres, but there are also modifications under 100 atmospheres. They are divided into laboratory and classical industrial ones.
Construction- are used for the production of the same brick or more complex structures by the type of triplex, carbon, kevlar.
Medical- are used for sterilization of tools and materials.

According to European standard EN 13060

Autoclaves are divided into the following three classes:

"IN"- are intended for sterilization of any objects, including fabrics, both porous and hollow, and massive. The most functional devices.
"S"- are involved in the medical field. More economical systems, in contrast to class "B". They are considered the most in demand, due to the provision of an acceptable level of sterilization.
"N"- in terms of application, the most limited class: used for processing unpackaged items that do not contain gaps and voids.

Modern industrial gas and electric autoclaves are complex plants with high performance rates.

NIPKI PTO "Konservprod" offers the manufacture of industrial autoclaves, the quality of which has been proven by no production in the Russian Federation and other countries.

An autoclave is an apparatus designed to carry out a variety of processes when heated and under pressure exceeding atmospheric pressure. The presence of these conditions makes it possible to achieve an acceleration of the reaction, as well as an increase in the yield of the product.

Using in the chemical field to carry out a variety of chemical reactions, this unit called a chemical reactor. Used in medicine (sterilization at high temperatures and high pressure), this apparatus is only called an autoclave. If the sterilization process is carried out without exposure to high pressure, then the term sterilizer or drying cabinet is used.

Varieties of autoclaves

There are autoclaves vertical, column, horizontal, swinging, rotating. The autoclave can be presented in the form of a closed vessel or with a lid. Autoclaves can be equipped with external, remote, internal heat exchangers, as well as electromagnetic, pneumatic or mechanical agitators. In addition, autoclaves, as required, can be equipped with control and measuring devices for regulating and measuring temperature, liquid level, pressure, etc.

Autoclave design

The main parameters and design of industrial autoclaves are varied. They can have a capacity from several hundred m3 to tens of cm3 and are intended for operation at temperatures up to 5000C and under pressure up to 1500 kgf/cm2.

In the chemical industry, sealless autoclaves with a shielded electric motor are promising, which do not require sealing. In this electric motor, the rotor is mounted directly on the stirrer shaft, covered with a thin-walled sealed screen made of non-magnetic materials that do not prevent the penetration of magnetic lines of force from the stator to the motor rotor. In the process of production of building materials, dead-end or tunnel autoclaves are used. Outwardly, these are pipes from 15 to 20 meters in length and from three to six meters in diameter, covered with a lid.

Application of autoclaves

Autoclaves are used in:
- Hydrometallurgy (leaching and subsequent recovery from solutions of precious and non-ferrous metals, rare elements).
- Chemical industry (production of organic dyes and intermediates, herbicides, in synthesis processes).
- In the rubber industry (the process of vulcanization of technical products).
- In the production of building materials.
- In the canning industry.
- In the medical field.
- When creating objects from carbon fiber (to give them solid shapes).

STATE STANDARD OF THE UNION OF THE SSR

AUTOCLAVE FOR THE CONSTRUCTION INDUSTRY

TECHNICAL CONDITIONS

GOST 10037-83

IPK STANDARDS PUBLISHING HOUSE

Moscow

STATE STANDARD OF THE UNION OF THE SSR

Introduction date 01.01.85

This International Standard applies to autoclaves intended for thermal and moisture treatment. silicate brick and silicate products from cellular concrete.

The requirements of this standard are mandatory.

1. TYPES, MAIN PARAMETERS AND DIMENSIONS

1.1. Autoclaves are of two types:

AT - dead ends;

AP - through.

Working at temperatures up to 200° C - from steel grade 15K or 20K of the third category according to GOST 5520;

Working at temperatures above 200° C - from steel grade 15K or 20K of the fourth category according to GOST 5520 with verification mechanical properties and impact strength after mechanical aging of each sheet.

The use of steel grade 15K is not allowed in newly designed and modernized autoclaves.

Fistulas and porosity outer surface seam;

Undercuts with a depth of more than 0.5 mm and a length of more than 10% of the length of the seam;

Influxes, burns and unmelted craters;

Displacement and joint removal of the edges of the elements to be welded in excess of the norms provided for by this standard;

Non-compliance of shape and size with the requirements of standards, specifications or working drawings;

For joints subject to ultrasonic and magnetic particle flaw detection, surface scalyness and sinking between the weld beads, exceeding 0.2 mm in depth and 0.2 in lengthS, Where S- nominal thickness of the welded element in millimeters.

(Revised edition, Rev. No. 2).

2.5.20. The following internal defects are not allowed in welded joints:

Cracks of all types and directions;

fistulas;

Lack of penetration (non-fusion) located in the section of the welded joint.

2.5.21. In welded butt joints, during radiographic control, the following are not allowed:

Internal single pores, slag and other inclusions with a width (diameter) of more than 0.1 S and longer than 0.2 S;

- accumulations of internal pores, slag and other inclusions with a length of more than 0.3 S.

The total length of pores, slag and other inclusions for any section of the radiogram with a length of 10 S must not exceed 1.0 S. For a smaller length of radiograms, the allowable total length of pores and other inclusions (for any section of radiograms with a length of 10 S) decreases in proportion to the length of radiograms. In this case, the minimum length of radiograms cannot be less than 2 S.

Notes :

1. When different thickness welded elements, the maximum allowable size of defects is selected according to the smaller thickness.

2. For the sizes of pores and other inclusions, the following sizes of their images on radiograms should be taken:

Diameter - for spherical pores and inclusions;

Width and length - for elongated pores and inclusions.

3. An accumulation is three or more randomly arranged pores and other inclusions with a distance between any two adjacent edges of the images of pores or inclusions more than one, but not more than three of their maximum widths or diameters.

4. The size of an accumulation of pores and other inclusions is taken to be its length, measured along the most distant edges of the images of pores or inclusions in the accumulation.

5. Pores or inclusions with a distance between them not exceeding their maximum width or diameter, regardless of their number and relative position, are considered as one pore or one inclusion.

Notes:

1. The maximum allowable number of single defects for any 100 mm length of the weld seam is 3.

2. Extended defects found on fixation sensitivity are not allowed.

2.5.20 - 2.5.23.(Introduced additionally, rev. № 2).

2.6. Quality control of welded joints

Visual inspection and measurements of seams;

Mechanical tests;

Transillumination (gammagraphy);

Hydraulic test;

Capillary or magnetic particle inspection.

2.6.2. External inspection and measurement of welds must be carried out after cleaning the welds and adjacent surfaces of the base metal on both sides of the weld from slag, splashes and other contaminants.

All welded joints are subject to external inspection in order to identify the defects in them specified in paragraphs. - , And .

2.6.1, 2.6.2. (Revised edition, Rev. No. 2).

2.9. Reliability Requirements

12000 (14700 from 01/01/95) working cycles for autoclaves with an internal diameter of 2000 mm, except for long-length autoclaves with a length of 41000 mm;

11000 (12000 from 01.01.95) working cycles - for autoclaves with an internal diameter of 2600 and 3600 mm.

After the expiration of the assigned resource or the discovery of damage, the autoclaves must be subjected to a special technical examination to determine the possibility of further operation.

Each autoclave must be subjected to a technical inspection according to a special provision for the inspection and repair of autoclaves, agreed with the USSR Gosgortekhnadzor, after which a decision is made on the possibility and period of its further operation.

2.9.2. Indicators of maintainability of autoclaves:

Specific total operational labor intensity of current repairs - no more than 0.2 (0.19 from 01.01.95) man-hour / cycle;

The specific total operational duration of maintenance is no more than 0.33 (0.31 from 01.01.95) man-hours / cycle.

2.9.1, 2.9.2.(Changed edition, Rev. No. 1, 2).

3. SAFETY REQUIREMENTS

3.12. The outlet of the control valve must be directed to a safe place.

Operational documentation in accordance with GOST 2.601;

Passport of a pressure vessel (autoclave);

A set of drawings.

4.3. Mating flanges must be attached to autoclaves with working gaskets and fasteners.

4.4. Wear parts - in an amount that ensures the operation of autoclaves during the warranty period.

5. ACCEPTANCE RULES

5.1. To verify the conformity of autoclaves with the requirements of this standard, the manufacturer must carry out acceptance, periodic and operational tests.

5.2. Acceptance tests are subjected to each autoclave for compliance with the requirements of paragraphs. tab. , , (in terms of hydraulic tests), , , and also carry out at least three opening and closing of covers and checking the operation of the mechanism for lifting the cover and turning (cover or bayonet ring) in the adjustment mode on the technological stand, while ensuring the correct interaction of the mechanisms control, blocking and signaling systems.

(Revised edition, Rev. No. 2).

5.3. Before testing for compliance with the requirements of clause regarding hydraulic tests, the autoclave should be inspected without the use of magnifying instruments.

On the outer and inner surfaces there should be no captivity, sunsets, delaminations, rough marks, cracks, and on welds there should also be no sagging, undercuts, cracks, pores and other defects that reduce quality and worsen marketable condition. No dirt or foreign objects inside the case.

5.4. During inspection, check the presence and correctness of marking on the shells, bottoms, flanges and name plate. Check for weld marks on welds.

5.5. Periodic tests under operating conditions are subjected to one autoclave of each size at least once every three years.

Tests are carried out according to the program and methodology approved in the prescribed manner.

5.6. Operational tests are carried out according to the program and within the time limits established special rules Gosgortekhnadzor of the USSR.

6. TEST METHODS

6.1. The length, width, height, track are checked with a tape measure according to GOST 7502 with an upper measurement limit of 30,000 mm and a division value of 1 mm; the inner diameter is checked by measuring the outer circumference, converted to the inner diameter, taking into account the thickness of the sheets taken according to the certificate.

6.2. Working pressure (table. ) check with a manometer according to GOST 2405 with measurement limits from 0 to 2.5 MPa, accuracy class not lower than 1.5.

(Revised edition, Rev. No. 2).

6.3. Operating temperature (table. ) during operation is checked using a thermocouple with the parameters of GOST 3044.

(Revised edition, Rev. No. 1).

6.4. The mass of the autoclave (table) is checked by summing up the assembly units and parts included in the delivery.

6.5. Hydraulic tests (p. ) are carried out at the manufacturer with test pressure R pr, MPa (kgf / cm 2), calculated by the formulas:

For autoclaves with forged bayonet fittings

;(1)

For autoclaves with molded bayonet fittings

,(2)

Where [ s] 20 - allowable voltage at a temperature of 20° WITH;

[ s] t - allowable voltage at operating temperature;

R- working pressure, MPa (kgf / cm 2).

Testing time at trial pressure - not less than 10 min.

For hydraulic test use water with a temperature of at least 5° C and not higher than 40 ° C. The autoclave is considered to have passed the hydraulic test if there are no signs of rupture, leakage, tears and sweating in welded joints and on the base metal, visible residual deformations.

The rise in water pressure in the vessel is carried out by a pump without shocks and shocks.

Pressure equal to the working pressure is maintained during the entire time necessary to inspect the autoclave. Tapping the pressurized autoclave is prohibited.

The rate of pressure rise during hydrotesting is not more than 0.5 MPa/min.

(Revised edition, Rev. No. 2).

6.6. Check coatings(p.) carried out visually.

6.7. Assigned resource (p.

The autoclave from China is characterized by long service life, easy maintenance. The Chinese autoclave has everything Required documents and technical information.

The autoclave is used for thermal wet treatment of aerated concrete blocks, concrete hollow piles, sand-lime bricks, pulverized coal bricks, microporous silicate boards, heat-insulated asbestos boards, high-strength gypsum boards and other building materials that require a steaming process. In the process of thermo-moist processing, autoclave hardening of the processed products takes place.

The autoclave is a cylindrical horizontal welded vessel: a pipe with a possible length of 1-55 m and a possible diameter of 0.8-4.0 m, operating under steam pressure, equipped with one or two quick-release lids. Processed materials are loaded into the autoclave on trolleys, for which the autoclave is equipped with a rail track. For autoclaves (dead end) with a quick-release cover, materials are loaded and unloaded from one side. In autoclaves (pass-through) with two quick-release covers, loading is carried out from one side, and unloading from the opposite side. Autoclaves are equipped with a reliable signal blocking device providing safe operation; automated system condensate drain; a device for controlling the temperature difference between the upper and lower generatrices of the housing; automatic control device technological process steaming.

The work of autoclaves is carried out cyclically; the duration of the cycle is determined by the type of processed materials and the parameters of the steam used. The autoclave is mounted on supports that allow it to elongate when heated. Steam is supplied through a fitting to a perforated pipe placed inside the autoclave, the condensate is removed through a drain valve. Inside the autoclave, a rail track is laid along which trolleys with steamed products pass. To avoid large heat losses in environment all external surfaces of the autoclave are covered with thermal insulation, which contributes to the intensification of the technological process itself and, in addition, is one of the most important measures for labor protection.

The design of the vessels ensures reliability, durability and safety of operation during the estimated service life and provides for the possibility of technical certification, cleaning, washing, complete emptying, blowing, repair, operational control of metal and connections. The vessels are supplied necessary quantity hatches and inspection hatches, providing inspection, cleaning and repair of vessels, as well as installation and dismantling of collapsible internal devices. The materials used for the manufacture of vessels provide them reliable performance during the estimated service life, taking into account the specified operating conditions (design pressure, negative minimum and maximum design temperatures), the composition and nature of the medium (corrosion activity, explosion hazard, toxicity, etc.) and the effect of ambient temperature.

All vessels are subject to hydraulic testing after their manufacture. For hydraulic testing of vessels, water with a temperature not lower than 5 °C and not higher than 40 °C is used.

Each vessel is delivered to the customer with a passport of the established form. The passport is accompanied by instructions for installation and operation. Each vessel is affixed with a plate made in accordance with the standard.

Technical Parameters of China Autoclave for Steaming Aerated Concrete, Silicate Brick

Index	Unit ism	Models and parameters
Index	Unit ism	φ1.65×21	φ2×31	φ2.25×31.5	φ2.4×31	φ2.5×31	φ2.6×32	φ2.68×38	φ2.85×38	φ3×36.5	φ3.2×46
Inner diameter		1.65		2.25				2.68	2.85
Effective length				31.5						36.5
Design pressure			1.4/1.6
Estimated temp.	O S		198/204
Slave. pressure			1.3/1.5
Working temp.	O S		194/200
Wednesday	Saturated steam, condensate
Distance of inner rails										1200	1230
Distance of inner rails		By user's request
Opening method	Manual side or top opening, hydraulic top opening
Overall dimension L×W×H	m×m	21.65×2.62×2.6	32.3×2.73 ×3.33	33.23×3.2 ×4.7	31.69×3.5 ×5.05	32.4×3.8 ×5.07	3.4×3.4 ×4.3	39.63×3.46 ×4.32	39.76×3.83 ×4.5	38.55×3.7 ×4.74	48.25×3.88 ×4.9

Control system uses Mitsubishi PLC+ programmable logic controller touch screen. During operation, you can switch to manual mode. The system will automatically complete the work process according to the set pressure curve.

System functions:

Warning of high pressure, temperature.
Alarm warning display.
Indication of the simultaneous comparison of the actual process curve and the set process curve.
Proportional control of intake and exhaust valves.
Automatic drainage control.
warning too high level water stagnation.
Manual control of each valve.
System Check Indication.
Indication and recording of temperature and pressure inside the autoclave.
Exhaust and intake valve opening indication.
Indication of the opening and closing status of the drain valve.
Indication of the state of presence and absence of pressure inside the autoclave.
Indication of the status of the autoclave lid switch.
Ready position indication of the system
Autoclave surface temperature display at 4 points.

STATE STANDARD OF THE UNION OF THE SSR

AUTOCLAVE FOR THE CONSTRUCTION INDUSTRY

TECHNICAL CONDITIONS

GOST 10037-83

IPK STANDARDS PUBLISHING HOUSE

Moscow

STATE STANDARD OF THE UNION OF THE SSR

Introduction date 01.01.85

This standard applies to autoclaves designed for thermal and moisture treatment of sand-lime bricks and silicate products made of cellular concrete.

The requirements of this standard are mandatory.

1. TYPES, MAIN PARAMETERS AND DIMENSIONS

1.1. Autoclaves are of two types:

AT - dead ends;

2. TECHNICAL REQUIREMENTS

2.1. General requirements

2.1.1. Autoclaves should be manufactured in accordance with the requirements of this standard, the Rules for the Design and Safe Operation of Pressure Vessels, approved by the USSR Gosgortekhnadzor, according to working drawings approved in the prescribed manner.

2.2. Design requirements

Table 1

Dimensions in mm

Working part length L	Working pressure, MPa, no more	Working temperature, °С	Rated value of track	dimensions with lids closed, no more
				Length for types

Note. At the request of the consumer, it is allowed to manufacture autoclaves of each standard size with a length L up to 41000 mm.

On a dead-end autoclave, the inner diameter of the body can be made according to the actual diameter of the bottom within the tolerance for deviations in the bottom diameter.

Example symbol dead-end autoclave for pressure 1.2 MPa, inner diameter 3600 mm, working part length 27000 mm:

AutoclaveAT 1,2 - 3,6 ´ 27 GOST 10037-83

2.2.1. The design of autoclaves should provide:

Fast opening and closing of covers and sealing of their connection;

Continuous removal of condensate;

Automatic regulation of the technological process of steaming;

Remote control of the bayonet lock and opening - closing of the autoclave lid;

Fixing the lid in the open position;

Overlapping along the entire length of the teeth of the cover flange and the housing flange (bayonet ring) in accordance with Fig. ;

Clearance difference S between the tooth of the cover flange and the cavity of the body (bayonet ring) in accordance with Fig. for any two diametrically located engagement teeth - no more than 3 mm;

Freedom of axial temperature movement of the body;

Impossibility of opening pressure autoclave lids;

The impossibility of supplying steam to an open autoclave;

Visual control of steam pressure.

2.2.2. The design of the autoclave should provide for continuous recording on paper tape the following options:

Steam temperature inside the autoclave;

Temperature difference between the upper and lower generatrices of the housing in the central section.

The design of the autoclave should provide the ability to control the following parameters during operation:

The presence of condensate;

Case heating and cooling rates;

Values of thermal elongation of the body;

Steam pressure inside the autoclave;

Overlapping along the entire length of the teeth of the cover flange and body flange (bayonet ring) in accordance with Fig. ;

The difference between the gaps between the teeth of the cover flange and the cavity of the body flange (bayonet ring) for any two diametrically located teeth in accordance with Fig. .

Bayonet engagement

1 - bayonet ring; 2 - lid; 3 - frame

2.2.1, 2.2.2.(Changed edition, Rev. No. 1, 2).

2.3. Material Requirements

Working at temperatures up to 200 ° C - from steel grade 15K or 20K of the third category according to GOST 5520;

Working at temperatures above 200 ° C - from steel grade 15K or 20K of the fourth category according to GOST 5520 with a check of mechanical properties and impact strength after mechanical aging of each sheet.

The use of steel grade 15K is not allowed in newly designed and modernized autoclaves.

(Revised edition, Rev. No. 2).

2.3.2, 2.3.3. (Revised edition, Rev. No. 2).

(Revised edition, Rev. No. 2).

Single shells and other similar defects located at a distance of St. 50 mm, no more than 5 mm each, but no more than 8 pcs. for 1 linear meter;

Roughness and waviness not more than 4 mm high;

The remains of feeders and bays with a height of not more than 3 mm;

Remains of profits with a height of not more than 4 mm.

Local surface depressions, sinkholes and solder joints with a size of not more than 4 mm are subject to cutting and cleaning.

Metallized burn in the form of a film with a thickness of not more than 2 mm is subject to embossing.

Cracks of all types and directions without corrections are not allowed.

2.3.8. Casting defects, the dimensions and number of which are more than those indicated in paragraphs. and , should be corrected by welding.

2.3.9. On castings made of steel grade 20L or 25L, defects up to ⅛ of the thickness of the part in the place of the defect and with an area of \u200b\u200bnot more than 50 cm2 each, located dispersed in an amount of not more than 4 pcs. on the part, it should be corrected by welding without subsequent heat treatment, and from steel grade 35L - with subsequent heat treatment. Defects with a depth of up to 1/3 of the thickness of the casting in the place of the defect and an area of not more than 300 cm2 each in an amount of not more than 4 pcs. on the part should be corrected by welding followed by heat treatment.

Details with defects depth of St. 1/3 of the thickness of the part itself at the site of the defect cannot be corrected.

2.3.11. Autoclaves should be made from materials whose quality must be confirmed by certificates or test results. Certificate data or material test results should be indicated in the autoclave passport.

2.4. Manufacturing Requirements

2.4.1. Methods for assembling elements for welding must ensure the correct mutual arrangement mating elements and free access to welding.

2.4.2. The manufacturer in the manufacture of autoclaves must carry out step-by-step control.

2.4.3. On the sheets accepted for the manufacture of shells, the marking of the metal manufacturer must be preserved, and in the case of their cutting into blanks, the marking must be transferred to each blank.

2.4.4. Each workpiece or its parts must be marked with the following data:

Steel mark;

Number of batch-melting;

Sheet number.

On the shells of the autoclave there should be a marking consisting of the serial number of the shell and the designation of the working drawing.

The place of marking is the corner of the cut sheet, at a distance of 300 mm from the edges.

(Revised edition, Rev. No. 2).

2.4.5. Permissible deviations of the shell length ±5 mm.

2.4.6. (Deleted, Rev. No. 2).

2.4.7. Deviations of the length of the development of the circumference of the shells should not be more than:

±5 mm - for sheets 18 mm thick;

±7 mm » » » 20 mm;

±9 mm » » » 28 mm.

The length of the reamer is measured from both ends of the shell blank.

2.4.8. Deviations (due to any reasons) of the shell wall thickness should not be such that its actual thickness is lower than the calculated one.

2.4.9. Non-perpendicularity of the end of the shell to its generatrix is allowed up to 1 mm per 1 m of diameter, but not more than 3 mm for a shell with a diameter of 3.6 m.

It is allowed for one of the joined shells to cut an edge with a depth of not more than 2 mm for an arc length of up to 150 mm.

2.4.10. After assembly and welding, the autoclave bodies must meet the following requirements:

Length deviation - within ±0.3% of the nominal length of the hull (without bottom), but not more than ±75 mm;

The deviation from the straightness of the body must not exceed 30 mm.

Taper 4 mm - for bottoms with a wall thickness of 18 and 20 mm;

6 mm - for bottoms with a wall thickness of 28 mm (Fig. a);

The height of the corrugations on the cylindrical part of the bottom is more than 2 mm (Fig. e);

Thinning of the wall 15% of the original thickness of the workpiece and thickening of the side of the bottom 15%.

table 2

bottom wall thickness	Limit deviation(crap. d)		Concavity and convexity WITH(crap. b, V)	End runout f(crap. G)	Clearance between the template and the bottom surface in any diametrical section
	inner diameter D V	the heights of the spheres h V

2.4.17.(Deleted, Rev. No. 2).

* Crap. 6. (Deleted, Rev. No. 2).

2.4.18. It is allowed to install fittings with a diameter of not more than 150 mm on the longitudinal seams of the autoclave shells.

At the intersections of the seams, the installation of fittings is not allowed.

2.4.19. When welding fittings to the body, the distance between the edge of the welding seam of the fitting and the edge of the nearest weld must be at least the thickness of the body wall, but not less than 20 mm.

2.5. Welding Requirements

2.5.1. Welding work in the manufacture of autoclaves should be carried out in accordance with the "Rules for the certification of welders" approved by the USSR Gosgortekhnadzor.

2.5.2. In the manufacture of autoclaves, all types of welding are used, except for gas welding.

2.5.3. Welding work should be carried out at a positive ambient temperature.

2.5.4. Welding of the shells, welding of the bottoms and flanges of the autoclave body should be done with double-sided butt welds, and welding of fittings with fillet welds.

2.5.5. The edges of the elements prepared for welding and the surfaces adjacent to them must be cleaned to pure metal to a width of 20 mm.

2.5.6. The tacking of the elements to be welded should be carried out with filler materials intended for welding this metal.

2.5.7. Each weld is subject to branding, allowing you to identify the welder who made these seams. The stamp should be placed at a distance of 20 - 50 mm from the weld. On longitudinal seams, the stamp should be placed at the beginning or end of the seam at a distance of 100 mm from the annular seam. On the circumferential seams, the brand should be placed at the intersection of the circumferential weld with the longitudinal one and then every 2 m, but at the same time there should be at least three brands on each seam. Stamps should be placed on the outer surface of the autoclave.

2.5.8. Longitudinal welds of autoclaves should be located outside the central angle of the lower part of the body, the value of which should be at least 75°.

2.5.9. When welding supports or other elements to the autoclave body, the distance between the edge of the welded seam of the vessel and the edge of the welded seam of the element to be welded must be not less than the thickness of the autoclave body, but not less than 20 mm.

(Revised edition, Rev. No. 2).

2.5.10. The sutures should be positioned so that they can be passed through visual inspection and quality control and eliminate defects. Supports should not cross circumferential welds for a length of more than 0.35 pD.

2.5.12. The displacement of the edges of sheets in butt joints, which determine the strength of the autoclave, should not exceed 10% of the nominal thickness for more than thin sheet, but it should not be more than 3 mm (damn).

2.5.13. The displacement of the edges in the circumferential seams with a sheet thickness of up to 20 mm should not exceed 10% of the nominal thickness of a thinner sheet plus 1 mm, and with a sheet thickness of over 1 mm. 20 mm - 15% of the nominal thickness of a thinner sheet, but it should not be more than 5 mm (fig.).

2.5.14. The longitudinal seams of adjacent shells must be offset relative to each other by at least 100 mm between the axes of the seams.

2.5.16. The value of the tensile strength of the welded joint, obtained for each of the two samples, must correspond to the tensile strength of the base metal, while on one sample it is allowed to obtain the results below established norm for the base metal by no more than 7%.

2.5.17. When testing samples for bending, the bending angle must be at least 100 ° at D = 2S, Where D- punch diameter; S- the thickness of the test sample.

2.5.18. Welded joints of the "sheet-forging" type correspond to the "sheet-to-sheet" type, while the bending angle must be at least 70°.

Fistulas and porosity of the outer surface of the seam;

Undercuts with a depth of more than 0.5 mm and a length of more than 10% of the length of the seam;

Influxes, burns and unmelted craters;

Displacement and joint removal of the edges of the elements to be welded in excess of the norms provided for by this standard;

Non-compliance of the shape and dimensions with the requirements of standards, specifications or working drawings;

For joints subject to ultrasonic and magnetic particle flaw detection, surface scalyness and sinking between the weld beads, exceeding 0.2 mm in depth and 0.2 in length S, Where S- nominal thickness of the welded element in millimeters.

(Revised edition, Rev. No. 2).

2.5.20. The following internal defects are not allowed in welded joints:

Cracks of all types and directions;

Lack of penetration (non-fusion) located in the section of the welded joint.

2.5.21. In welded butt joints, during radiographic control, the following are not allowed:

Internal single pores, slag and other inclusions with a width (diameter) of more than 0.1 S and longer than 0.2 S;

- accumulations of internal pores, slag and other inclusions with a length of more than 0.3 S.

Notes:

1. With different thicknesses of the welded elements, the maximum allowable size of defects is selected according to the smaller thickness.

2. For the sizes of pores and other inclusions, the following sizes of their images on radiograms should be taken:

Diameter - for spherical pores and inclusions;

Width and length - for elongated pores and inclusions.

4. The size of an accumulation of pores and other inclusions is taken to be its length, measured along the most distant edges of the images of pores or inclusions in the accumulation.

5. Pores or inclusions with a distance between them not exceeding their maximum width or diameter, regardless of their number and relative position, are considered as one pore or one inclusion.

Table 3

Notes:

1. The maximum allowable number of single defects for any 100 mm length of the weld seam is 3.

2. Extended defects found on fixation sensitivity are not allowed.

2.5.20 - 2.5.23.(Introduced additionally, rev. № 2).

2.6. Quality control of welded joints

External examination and measurements of seams;

Mechanical tests;

Ultrasonic flaw detection;

Transillumination (gammagraphy);

Hydraulic test;

Capillary or magnetic particle inspection.

All welded joints are subject to external inspection in order to identify the defects in them specified in paragraphs. - , And .

2.6.1, 2.6.2. (Revised edition, Rev. No. 2).

2.6.12. The control method (ultrasonic flaw detection, transillumination, or a combination thereof) should be chosen based on the need for a more complete and accurate detection of unacceptable defects, taking into account the specifics physical properties metal, as well as the features of the method of control of welded joints of this type and products.

2.6.14. NDT 100% of the length of all welded joints of autoclave elements operating under pressure are subject to radiographic or ultrasonic methods, while quality control of welds of permanent joints of cast parts with each other, with rolled products or forgings must be performed by radiographic method.

2.6.13, 2.6.14.(Revised edition, Rev. No. 2).

2.6.15. Prior to inspection, the relevant sections of welded joints should be marked so that they can be easily found on inspection charts or gamma images.

2.9. Reliability Requirements

12000 (14700 from 01/01/95) working cycles for autoclaves with an internal diameter of 2000 mm, except for long-length autoclaves with a length of 41000 mm;

11000 (12000 from 01.01.95) working cycles - for autoclaves with an internal diameter of 2600 and 3600 mm.

After the expiration of the assigned resource or the discovery of damage, the autoclaves must be subjected to a special technical examination to determine the possibility of further operation.

2.9.2. Indicators of maintainability of autoclaves:

Specific total operational labor intensity of current repairs - no more than 0.2 (0.19 from 01.01.95) man-hour / cycle;

The specific total operational duration of maintenance is no more than 0.33 (0.31 from 01.01.95) man-hours / cycle.

2.9.1, 2.9.2.(Changed edition, Rev. No. 1, 2).

3. SAFETY REQUIREMENTS

3.12. The outlet of the control valve must be directed to a safe place.

(Revised edition, Rev. No. 1).

3.15.(Deleted, Rev. No. 2).

3.16. Permissible temperature difference between the upper and lower generatrices of the autoclave during pressure rise and holding is not more than 45 °С.

3.17. Permissible rate of heating and cooling of the autoclave body from strength conditions - no more than 5 °C/min.

3.16, 3.17.(Introduced additionally, Amendment No. 2).

4. COMPLETENESS

4.1. The autoclave kit should include:

Enclosure (with rail track):

Cover (for type AP - two covers);

Lid opening and closing mechanism (in case of hydraulic drive pumping station supplied with each autoclave with a diameter of 2600 and 3600 mm; one pumping station is supplied for a group of autoclaves with a diameter of 2000 mm, while a shut-off valve is installed on the oil pipeline of each autoclave);

Sub-autoclave supports;

Rollers with anti-theft device for mobile supports;

reference device;

A set of wear parts according to the list of spare parts and accessories;

Set of foundation bolts;

Remote Control;

Safety valve and pressure gauges (one for a dead-end autoclave, two for a straight-through autoclave);

Signal blocking and fixing device with control valve and "Key-brand";

System of continuous removal of condensate with the indicator of level;

Device for automatic control of the technological process of steaming, providing a predetermined rate of heating and cooling of the body (at the request of the consumer);

Device for controlling the rate of heating and cooling of the housing and the temperature difference between the upper and lower generatrices of the housing;

Flip bridge for autoclaves with a diameter of 2000 mm;

Low voltage complete devices.

(Revised edition, Rev. No. 2).

Operational documentation in accordance with GOST 2.601;

Passport of a pressure vessel (autoclave);

A set of drawings.

4.3. Mating flanges must be attached to autoclaves with working gaskets and fasteners.

4.4. Wear parts - in an amount that ensures the operation of autoclaves during the warranty period.

5. ACCEPTANCE RULES

5.1. To verify the conformity of autoclaves with the requirements of this standard, the manufacturer must carry out acceptance, periodic and operational tests.

(Revised edition, Rev. No. 2).

5.3. Before testing for compliance with the requirements of clause regarding hydraulic tests, the autoclave should be inspected without the use of magnifying instruments.

On the outer and inner surfaces there should be no captivity, sunsets, delaminations, rough marks, cracks, and on welds there should also be no sagging, undercuts, cracks, pores and other defects that reduce quality and worsen the presentation. No dirt or foreign objects inside the case.

5.4. During inspection, check the presence and correctness of marking on the shells, bottoms, flanges and name plate. Check for weld marks on welds.

5.5. Periodic tests under operating conditions are subjected to one autoclave of each size at least once every three years.

Tests are carried out according to the program and methodology approved in the prescribed manner.

5.6. Operational tests are carried out according to the program and within the time limits established by the special rules of the USSR Gosgortekhnadzor.

6. TEST METHODS

6.2. Working pressure (table.) is checked with a pressure gauge according to GOST 2405 with measurement limits from 0 to 2.5 MPa, accuracy class not lower than 1.5.

(Revised edition, Rev. No. 2).

6.3. Operating temperature (table.) during operation is checked using a thermocouple with the parameters of GOST 3044.

(Revised edition, Rev. No. 1).

6.4. The mass of the autoclave (table) is checked by summing up the assembly units and parts included in the delivery.

6.5. Hydraulic tests (p. ) are carried out at the manufacturer with test pressure R pr, MPa (kgf / cm2), calculated by the formulas:

For autoclaves with forged bayonet fittings

; (1)

For autoclaves with molded bayonet fittings

, (2)

where [s]20 - allowable voltage at a temperature of 20 ° C;

[s]t - allowable stress at operating temperature;

R- working pressure, MPa (kgf/cm2).

Testing time at trial pressure - not less than 10 min.

For hydraulic testing, water with a temperature not lower than 5 °C and not higher than 40 °C is used. The autoclave is considered to have passed the hydraulic test if there are no signs of rupture, leakage, tears and sweating in welded joints and on the base metal, visible residual deformations.

The rise in water pressure in the vessel is carried out by a pump without shocks and shocks.

Pressure equal to the working pressure is maintained during the entire time necessary to inspect the autoclave. Tapping the pressurized autoclave is prohibited.

The rate of pressure rise during hydrotesting is not more than 0.5 MPa/min.

(Revised edition, Rev. No. 2).

6.6. Inspection of paint and varnish coatings (p.) is carried out visually.

6.7. The assigned resource (p. ) is checked according to the data of controlled operation.

7. MARKING, PACKAGING, TRANSPORT AND STORAGE

7.1. Each autoclave must be affixed with a GOST 12969 and GOST 12971 containing the following data:

Name of the manufacturer or its trademark;

Autoclave index;

Serial number according to the numbering system of the manufacturer;

Year of issue;

Operating pressure;

Trial pressure;

Permissible maximum working temperature of the wall;

Designation of this standard.

The material, the location of the plate, the method of fastening and marking should ensure its safety during the entire service life of the autoclave.