CN112196350B - Hydraulic internally-hung lifting chimney FRP inner barrel mounting structure and construction method - Google Patents

Hydraulic internally-hung lifting chimney FRP inner barrel mounting structure and construction method Download PDF

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Publication number
CN112196350B
CN112196350B CN202011147677.XA CN202011147677A CN112196350B CN 112196350 B CN112196350 B CN 112196350B CN 202011147677 A CN202011147677 A CN 202011147677A CN 112196350 B CN112196350 B CN 112196350B
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lifting
section
inner cylinder
hydraulic
chimney
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CN112196350A (en
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方彦忠
姚添富
周颖
胡宇
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NO3 CONSTRUCTION ENGINEERING Co Ltd OF GUIZHOU CONSTRUCTION ENGINEERING GROUP
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NO3 CONSTRUCTION ENGINEERING Co Ltd OF GUIZHOU CONSTRUCTION ENGINEERING GROUP
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
    • E04H12/28—Chimney stacks, e.g. free-standing, or similar ducts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
    • E04H12/16—Prestressed structures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
    • E04H12/34—Arrangements for erecting or lowering towers, masts, poles, chimney stacks, or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
    • E04H12/34—Arrangements for erecting or lowering towers, masts, poles, chimney stacks, or the like
    • E04H12/344—Arrangements for lifting tower sections for placing additional sections under them

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  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Working Measures On Existing Buildindgs (AREA)

Abstract

The invention discloses a hydraulic internally-hung lifting chimney FRP inner cylinder mounting structure and a construction method, and relates to the technical field of chimneys. This chimney FRP inner tube mounting structure is promoted in hanging in hydraulic pressure, through the extension combination that utilizes lifting means, promotes weight, span, area unrestricted to it is comparatively safe to promote the process, and the component can be in the arbitrary position locking of promotion in-process, and arbitrary lifting mechanism also can adjust alone, and the adjustment precision is high, and the effectual controllability that has improved structure promotion in-process installation accuracy does benefit to assurance engineering quality.

Description

Hydraulic internally-hung lifting chimney FRP inner barrel mounting structure and construction method
Technical Field
The invention relates to the technical field of chimneys, in particular to a hydraulic internal hanging and lifting chimney FRP inner cylinder mounting structure and a construction method.
Background
A chimney is a structure that provides ventilation for hot flue gases or fumes from a boiler, furnace, stove or fireplace. The chimney is usually vertical, or as close to vertical as possible, to ensure a smooth flow of gases, the intake air entering the so-called chimney combustion or chimney effect.
The sleeve type chimney is high (generally more than 100 m), the inner barrel is located in the concrete chimney, the inner barrel can not be installed through a large crane after the concrete construction is finished, the chimney construction efficiency is affected, and the existing sleeve type chimney is poor in stability, efficiency, flexibility, portability and safety effect, so that a hydraulic inner hanging lifting chimney FRP inner barrel installation structure and a construction method are provided.
Disclosure of Invention
The invention provides a hydraulic internal hanging and lifting chimney FRP inner cylinder mounting structure and a construction method, which solve the problems in the background technology.
In order to achieve the purpose, the invention is realized by the following technical scheme: the utility model provides a hydraulic pressure is interior to hang and is promoted chimney FRP inner tube mounting structure, includes chimney concrete urceolus, chimney concrete urceolus is installed on the bearing platform, operation platform is installed to the inner chamber of chimney concrete urceolus, and operation platform's top and bottom are connected with the inner chamber of chimney concrete urceolus through promoting the support respectively, the last lifting means that installs of operation platform, and lifting means's inside is provided with the steel strand wires, the inner chamber of chimney concrete urceolus is provided with upper portion and has promoted the inner tube and take the promotion inner tube, the top position department cover that upper portion has promoted the inner tube surface is equipped with and promotes hoisting point and beaded finish, and promotes hoisting point and beaded finish and be connected with the steel strand wires, the bottom that the area promoted the inner tube is provided with self-control flat car, the bottom of chimney concrete urceolus one side is seted up and is link up to its inside construction door opening.
Optionally, an inner cavity of the chimney concrete outer cylinder is provided with a foundation bolt preformed hole located on the bearing platform.
Optionally, a trolley rail located below the upper lifted inner cylinder is arranged at the bottom of the inner cavity of the chimney concrete outer cylinder, and the trolley rail extends to the outside of the chimney concrete outer cylinder.
Optionally, the inner cavity of the chimney concrete outer cylinder is provided with a shake-stopping platform and a platform ladder.
An FRP inner cylinder mounting structure of a hydraulic internal-hanging lifting chimney and a construction method thereof comprise the following steps,
the first step is as follows:
s1, preparation work before hoisting
1. Firstly, the measuring instrument is qualified in response, and the structure is accurately positioned;
2. the construction road is smooth, and the construction site can meet the construction requirement;
3. after the construction of the bearing platform, the shaking stopping platform and the platform ladder is finished, the acceptance is qualified;
4. all the entering machines and equipment vehicles are qualified after overhaul and test operation;
5. mounting and debugging the lifting equipment;
1): please refer to fig. 4 for installation of the lifting device
a. The hydraulic lifting device is lifted to a construction platform at the top of the chimney from a lifting hole in the chimney by a winch arranged on the ground for assembly, the hydraulic lifting device is composed of a hydraulic pump station and a jack, and a hydraulic lifting system is arranged on a lifting support platform beam and comprises a hydraulic lifter, a sensor, a hydraulic oil pipe, a steel strand (the steel strand cannot have scars, hard bends and dead bends) and the like; electric welding operation is not allowed to be carried out on the periphery in the process of penetrating and installing the steel strand and the process of hoisting, so that electric injury is prevented;
b. manufacturing a steel strand lead frame and a steel strand uncoiling device according to an operation instruction;
c. the hole positions of the guide anchor and the safety anchor correspond to the hole positions of the anchorage device on the jack, and the phenomena of torsion and dislocation do not exist, so that the steel strands are prevented from being unparallel and twisted during jacking;
d. checking whether lubricant exists between the outer conical surfaces of the clamping pieces of the guide anchor and the safety anchor and the anchor plate hole or not so as to ensure that the anchor is loosened and clamped freely during jacking construction;
e. checking whether lubricant exists between the outer conical surfaces of the clamping pieces of the guide anchor and the safety anchor and the anchor plate hole or not so as to ensure that the anchor is loosened and clamped freely during jacking construction;
f. the jack and the base are fixed by bolts, the center hole of the jack is ensured to be aligned with the center of the reserved hole, and the upper part of the jack is fixed by a guide frame and provided with a guide device;
g. in the step a, the control system, the pump station and the valve body box are designed and installed on a design position, the installation position of the control system, the pump station and the valve body box takes the operating space of the steel strand into consideration when the steel strand is installed, and the pump station is placed to occupy all steel connecting beam platforms occupied by the pump station due to the fact that the operating space is too small, so that a channel crossing pump station is required to be built;
h. connecting oil pipes between the jack and the hydraulic pump according to the design number, wherein the oil pipes are connected in a one-to-one correspondence manner, and a main engineer checks the oil pipes after the connection is finished, and if errors occur, the oil pipes are corrected in time;
i. the control chamber is arranged at the jacking platform and is connected with an electric circuit according to a design number, and the control cable is laid and fixed in the air, so that personnel is prevented from trampling or hard objects are prevented from being damaged;
2): debugging hydraulic lifting device (ensuring one-to-one correspondence and correctness of operation and equipment operation actions in manual and automatic processes)
a. Starting each pump station, selecting a manual gear for the control cabinet, operating the jacks one by one through buttons of the control cabinet, performing cylinder extending and retracting actions, and checking whether the actions of the jacks are correct or not;
b. on the premise that the manual trial run of the system is correct in action, the control cabinet selects an automatic file, the system is started, the action harmony and synchronism of all jacks of the system are checked, if the design requirements are not met, reasons should be carefully searched, faults are eliminated, and after the action of the system is completely coordinated, the system is normally qualified in debugging;
c. regulating the flow of each pump station by combining the automatic test process of the system to ensure that the running speeds of jacks at all points are the same;
d. adjusting a detection assembly of the main top stroke detection device to ensure that the detection device is normally contacted and detected;
2): steel strand
a. Transporting the steel strand to the lower part of the platform (left and right rotation are separated), and uncoiling the steel strand from an uncoiling device according to an operation instruction;
b. opening all the clamping pieces connected with the jacking jacks by using a hydraulic pump station, and supporting the clamping pieces of the safety anchor;
c. the steel strand sequentially passes through a wire combing device, a safety anchor, a jacking jack and a guide anchor from bottom to top according to the serial number, extends out of the guide anchor for 2 meters, then anchors a clamping piece of the guide anchor, and compresses the steel strand by a rope clamp or compresses the steel strand by double rope clamps, the steel strand is arranged at intervals according to left and right turns, and a wire leading rod can be used for guiding in order to facilitate threading;
d. reversely anchoring the threaded steel strand on a lower hoisting point, controlling the exposed length of the steel strand to be 200mm, fastening the screws of the limiting plates by a specially-assigned person, checking that the steel strand can be used after the steel strand is jacked and loaded, and then sending the person to symmetrically fasten the screws of the limiting plates of the bearing anchor;
4): steel strand pre-tightening
Pre-tightening each steel strand by using a single pre-tightening method, tightening a clamping piece of the guide anchor after each pre-tightening is completed, and preventing the steel strands from falling off until the pre-tightening of the whole bundle of steel strands is completed; adjusting a jack to a jacking state, then pre-tightening the whole bundle of steel strands by using a main jack, taking down a clamping piece for pre-tightening on the guide anchor, and installing a limiting plate of the guide anchor;
5): jacking preparation work inspection
Before jacking, comprehensively and carefully checking a hydraulic system, a circuit system, a clamp system, a control and display system and a steel strand of the jacking device again, recording and registering the checking results in a table (a jack and clamp system installation and debugging condition checking table and a pump station and control system operation condition checking table), and reporting the total command after checking;
6): operated manually
a. Manually controlling all the jack main jacks to return to the initial position, and entering manual jacking preparation;
b. checking all equipment, a jack, an upper anchor, a lower anchor, each stroke switch, a control switch, a pressure gauge, a steel strand and an encoder;
7): jack jacking synchronous control and parameter setting
The parameter setting is carried out on a 'monitoring control' screen of an upper computer;
s2 FRP transportation rail and trolley manufacturing and mounting
1. Manufacturing method of small rail car
The specification is rectangular, channel steel is buckled with each other to form a trolley framework, angle steel inclined struts are welded at corners, 4 groove wheels are arranged on the lower sides of four corners, the contact parts are fully welded, and structural reinforcement measures are adopted to ensure the rigidity of the trolley;
2. track design
Selecting a track pitch according to the small wheel pitch; lofting is carried out according to the position and the size of a chimney door, the central position of the FRP inner cylinder, the specification of the trolley and the like so as to determine a track route, a track base is buckled on the ground, and reinforcing steel bars are laid on a web plate to serve as tracks (the wheels of the trolley are provided with grooves); the middle of the track is connected with channel steel to avoid track slippage; the track base channel steel can be welded with a transverse stiffening plate or concrete is poured to prevent the track base channel steel from being deformed under pressure, and in order to ensure that the FRP inner cylinders are vertically lifted, the tracks need to be laid horizontally to ensure that each section of the FRP inner cylinder is horizontal;
s3 setting internal and external operation platforms of FRP inner cylinder
According to the height of a standard section of a FRP inner barrel body, an operation platform must be erected during hoisting assembly operation, a movable operation platform is erected on an inlet-outlet channel on the outer surface of the barrel, the operation platform is moved away after assembly is completed, the operation platform is synchronously in place when a barrel section of the FRP inner barrel is in place, fixed platforms are erected at the rest positions, a temporary operation platform convenient to disassemble and assemble is erected on the inner side of the barrel, the platform is arranged on a trolley, the operation platform is installed when the barrel section is in place, the operation platform is disassembled after assembly is completed, the trolley is pulled out, the next barrel body is installed, and the operation platform is made of profile steel to ensure strength, rigidity and stability;
the second step is that: FRP inner barrel transport
Before the hoisting combination, the FRP inner cylinder which is qualified by inspection is transported to an installation site from a manufacturing site, in order to reduce the deformation of the FRP inner cylinder, a two-point symmetrical hoisting mode is adopted to hoist the FRP inner cylinder to a transport vehicle when the FRP inner cylinder is loaded and unloaded, the transport vehicle is provided with a special bracket which is temporarily manufactured, and a soft cushion is arranged to realize the soft contact of the FRP inner cylinder and the transport vehicle, so that the FRP inner cylinder is prevented from being damaged, the loading is stable, the cylinder and the vehicle are firmly fixed by a chain block, and the transport vehicle slowly and stably moves forward;
the third step: carrying FRP inner barrel to lifting position
Directly placing the cylinder on a self-made conveying rail trolley by using a 25T truck crane, and pushing the rail trolley and the cylinder to a central hoisting position;
the fourth step: lifting FRP inner barrel
1. A first stiffening ring position at the head of each section is provided with a lifting point, and a temporary lifting point is additionally arranged at the first stiffening ring position above the original bearing ring of the first section and is used as a replacement lifting point;
2. manufacturing of bearing ring and box-type hoop
According to the material performance and the hoisting requirement, in order to ensure the safe and rapid installation of the FRP inner cylinder, a bearing ring and a box-type hoop are additionally manufactured, so that the hydraulic lifting installation can be realized;
hoisting bearing ring
The first stiffening ring position of the first section of each section is arranged, and the first stiffening ring position above the original bearing ring position of the first section is arranged;
the specification is determined by an FRP inner cylinder manufacturer, the lifting requirement is met, and the thickness is not more than the thickness of the original stiffening ring;
hoop
The box-type ring beam is made of steel plates, the rolled steel plates and the FRP inner cylinder have the same radian to form a circle, and the joints are connected through bolts to realize pre-tightening;
the upper surface of the hoop is contacted with the bearing ring, and a rubber pad is added to protect the bearing ring;
a horizontal steel plate with the thickness of 20mm is welded on the lower surface of the hoop and is used as a horizontal bearing plate of a lifting point (the horizontal steel plate is welded with a limit baffle plate);
the side surface of the hoop is welded with a vertical stiffening plate for pressing a bottom anchor plate of the steel strand;
3. FRP chimney inner barrel lifting
The factory-leaving FRP inner cylinders are sections with different lengths, the sections are called sections after being combined, the number of the sections and the number of each section of the FRP section are designed according to the actual engineering (the inner cylinder is divided into 3 sections totally, the first section is 69.8m in length and is suspended on a platform with an elevation of 202.5m, the second section is 68.4m in length and is suspended on a platform with an elevation of 133.5m, the third section is 26.2m in length and is self-supported on the platform with an elevation of 44.8m, the sections are connected with each other through nonmetal expansion joints, the expansion joints are respectively positioned above the labels of 71.2m and 140.0m, the installation of the whole FRP chimney inner cylinder can be divided into three stages, the first stage is provided with 9 sections of FRP inner cylinders at the upper part and is lifted while being butted, then the 9 sections are used as a whole body to be lifted once at the position height and then fixed, and then the;
specific lifting installation procedure
a. Conveying the first section of the first FRP inner cylinder to the center of the chimney by using a rail trolley, and combining the first section of the first FRP inner cylinder with four groups of suspended steel strands to form a complete set of lifting system;
lifting the first section of inner cylinder by using a hydraulic lifting device to enable the lower end of the first section of inner cylinder to be positioned on the operation platform, wherein the lifting height exceeds the height of the next section of inner cylinder by about 50-100mm, so that the next section of inner cylinder can be conveniently pushed in, and enough personnel operation space is reserved for workers to bond paste openings conveniently;
conveying the second section of inner cylinder to the center of the chimney along a rail, adjusting the position of the second section of inner cylinder to align the second section of inner cylinder with the lower end of the first section of inner cylinder, loosening a lower chuck of a jack, descending the jack to drop the upper section of inner cylinder on the second section of inner cylinder, and then respectively carrying out butt joint and bonding on the first section of inner cylinder and the second section of inner cylinder from the inner side and the outer side;
removing the sling of the first section of the cylinder body, connecting the sling to the hanging ring of the second section of the cylinder body, and lifting the first section of the cylinder body and the second section of the cylinder body by the height of one section of the cylinder body;
repeating the steps to install the third section of the cylinder body to the last section of the cylinder body of the first section, namely, each section of the cylinder body above the expansion joint, connecting the expansion joint below the lowest section of the cylinder body of the first section, and lifting the section of the cylinder body to the bearing platform integrally to be fixed;
installing a second section of FRP inner barrel below the second section of FRP inner barrel by the same method as the method before until the lifting installation is finished;
4. hoist construction process monitoring
a. Lifting support platform deformation observation and node inspection
In the hoisting process of the first FRP inner cylinder, a level meter is used for regularly observing, one-time observation is added before and after the conversion of a hoisting point, the elastic recovery condition of the deflection of the steel beam is verified, the observation frequency is increased before the load is close to the design load of the platform, and the connection welding line of the bearing steel beam is often checked;
b. hydraulic lifting device operation monitoring
The operation operator is responsible for daily monitoring of the operation of the hydraulic lifting device and mainly carries out the operation according to the specification of assembling, using and maintaining the steel cable type hydraulic lifting device;
5. stability control in a lifting process
a. Stability of hydraulic lift
The chimney inner cylinder is integrally and synchronously lifted by adopting hydraulic lifting, and different from lifting by using a winch or a crane, the starting acceleration and the braking acceleration can be strictly controlled by adjusting the pressure and the flow of a system, so that the starting acceleration and the braking acceleration are close to zero and can be ignored, and the stability of a chimney structure and a lifting temporary support structure in the lifting process is ensured;
b. stability control of temporary structural design
The temporary structure design related to the integral lifting, including the reinforcement measures, fully considers the influence of various adverse factors, and ensures the stability and absolute safety of the integral lifting process;
c. control of hydraulic lift
Lifting counter-force values of all lifting points in the lifting process of the chimney structure are obtained through pre-analysis and calculation, and the maximum lifting force of each hydraulic lifter is correspondingly set in the hydraulic synchronous lifting system according to calculation data;
d. stability control of airborne staying
Because the lifting height is higher, in order to guarantee the safety of the lifting process, when the lifting process encounters an emergency, such as strong wind, heavy rain and the like, the lifting needs to be suspended, and the stability of the lifting system is mainly considered from the following aspects:
the hydraulic lifter is a unique mechanical and hydraulic self-locking device, so that the chimney structure can stay in the air for a long time in the integral lifting process;
the chimney structure is lifted in the reinforced concrete outer barrel, the influence of wind load is limited, and the chimney structure can be lifted when meeting severe weather such as strong wind, rainstorm and the like;
e. synchronous control measure for lifting process
In the integral synchronous lifting process of the chimney structure, the synchronism control of a hydraulic lifting system is an important link of stability control;
firstly, the safety of the self design of hydraulic synchronous lifting system equipment is guaranteed, and through a hydraulic self-locking device and a mechanical self-locking system arranged in a hydraulic loop, when the hydraulic lifter stops working or meets the accident conditions of power failure, oil pipe burst and the like, the hydraulic lifter can lock a steel strand for a long time, so that the safety of a lifted structure is ensured;
secondly, the integrity of the hydraulic lifting system equipment is ensured, and full debugging is carried out before formal lifting so as to ensure that the synchronization precision can be controlled within a preset safety range in the whole lifting process;
the fifth step: FRP inner tube connection
The manufacture of the connection and butt joint port of the inner cylinder is crucial, the construction is strictly carried out according to the process and the design, the forming of the butt joint port is firstly polished into a groove, then the groove is fixed, then the forming is carried out by hand pasting, the inner side and the outer side of the joint port are both pasted and formed according to the designed thickness, and the strength of the butt joint port is not lower than that of the pipe section body;
and a sixth step: installing expansion joint, bearing ring and shake-stopping point
1. Before the inner cylinder is installed, the bearing support and the shake-stopping fixed point component are manufactured and conveyed to an installation elevation platform; after the FRP inner cylinder is lifted to the mounting height, a bearing support is mounted under the condition that the jack is loaded, the bearing support is fixed by bolts according to the design requirement, and after the bearing support is mounted in place, the jack is slowly descended until the stress of the jack is relieved;
after the bearing support is installed, installing a shake-stopping fixed point;
2. installation of non-metal expansion joint
The non-metal expansion joint is connected with the chimney inner barrel through a flange, a gasket is made of fluororubber, the bolt butt joint is strengthened, the flange is prefabricated in a factory, and the flange is fixed with the FRP inner barrel through hand pasting and wound butt joint after being transported to the site;
the seventh step: and (5) after the defects are eliminated and completed, checking and accepting the installation.
The invention has the following beneficial effects:
1. this chimney FRP inner tube mounting structure is promoted in hydraulic pressure, through the extension combination that utilizes lifting means, promote weight, span, the area is unrestricted, and promote the process comparatively safe, and the component can be in the locking of the optional position of promotion in-process, arbitrary lifting means also can adjust alone, the adjustment precision is high, the effectual controllability that has improved the installation precision of structure promotion in-process, do benefit to and guarantee engineering quality, adopt flexible rigging bearing, as long as there is reasonable bearing hoisting point, it can satisfy any chimney design height to promote the height, hydraulic lifting means is light nimble, be convenient for installation and dismantlement, equipment investment is few, degree of mechanization is high, and can reuse, convenient operation is nimble, the security is good, high reliability, wide use, the commonality is strong, engineering cost has been reduced.
Drawings
FIG. 1 is a schematic structural view of the present invention;
FIG. 2 is a schematic top view of the self-made flat car according to the present invention;
FIG. 3 is a plan view of the load bearing support platform of the present invention;
FIG. 4 is a schematic view of a connection structure of the lifting apparatus of the present invention;
FIG. 5 is a schematic structural view of a bottom frame of the rail car of the present invention;
FIG. 6 is a schematic structural diagram of the inner barrel connection interface of the present invention.
In the figure: 1. a chimney concrete outer cylinder; 2. lifting the support; 3. lifting equipment; 4. steel strand wires; 5. an operating platform; 6. lifting a lifting point and a reinforcing ring; 7. the upper part is provided with a lifting inner cylinder; 8. a belt lifting inner cylinder; 9. self-manufacturing a flat trolley; 10. a trolley track; 11. reserving a hole for the foundation bolt; 12. and constructing a door opening.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1 to 6, the present invention provides a technical solution: a hydraulic internal hanging lifting chimney FRP inner cylinder mounting structure comprises a chimney concrete outer cylinder 1, the chimney concrete outer cylinder 1 is mounted on a bearing platform, an operation platform 5 is mounted in an inner cavity of the chimney concrete outer cylinder 1, the top and the bottom of the operation platform 5 are respectively connected with the inner cavity of the chimney concrete outer cylinder 1 through a lifting support 2, a lifting device 3 is mounted on the operation platform 5, a steel strand 4 is arranged inside the lifting device 3, an upper lifted inner cylinder 7 and a lifting inner cylinder 8 are arranged in the inner cavity of the chimney concrete outer cylinder 1, a lifting point and a reinforcing ring 6 are sleeved at the top position of the outer surface of the upper lifted inner cylinder 7, the lifting point and the reinforcing ring 6 are connected with the steel strand 4, a self-made flat trolley 9 is arranged at the bottom of the lifting inner cylinder 8, a construction door opening 12 penetrating into the chimney concrete outer cylinder 1 is formed in the bottom of one side of the chimney concrete outer cylinder, by utilizing the expansion combination of the lifting equipment, the lifting weight, span and area are not limited, the lifting process is safer, the component can be locked at any position in the lifting process, any lifter can be independently adjusted, the adjustment precision is high, the controllability of the installation precision in the structure lifting process is effectively improved, the engineering quality is favorably ensured, the flexible rigging is adopted for bearing, as long as a reasonable bearing lifting point is provided, the lifting height can meet the design height of any chimney, the hydraulic lifting equipment is light and flexible, convenient to install and disassemble, low in equipment investment, high in mechanization degree, reusable, convenient and flexible to operate, good in safety, high in reliability, wide in use range and strong in universality, the engineering cost is reduced, a supporting steel platform is designed at a proper space at a certain elevation on the inner wall of the reinforced concrete outer cylinder of the chimney in the installation and construction of the FRP inner cylinder of the hydraulic internal hanging lifting chimney, the hydraulic lifting device is installed on a supporting steel platform, the hydraulic jack device, the steel strand and the inner cylinder section with the hanging ring are connected through an anchoring system, finally the steel platform on the top of the outer cylinder is used as a support, the steel strand is used as a link, hydraulic oil is used as power, the hydraulic jack is driven, a section of height is lifted from top to bottom, a section of cylinder section is filled, and finally lifting installation of all cylinder sections is completed.
Wherein, the inner chamber of chimney concrete urceolus 1 is provided with rag bolt preformed hole 11 that is located on the bearing platform, through utilizing rag bolt preformed hole 11, can conveniently connect fixedly to the chimney, has guaranteed the bottom stable in structure of chimney.
Wherein, the bottom of the inner cavity of the chimney concrete outer barrel 1 is provided with a trolley track 10 which is positioned below the upper lifted inner barrel 7, the trolley track 10 extends to the outside of the chimney concrete outer barrel 1, and the trolley track 10 is arranged to facilitate the lifting inner barrel 8 and the self-made flat trolley 9 to move on the trolley track, so that subsequent installation is facilitated.
Wherein, the inner cavity of the chimney concrete outer barrel 1 is provided with a shake-stopping platform and a platform ladder, and the chimney can be installed in an auxiliary manner.
An FRP inner cylinder mounting structure of a hydraulic internal-hanging lifting chimney and a construction method thereof comprise the following steps,
the first step is as follows:
s1, preparation work before hoisting
1. Firstly, the measuring instrument is qualified in response, and the structure is accurately positioned;
2. the construction road is smooth, and the construction site can meet the construction requirement;
3. after the construction of the bearing platform, the shaking stopping platform and the platform ladder is finished, the acceptance is qualified;
4. all the entering machines and equipment vehicles are qualified after overhaul and test operation;
5. mounting and debugging of lifting equipment
1): lifting equipment installation
a. The hydraulic lifting device is lifted to a construction platform at the top of the chimney from a lifting hole in the chimney by a winch arranged on the ground for assembly, the hydraulic lifting device is composed of a hydraulic pump station and a jack, and a hydraulic lifting system is arranged on a lifting support platform beam and comprises a hydraulic lifter, a sensor, a hydraulic oil pipe, a steel strand (the steel strand cannot have scars, hard bends and dead bends) and the like; electric welding operation is not allowed to be carried out on the periphery in the process of penetrating and installing the steel strand and the process of hoisting, so that electric injury is prevented;
b. manufacturing a steel strand lead frame and a steel strand uncoiling device according to an operation instruction;
c. the hole positions of the guide anchor and the safety anchor correspond to the hole positions of the anchorage device on the jack, and the phenomena of torsion and dislocation do not exist, so that the steel strands are prevented from being unparallel and twisted during jacking;
d. checking whether lubricant exists between the outer conical surfaces of the clamping pieces of the guide anchor and the safety anchor and the anchor plate hole or not so as to ensure that the anchor is loosened and clamped freely during jacking construction;
e. checking whether lubricant exists between the outer conical surfaces of the clamping pieces of the guide anchor and the safety anchor and the anchor plate hole or not so as to ensure that the anchor is loosened and clamped freely during jacking construction;
f. the jack and the base are fixed by bolts, the center hole of the jack is ensured to be aligned with the center of the reserved hole, and the upper part of the jack is fixed by a guide frame and provided with a guide device;
g. in the step a, the control system, the pump station and the valve body box are designed and installed on a design position, the installation position of the control system, the pump station and the valve body box takes the operating space of the steel strand into consideration when the steel strand is installed, and the pump station is placed to occupy all steel connecting beam platforms occupied by the pump station due to the fact that the operating space is too small, so that a channel crossing pump station is required to be built;
h. connecting oil pipes between the jack and the hydraulic pump according to the design number, wherein the oil pipes are connected in a one-to-one correspondence manner, and a main engineer checks the oil pipes after the connection is finished, and if errors occur, the oil pipes are corrected in time;
i. the control chamber is arranged at the jacking platform and is connected with an electric circuit according to a design number, and the control cable is laid and fixed in the air, so that personnel is prevented from trampling or hard objects are prevented from being damaged;
2): debugging hydraulic lifting device (ensuring one-to-one correspondence and correctness of operation and equipment operation actions in manual and automatic processes)
a. Starting each pump station, selecting a manual gear for the control cabinet, operating the jacks one by one through buttons of the control cabinet, performing cylinder extending and retracting actions, and checking whether the actions of the jacks are correct or not;
b. on the premise that the manual trial run of the system is correct in action, the control cabinet selects an automatic file, the system is started, the action harmony and synchronism of all jacks of the system are checked, if the design requirements are not met, reasons should be carefully searched, faults are eliminated, and after the action of the system is completely coordinated, the system is normally qualified in debugging;
c. regulating the flow of each pump station by combining the automatic test process of the system to ensure that the running speeds of jacks at all points are the same;
d. adjusting a detection assembly of the main top stroke detection device to ensure that the detection device is normally contacted and detected;
2): steel strand
a. Transporting the steel strand to the lower part of the platform (left and right rotation are separated), and uncoiling the steel strand from an uncoiling device according to an operation instruction;
b. opening all the clamping pieces connected with the jacking jacks by using a hydraulic pump station, and supporting the clamping pieces of the safety anchor;
c. the steel strand sequentially passes through a wire combing device, a safety anchor, a jacking jack and a guide anchor from bottom to top according to the serial number, extends out of the guide anchor for 2 meters, then anchors a clamping piece of the guide anchor, and compresses the steel strand by a rope clamp or compresses the steel strand by double rope clamps, the steel strand is arranged at intervals according to left and right turns, and a wire leading rod can be used for guiding in order to facilitate threading;
d. reversely anchoring the threaded steel strand on a lower hoisting point, controlling the exposed length of the steel strand to be 200mm, fastening the screws of the limiting plates by a specially-assigned person, checking that the steel strand can be used after the steel strand is jacked and loaded, and then sending the person to symmetrically fasten the screws of the limiting plates of the bearing anchor;
4): steel strand pre-tightening
Pre-tightening each steel strand by using a single pre-tightening method, tightening a clamping piece of the guide anchor after each pre-tightening is completed, and preventing the steel strands from falling off until the pre-tightening of the whole bundle of steel strands is completed; adjusting a jack to a jacking state, then pre-tightening the whole bundle of steel strands by using a main jack, taking down a clamping piece for pre-tightening on the guide anchor, and installing a limiting plate of the guide anchor;
5): jacking preparation work inspection
Before jacking, comprehensively and carefully checking a hydraulic system, a circuit system, a clamp system, a control and display system and a steel strand of the jacking device again, recording and registering the checking results in a table (a jack and clamp system installation and debugging condition checking table and a pump station and control system operation condition checking table), and reporting the total command after checking;
6): operated manually
a. Manually controlling all the jack main jacks to return to the initial position, and entering manual jacking preparation;
b. checking all equipment, a jack, an upper anchor, a lower anchor, each stroke switch, a control switch, a pressure gauge, a steel strand and an encoder;
7): jack jacking synchronous control and parameter setting
The parameter setting is carried out on a 'monitoring control' screen of an upper computer;
s2 FRP transportation rail and trolley manufacturing and mounting
1. Manufacturing method of small rail car
The specification is rectangular, channel steel is buckled with each other to form a trolley framework, angle steel inclined struts are welded at corners, 4 groove wheels are arranged on the lower sides of four corners, the contact parts are fully welded, and structural reinforcement measures are adopted to ensure the rigidity of the trolley;
2. track design
Selecting a track pitch according to the small wheel pitch; lofting is carried out according to the position and the size of a chimney door, the central position of the FRP inner cylinder, the specification of the trolley and the like so as to determine a track route, a track base is buckled on the ground, and reinforcing steel bars are laid on a web plate to serve as tracks (the wheels of the trolley are provided with grooves); the middle of the track is connected with channel steel to avoid track slippage; the track base channel steel can be welded with a transverse stiffening plate or concrete is poured to prevent the track base channel steel from being deformed under pressure, and in order to ensure that the FRP inner cylinders are vertically lifted, the tracks need to be laid horizontally to ensure that each section of the FRP inner cylinder is horizontal;
s3 setting internal and external operation platforms of FRP inner cylinder
According to the height of a standard section of a FRP inner barrel body, an operation platform must be erected during hoisting assembly operation, a movable operation platform is erected on an inlet-outlet channel on the outer surface of the barrel, the operation platform is moved away after assembly is completed, the operation platform is synchronously in place when a barrel section of the FRP inner barrel is in place, fixed platforms are erected at the rest positions, a temporary operation platform convenient to disassemble and assemble is erected on the inner side of the barrel, the platform is arranged on a trolley, the operation platform is installed when the barrel section is in place, the operation platform is disassembled after assembly is completed, the trolley is pulled out, the next barrel body is installed, and the operation platform is made of profile steel to ensure strength, rigidity and stability;
the second step is that: FRP inner barrel transport
Before the hoisting combination, the FRP inner cylinder which is qualified by inspection is transported to an installation site from a manufacturing site, in order to reduce the deformation of the FRP inner cylinder, a two-point symmetrical hoisting mode is adopted to hoist the FRP inner cylinder to a transport vehicle when the FRP inner cylinder is loaded and unloaded, the transport vehicle is provided with a special bracket which is temporarily manufactured, and a soft cushion is arranged to realize the soft contact of the FRP inner cylinder and the transport vehicle, so that the FRP inner cylinder is prevented from being damaged, the loading is stable, the cylinder and the vehicle are firmly fixed by a chain block, and the transport vehicle slowly and stably moves forward;
the third step: carrying FRP inner barrel to lifting position
Directly placing the cylinder on a self-made conveying rail trolley by using a 25T truck crane, and pushing the rail trolley and the cylinder to a central hoisting position;
the fourth step: lifting FRP inner barrel
1. A first stiffening ring position at the head of each section is provided with a lifting point, and a temporary lifting point is additionally arranged at the first stiffening ring position above the original bearing ring of the first section and is used as a replacement lifting point;
2. manufacturing of bearing ring and box-type hoop
According to the material performance and the hoisting requirement, in order to ensure the safe and rapid installation of the FRP inner cylinder, a bearing ring and a box-type hoop are additionally manufactured, so that the hydraulic lifting installation can be realized;
hoisting bearing ring
The first stiffening ring position of the first section of each section is arranged, and the first stiffening ring position above the original bearing ring position of the first section is arranged;
the specification is determined by an FRP inner cylinder manufacturer, the lifting requirement is met, and the thickness is not more than the thickness of the original stiffening ring;
hoop
The box-type ring beam is made of steel plates, the rolled steel plates and the FRP inner cylinder have the same radian to form a circle, and the joints are connected through bolts to realize pre-tightening;
the upper surface of the hoop is contacted with the bearing ring, and a rubber pad is added to protect the bearing ring;
a horizontal steel plate with the thickness of 20mm is welded on the lower surface of the hoop and is used as a horizontal bearing plate of a lifting point (the horizontal steel plate is welded with a limit baffle plate);
the side surface of the hoop is welded with a vertical stiffening plate for pressing a bottom anchor plate of the steel strand;
3. FRP chimney inner barrel lifting
The factory-leaving FRP inner cylinders are sections with different lengths, the sections are called sections after being combined, the number of the sections and the number of each section of the FRP section are designed according to the actual engineering (the inner cylinder is divided into 3 sections totally, the first section is 69.8m in length and is suspended on a platform with an elevation of 202.5m, the second section is 68.4m in length and is suspended on a platform with an elevation of 133.5m, the third section is 26.2m in length and is self-supported on the platform with an elevation of 44.8m, the sections are connected with each other through nonmetal expansion joints, the expansion joints are respectively positioned above the labels of 71.2m and 140.0m, the installation of the whole FRP chimney inner cylinder can be divided into three stages, the first stage is provided with 9 sections of FRP inner cylinders at the upper part and is lifted while being butted, then the 9 sections are used as a whole body to be lifted once at the position height and then fixed, and then the two sections of FRP inner cylinders at the lower part are sequentially installed, lifted and fixed);
specific lifting installation procedure
a. Conveying the first section of the first FRP inner cylinder to the center of the chimney by using a rail trolley, and combining the first section of the first FRP inner cylinder with four groups of suspended steel strands to form a complete set of lifting system;
lifting the first section of inner cylinder by using a hydraulic lifting device to enable the lower end of the first section of inner cylinder to be positioned on the operation platform, wherein the lifting height exceeds the height of the next section of inner cylinder by about 50-100mm, so that the next section of inner cylinder can be conveniently pushed in, and enough personnel operation space is reserved for workers to bond paste openings conveniently;
conveying the second section of inner cylinder to the center of the chimney along a rail, adjusting the position of the second section of inner cylinder to align the second section of inner cylinder with the lower end of the first section of inner cylinder, loosening a lower chuck of a jack, descending the jack to drop the upper section of inner cylinder on the second section of inner cylinder, and then respectively carrying out butt joint and bonding on the first section of inner cylinder and the second section of inner cylinder from the inner side and the outer side;
removing the sling of the first section of the cylinder body, connecting the sling to the hanging ring of the second section of the cylinder body, and lifting the first section of the cylinder body and the second section of the cylinder body by the height of one section of the cylinder body;
repeating the steps to install the third section of the cylinder body to the last section of the cylinder body of the first section, namely, each section of the cylinder body above the expansion joint, connecting the expansion joint below the lowest section of the cylinder body of the first section, and lifting the section of the cylinder body to the bearing platform integrally to be fixed;
installing a second section of FRP inner barrel below the second section of FRP inner barrel by the same method as the method before until the lifting installation is finished;
4. hoist construction process monitoring
a. Lifting support platform deformation observation and node inspection
In the hoisting process of the first FRP inner cylinder, a level meter is used for regularly observing, one-time observation is added before and after the conversion of a hoisting point, the elastic recovery condition of the deflection of the steel beam is verified, the observation frequency is increased before the load is close to the design load of the platform, and the connection welding line of the bearing steel beam is often checked;
b. hydraulic lifting device operation monitoring
The operation operator is responsible for daily monitoring of the operation of the hydraulic lifting device and mainly carries out the operation according to the specification of assembling, using and maintaining the steel cable type hydraulic lifting device;
5. stability control in a lifting process
a. Stability of hydraulic lift
The chimney inner cylinder is integrally and synchronously lifted by adopting hydraulic lifting, and different from lifting by using a winch or a crane, the starting acceleration and the braking acceleration can be strictly controlled by adjusting the pressure and the flow of a system, so that the starting acceleration and the braking acceleration are close to zero and can be ignored, and the stability of a chimney structure and a lifting temporary support structure in the lifting process is ensured;
b. stability control of temporary structural design
The temporary structure design related to the integral lifting, including the reinforcement measures, fully considers the influence of various adverse factors, and ensures the stability and absolute safety of the integral lifting process;
c. control of hydraulic lift
Lifting counter-force values of all lifting points in the lifting process of the chimney structure are obtained through pre-analysis and calculation, and the maximum lifting force of each hydraulic lifter is correspondingly set in the hydraulic synchronous lifting system according to calculation data;
d. stability control of airborne staying
Because the lifting height is higher, in order to guarantee the safety of the lifting process, when the lifting process encounters an emergency, such as strong wind, heavy rain and the like, the lifting needs to be suspended, and the stability of the lifting system is mainly considered from the following aspects:
the hydraulic lifter is a unique mechanical and hydraulic self-locking device, so that the chimney structure can stay in the air for a long time in the integral lifting process;
the chimney structure is lifted in the reinforced concrete outer barrel, the influence of wind load is limited, and the chimney structure can be lifted when meeting severe weather such as strong wind, rainstorm and the like;
e. synchronous control measure for lifting process
In the integral synchronous lifting process of the chimney structure, the synchronism control of a hydraulic lifting system is an important link of stability control;
firstly, the safety of the self design of hydraulic synchronous lifting system equipment is guaranteed, and through a hydraulic self-locking device and a mechanical self-locking system arranged in a hydraulic loop, when the hydraulic lifter stops working or meets the accident conditions of power failure, oil pipe burst and the like, the hydraulic lifter can lock a steel strand for a long time, so that the safety of a lifted structure is ensured;
secondly, the integrity of the hydraulic lifting system equipment is ensured, and full debugging is carried out before formal lifting so as to ensure that the synchronization precision can be controlled within a preset safety range in the whole lifting process;
the fifth step: FRP inner tube connection
Referring to the schematic diagram of the interface of the inner cylinder in fig. 6, the manufacture of the interface of the inner cylinder connection is crucial and should be constructed strictly according to the process and design, the forming of the interface is firstly polished into a groove, then fixed and manufactured by a hand lay-up forming method, the inner side and the outer side of the interface are wrapped and laid up and formed according to the designed thickness, and the strength of the interface is not lower than that of the pipe section body;
and a sixth step: installing expansion joint, bearing ring and shake-stopping point
1. Before the inner cylinder is installed, the bearing support and the shake-stopping fixed point component are manufactured and conveyed to an installation elevation platform; after the FRP inner cylinder is lifted to the mounting height, a bearing support is mounted under the condition that the jack is loaded, the bearing support is fixed by bolts according to the design requirement, and after the bearing support is mounted in place, the jack is slowly descended until the stress of the jack is relieved;
after the bearing support is installed, installing a shake-stopping fixed point;
2. installation of non-metal expansion joint
The non-metal expansion joint is connected with the chimney inner barrel through a flange, a gasket is made of fluororubber, the bolt butt joint is strengthened, the flange is prefabricated in a factory, and the flange is fixed with the FRP inner barrel through hand pasting and wound butt joint after being transported to the site;
the seventh step: and (5) after the defects are eliminated and completed, checking and accepting the installation.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention; the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance, and furthermore, unless otherwise explicitly stated or limited, the terms "mounted," "connected," and "connected" are to be construed broadly and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.

Claims (1)

1. A construction method of a hydraulic internally-hung chimney FRP inner cylinder installation structure comprises a chimney concrete outer cylinder (1), the chimney concrete outer cylinder (1) is installed on a bearing platform, an operation platform (5) is installed in an inner cavity of the chimney concrete outer cylinder (1), the top and the bottom of the operation platform (5) are respectively connected with an inner cavity of the chimney concrete outer cylinder (1) through a lifting support (2), a lifting device (3) is installed on the operation platform (5), a steel strand (4) is arranged inside the lifting device (3), the inner cavity of the chimney concrete outer cylinder (1) is provided with an upper lifted inner cylinder (7) and a belt lifted inner cylinder (8), a lifting point and a reinforcing ring (6) are sleeved at the top position of the outer surface of the upper lifted inner cylinder (7), and the lifting point and the reinforcing ring (6) are connected with the steel strand (4), a self-made flat trolley (9) is arranged at the bottom of the lifting inner cylinder (8), and a construction door opening (12) penetrating into the chimney concrete outer cylinder (1) is formed at the bottom of one side of the chimney concrete outer cylinder; an inner cavity of the chimney concrete outer cylinder (1) is provided with a foundation bolt preformed hole (11) positioned on the bearing platform; the bottom of the inner cavity of the chimney concrete outer cylinder (1) is provided with a trolley track (10) which is positioned below the upper lifted inner cylinder (7), and the trolley track (10) extends to the outside of the chimney concrete outer cylinder (1); the inner cavity of the chimney concrete outer cylinder (1) is provided with a shake-stopping platform and a platform ladder;
the method is characterized in that: the construction method comprises the following steps of,
the first step is as follows:
s1, preparation work before hoisting
1. Firstly, the measuring instrument is qualified in response, and the structure is accurately positioned;
2. the construction road is smooth, and the construction site can meet the construction requirement;
3. after the construction of the bearing platform, the shaking stopping platform and the platform ladder is finished, the acceptance is qualified;
4. all the entering machines and equipment vehicles are qualified after overhaul and test operation;
5. mounting and debugging of lifting equipment
1): lifting equipment installation
a. The hydraulic lifting equipment is lifted to a chimney top construction platform from a chimney inner lifting hole by adopting a winch installed on the ground for assembly, the hydraulic lifting equipment is composed of a hydraulic pump station and a jack, a hydraulic lifting system is installed on a lifting support platform beam and comprises a hydraulic lifter, a sensor, a hydraulic oil pipe and a steel strand, and the steel strand cannot have scars, hard bends and dead bends; electric welding operation is not allowed to be carried out on the periphery in the process of penetrating and installing the steel strand and the process of hoisting, so that electric injury is prevented;
b. manufacturing a steel strand lead frame and a steel strand uncoiling device according to an operation instruction;
c. the hole positions of the guide anchor and the safety anchor correspond to the hole positions of the anchorage device on the jack, and the phenomena of torsion and dislocation do not exist, so that the steel strands are prevented from being unparallel and twisted during jacking;
d. checking whether lubricant exists between the outer conical surfaces of the clamping pieces of the guide anchor and the safety anchor and the anchor plate hole or not so as to ensure that the anchor is loosened and clamped freely during jacking construction;
e. the jack and the base are fixed by bolts, the center hole of the jack is ensured to be aligned with the center of the reserved hole, and the upper part of the jack is fixed by a guide frame and provided with a guide device;
f. in the step a, the control system, the pump station and the valve body box are designed and installed on a design position, the installation position of the control system, the pump station and the valve body box takes the operating space of the steel strand into consideration when the steel strand is installed, and the pump station is placed to occupy all steel connecting beam platforms occupied by the pump station due to the fact that the operating space is too small, so that a channel crossing pump station is required to be built;
g. connecting oil pipes between the jack and the hydraulic pump according to the design number, wherein the oil pipes are connected in a one-to-one correspondence manner, and a main engineer checks the oil pipes after the connection is finished, and if errors occur, the oil pipes are corrected in time;
h. the control chamber is arranged at the jacking platform and is connected with an electric circuit according to a design number, and the control cable is laid and fixed in the air, so that personnel is prevented from trampling or hard objects are prevented from being damaged;
2): the hydraulic lifting device is debugged to ensure that the operation and the equipment operation action are in one-to-one correspondence and correct in the manual and automatic processes;
a. starting each pump station, selecting a manual gear for the control cabinet, operating the jacks one by one through buttons of the control cabinet, performing cylinder extending and retracting actions, and checking whether the actions of the jacks are correct or not;
b. on the premise that the manual trial run of the system is correct in action, the control cabinet selects an automatic file, the system is started, the action harmony and synchronism of all jacks of the system are checked, if the design requirements are not met, reasons should be carefully searched, faults are eliminated, and after the action of the system is completely coordinated, the system is normally qualified in debugging;
c. regulating the flow of each pump station by combining the automatic test process of the system to ensure that the running speeds of jacks at all points are the same;
d. adjusting a detection assembly of the main top stroke detection device to ensure that the detection device is normally contacted and detected;
3): steel strand
a. Conveying the steel strand to the lower part of the platform, separating the steel strand from the left and right rotating parts, and uncoiling the steel strand by using an uncoiling device according to an operation instruction;
b. opening all the clamping pieces connected with the jacking jacks by using a hydraulic pump station, and supporting the clamping pieces of the safety anchor;
c. the steel strand sequentially passes through a wire combing device, a safety anchor, a jacking jack and a guide anchor from bottom to top according to the serial number, extends out of the guide anchor for 2 meters, then anchors a clamping piece of the guide anchor, and compresses the steel strand by a rope clamp or compresses the steel strand by double rope clamps, the steel strand is arranged at intervals according to left and right turns, and a wire leading rod can be used for guiding in order to facilitate threading;
d. reversely anchoring the threaded steel strand on a lower hoisting point, controlling the exposed length of the steel strand to be 200mm, fastening the screws of the limiting plates by a specially-assigned person, checking that the steel strand can be used after the steel strand is jacked and loaded, and then sending the person to symmetrically fasten the screws of the limiting plates of the bearing anchor;
4): steel strand pre-tightening
Pre-tightening each steel strand by using a single pre-tightening method, tightening a clamping piece of the guide anchor after each pre-tightening is completed, and preventing the steel strands from falling off until the pre-tightening of the whole bundle of steel strands is completed; adjusting a jack to a jacking state, then pre-tightening the whole bundle of steel strands by using a main jack, taking down a clamping piece for pre-tightening on the guide anchor, and installing a limiting plate of the guide anchor;
5): jacking preparation work inspection
Before jacking, comprehensively and carefully checking a hydraulic system, a circuit system, a clamp system, a control and display system and a steel strand of the jacking device again, recording and registering the checking results in a jack and clamp system installation and debugging condition checking table and a pump station and control system operation condition checking table, and reporting general command after checking;
6): operated manually
a. Manually controlling all the jack main jacks to return to the initial position, and entering manual jacking preparation;
b. checking all equipment, a jack, an upper anchor, a lower anchor, each stroke switch, a control switch, a pressure gauge, a steel strand and an encoder;
7): jack jacking synchronous control and parameter setting
The parameter setting is carried out on a 'monitoring control' screen of an upper computer;
s2 FRP transportation rail and trolley manufacturing and mounting
1. Manufacturing method of small rail car
The specification is rectangular, channel steel is buckled with each other to form a trolley framework, angle steel inclined struts are welded at corners, 4 groove wheels are arranged on the lower sides of four corners, the contact parts are fully welded, and structural reinforcement measures are adopted to ensure the rigidity of the trolley;
2. track design
Selecting a track pitch according to the small wheel pitch; according to the position and size of a chimney door, the central position of the FRP inner cylinder and the specification of the trolley, lofting is carried out to determine a track route, a track base is buckled on the ground, and reinforcing steel bars are laid on a web plate to serve as tracks corresponding to wheel grooves of the trolley; the middle of the track is connected with channel steel to avoid track slippage; the track base channel steel can be welded with a transverse stiffening plate or concrete is poured to prevent the track base channel steel from being deformed under pressure, and in order to ensure that the FRP inner cylinders are vertically lifted, the tracks need to be laid horizontally to ensure that each section of the FRP inner cylinder is horizontal;
s3 setting internal and external operation platforms of FRP inner cylinder
According to the height of a standard section of a FRP inner barrel body, an operation platform must be erected during hoisting assembly operation, a movable operation platform is erected on an inlet-outlet channel on the outer surface of the barrel, the operation platform is moved away after assembly is completed, the operation platform is synchronously in place when a barrel section of the FRP inner barrel is in place, fixed platforms are erected at the rest positions, a temporary operation platform convenient to disassemble and assemble is erected on the inner side of the barrel, the platform is arranged on a trolley, the operation platform is installed when the barrel section is in place, the operation platform is disassembled after assembly is completed, the trolley is pulled out, the next barrel body is installed, and the operation platform is made of profile steel to ensure strength, rigidity and stability;
the second step is that: FRP inner barrel transport
Before the hoisting combination, the FRP inner cylinder which is qualified by inspection is transported to an installation site from a manufacturing site, in order to reduce the deformation of the FRP inner cylinder, a two-point symmetrical hoisting mode is adopted to hoist the FRP inner cylinder to a transport vehicle when the FRP inner cylinder is loaded and unloaded, the transport vehicle is provided with a special bracket which is temporarily manufactured, and a soft cushion is arranged to realize the soft contact of the FRP inner cylinder and the transport vehicle, so that the FRP inner cylinder is prevented from being damaged, the loading is stable, the cylinder and the vehicle are firmly fixed by a chain block, and the transport vehicle slowly and stably moves forward;
the third step: carrying FRP inner barrel to lifting position
Directly placing the cylinder on a self-made conveying rail trolley by using a 25T automobile, and then pushing the rail trolley and the cylinder to a central hoisting position;
the fourth step: lifting FRP inner barrel
1. A first stiffening ring position at the head of each section is provided with a lifting point, and a temporary lifting point is additionally arranged at the first stiffening ring position above the original bearing ring of the first section and is used as a replacement lifting point;
2. manufacturing of bearing ring and box-type hoop
According to the material performance and the hoisting requirement, in order to ensure the safe and rapid installation of the FRP inner cylinder, a bearing ring and a box-type hoop are additionally manufactured, so that the hydraulic lifting installation can be realized;
hoisting bearing ring
The first stiffening ring position of the first section of each section is arranged, and the first stiffening ring position above the original bearing ring position of the first section is arranged;
the specification is determined by an FRP inner cylinder manufacturer, the lifting requirement is met, and the thickness is not more than the thickness of the original stiffening ring;
hoop
The box-type ring beam is made of steel plates, the rolled steel plates and the FRP inner cylinder have the same radian to form a circle, and the joints are connected through bolts to realize pre-tightening;
the upper surface of the hoop is contacted with the bearing ring, and a rubber pad is added to protect the bearing ring;
a horizontal steel plate with the thickness of 20mm is welded on the lower surface of the hoop and used as a horizontal bearing plate for lifting a lifting point, and a limit baffle is welded on the horizontal steel plate;
the side surface of the hoop is welded with a vertical stiffening plate for pressing a bottom anchor plate of the steel strand;
3. FRP chimney inner barrel lifting
The left FRP inner cylinders are sections with different lengths, the sections are combined to form sections, the number of the sections and the number of the sections of each FRP are designed according to the actual engineering, the inner cylinders are divided into 3 sections in total, the first section is 69.8m long, and the inner cylinders are hung on a platform with an elevation of 202.5 m; the second section is 68.4m long and is suspended on a platform with the elevation of 133.5 m; the third section is 26.2m long and is self-standing on a platform with the elevation of 44.8 m; the sections are connected through nonmetal expansion joints, the expansion joints are respectively positioned above the labels of 71.2m and 140.0m, the installation of the whole FRP chimney inner barrel can be divided into three stages, 9 sections of FRP inner barrels on the upper part are installed in the first stage, the FRP inner barrels are lifted while being butted, then the 9 sections are used as a whole, lifted once to the proper position and fixed, and then the two sections of FRP inner barrels on the lower part are sequentially installed, lifted and fixed;
specific lifting installation procedure
a. Conveying the first section of the first FRP inner cylinder to the center of the chimney by using a rail trolley, and combining the first section of the first FRP inner cylinder with four groups of suspended steel strands to form a complete set of lifting system;
lifting the first section of inner cylinder by using a hydraulic lifting device to enable the lower end of the first section of inner cylinder to be positioned on the operation platform, wherein the lifting height exceeds the height of the next section of inner cylinder by about 50-100mm, so that the next section of inner cylinder can be conveniently pushed in, and enough personnel operation space is reserved for workers to bond paste openings conveniently;
conveying the second section of inner cylinder to the center of the chimney along a rail, adjusting the position of the second section of inner cylinder to align the second section of inner cylinder with the lower end of the first section of inner cylinder, loosening a lower chuck of a jack, descending the jack to drop the upper section of inner cylinder on the second section of inner cylinder, and then respectively carrying out butt joint and bonding on the first section of inner cylinder and the second section of inner cylinder from the inner side and the outer side;
removing the sling of the first section of the cylinder body, connecting the sling to the hanging ring of the second section of the cylinder body, and lifting the first section of the cylinder body and the second section of the cylinder body by the height of one section of the cylinder body;
repeating the steps to install the third section of the cylinder body to the last section of the cylinder body of the first section, namely, each section of the cylinder body above the expansion joint, connecting the expansion joint below the lowest section of the cylinder body of the first section, and lifting the section of the cylinder body to the bearing platform integrally to be fixed;
installing a second section of FRP inner barrel below the second section of FRP inner barrel by the same method as the method before until the lifting installation is finished;
4. hoist construction process monitoring
a. Lifting support platform deformation observation and node inspection
In the hoisting process of the first FRP inner cylinder, a level meter is used for regularly observing, one-time observation is added before and after the conversion of a hoisting point, the elastic recovery condition of the deflection of the steel beam is verified, the observation frequency is increased before the load is close to the design load of the platform, and the connection welding line of the bearing steel beam is often checked;
b. hydraulic lifting device operation monitoring
The operation operator is responsible for daily monitoring of the operation of the hydraulic lifting device and mainly carries out the operation according to the specification of assembling, using and maintaining the steel cable type hydraulic lifting device;
5. stability control in a lifting process
a. Stability of hydraulic lift
The chimney inner cylinder is integrally and synchronously lifted by adopting hydraulic lifting, and different from lifting by using a winch or a crane, the starting acceleration and the braking acceleration can be strictly controlled by adjusting the pressure and the flow of a system, so that the starting acceleration and the braking acceleration are close to zero and can be ignored, and the stability of a chimney structure and a lifting temporary support structure in the lifting process is ensured;
b. stability control of temporary structural design
The temporary structure design related to the integral lifting, including the reinforcement measures, fully considers the influence of various adverse factors, and ensures the stability and absolute safety of the integral lifting process;
c. control of hydraulic lift
Lifting counter-force values of all lifting points in the lifting process of the chimney structure are obtained through pre-analysis and calculation, and the maximum lifting force of each hydraulic lifter is correspondingly set in the hydraulic synchronous lifting system according to calculation data;
d. stability control of airborne staying
Because the lifting height is higher, in order to guarantee the safety of the lifting process, when the lifting process encounters an emergency, such as strong wind and heavy rain, the lifting needs to be suspended, and the stability of the lifting system is mainly considered from the following aspects:
the hydraulic lifter is a unique mechanical and hydraulic self-locking device, so that the chimney structure can stay in the air for a long time in the integral lifting process;
the chimney structure is lifted in the reinforced concrete outer barrel, the influence of wind load is limited, and the chimney structure can be lifted when meeting strong wind and severe rainstorm weather;
e. synchronous control measure for lifting process
In the integral synchronous lifting process of the chimney structure, the synchronism control of a hydraulic lifting system is an important link of stability control;
firstly, the safety of the self design of hydraulic synchronous lifting system equipment is guaranteed, and through a hydraulic self-locking device and a mechanical self-locking system arranged in a hydraulic loop, when the hydraulic lifter stops working or meets the accident conditions of power failure and oil pipe burst, the hydraulic lifter can lock a steel strand for a long time, so that the safety of a lifted structure is ensured;
secondly, the integrity of the hydraulic lifting system equipment is ensured, and full debugging is carried out before formal lifting so as to ensure that the synchronization precision can be controlled within a preset safety range in the whole lifting process;
the fifth step: FRP inner tube connection
The manufacture of the connection and butt joint port of the inner cylinder is crucial, the construction is strictly carried out according to the process and the design, the forming of the butt joint port is firstly polished into a groove, then the groove is fixed, then the forming is carried out by hand pasting, the inner side and the outer side of the joint port are both pasted and formed according to the designed thickness, and the strength of the butt joint port is not lower than that of the pipe section body;
and a sixth step: installing expansion joint, bearing ring and shake-stopping point
1. Before the inner cylinder is installed, the bearing support and the shake-stopping fixed point component are manufactured and conveyed to an installation elevation platform; after the FRP inner cylinder is lifted to the mounting height, a bearing support is mounted under the condition that the jack is loaded, the bearing support is fixed by bolts according to the design requirement, and after the bearing support is mounted in place, the jack is slowly descended until the stress of the jack is relieved;
after the bearing support is installed, installing a shake-stopping fixed point;
2. installation of non-metal expansion joint
The non-metal expansion joint is connected with the chimney inner barrel through a flange, a gasket is made of fluororubber, the bolt butt joint is strengthened, the flange is prefabricated in a factory, and the flange is fixed with the FRP inner barrel through hand pasting and wound butt joint after being transported to the site;
the seventh step: and (5) after the defects are eliminated and completed, checking and accepting the installation.
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