CN117902469A - Air overturning construction method for large horizontal reactor - Google Patents
Air overturning construction method for large horizontal reactor Download PDFInfo
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- CN117902469A CN117902469A CN202311845210.6A CN202311845210A CN117902469A CN 117902469 A CN117902469 A CN 117902469A CN 202311845210 A CN202311845210 A CN 202311845210A CN 117902469 A CN117902469 A CN 117902469A
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- 238000010276 construction Methods 0.000 title claims abstract description 20
- 238000009434 installation Methods 0.000 claims abstract description 11
- 238000002360 preparation method Methods 0.000 claims abstract description 7
- 238000013439 planning Methods 0.000 claims abstract description 6
- 238000012790 confirmation Methods 0.000 claims abstract description 5
- 238000013459 approach Methods 0.000 claims abstract description 4
- 238000004513 sizing Methods 0.000 claims abstract description 4
- 229910000831 Steel Inorganic materials 0.000 claims description 57
- 239000010959 steel Substances 0.000 claims description 57
- 230000003014 reinforcing effect Effects 0.000 claims description 41
- 238000000034 method Methods 0.000 claims description 30
- 238000003466 welding Methods 0.000 claims description 11
- 239000004575 stone Substances 0.000 claims description 8
- 230000007306 turnover Effects 0.000 claims description 6
- 239000010410 layer Substances 0.000 claims description 5
- 238000012360 testing method Methods 0.000 claims description 5
- 238000005056 compaction Methods 0.000 claims description 4
- 239000002893 slag Substances 0.000 claims description 4
- 239000002344 surface layer Substances 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 3
- 238000005516 engineering process Methods 0.000 abstract description 3
- 238000010586 diagram Methods 0.000 description 8
- 241000219357 Cactaceae Species 0.000 description 4
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 4
- 238000007689 inspection Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 2
- 238000004364 calculation method Methods 0.000 description 2
- 238000006356 dehydrogenation reaction Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 239000001294 propane Substances 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 238000005452 bending Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000003137 locomotive effect Effects 0.000 description 1
- 238000007726 management method Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000009897 systematic effect Effects 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000012384 transportation and delivery Methods 0.000 description 1
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E30/00—Energy generation of nuclear origin
- Y02E30/30—Nuclear fission reactors
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Abstract
The invention discloses an aerial overturning construction method of a large horizontal reactor, which relates to the technical field of overturning and adjusting azimuth before hoisting for the large horizontal reactor with more external connecting pipes, complex structure and lateral loading to the field, in particular to an aerial overturning construction method of the large horizontal reactor, comprising the following steps: crane approach and assembly: after the main crane and the auxiliary crane enter the field, carrying out station positioning and assembly according to a hoisting plan; and (3) equipment entering and unloading: the large horizontal reactor is manufactured, and is transported to a specified position for hoisting by a transportation unit, and is driven in by a hoisting planning line, and the loading is required to be oriented according to the requirement; qualified equipment foundation acceptance, sizing block preparation, and confirmation of equipment installation conditions for the next step; the invention adopts two cranes, can realize continuous completion of equipment unloading, overturning and hoisting at one time, has advanced and reliable technology, is easy to operate, is economical and efficient, and has higher popularization and application values.
Description
Technical Field
The invention relates to the technical field of turning and azimuth adjustment before hoisting for a large horizontal reactor with more external connecting pipes and complex structure and side loading in the field, in particular to an air turning construction method for the large horizontal reactor.
Background
In recent years, domestic petrochemical industry and coal chemical industry have been unprecedented, and in order to pursue the best economic scale, the continuous large-scale development of the device has promoted the petrochemical equipment to increasingly develop to high, thick, heavy and oversized, and accordingly, new requirements are put forward for the design, manufacture, inspection, transportation and installation of the pressure vessel. On the basis of how to install the large-scale equipment on equipment foundation with severe construction conditions and narrow construction sites, a contractor unit needs to carry out systematic planning on various aspects such as equipment manufacture, transportation, construction site preparation, hoisting, safety management and the like so as to ensure that each link cannot cause problems, and the final installation quality and construction safety can be ensured.
The project installation project of producing propylene by dehydrogenation of 100 ten thousand tons of propane is accepted by our company in 2022. The reactor equipment completes the body preparation outside the field, top "cactus" is reserved, and two big takeovers in equipment bottom are accomplished outside the field along with equipment preparation, and equipment needs the lining construction of completion outside the field simultaneously, and the reactor transportation arrives the scene and is the side direction loading and enter the field, and the transportation state of entering is that the reactor base is not under, needs to overturn before equipment hoist and mount are put in place to equipment barrel wall thickness is thinner (thickness 25 mm), and equipment barrel outside has ferrule and structure crossbeam, and this has all increased great degree of difficulty for hoist and mount work.
The horizontal reactor of the device for preparing propylene by propane dehydrogenation is key core large-scale equipment of the device, and has the advantages of heavy lifting weight, large size, complex structure, multiple external connecting pipes and long extension. Often limited by site conditions, the reactor is mostly manufactured outside the site, and is laterally loaded to the site. The reactor needs to be turned over to adjust the azimuth before being lifted, the operation method usually adopts to set up a road timber pile or put a transfer tire, the equipment is lifted after being lifted to change the azimuth, the conventional method has complicated procedures, high labor intensity, large occupied space and large reservation requirement, the crane has longer operation period, large working amount of overhead operation and large risk.
Difficulty in hoisting and installing equipment
1. The bottom of the reactor is extended with a plurality of large connecting pipes, and the most protruded pipe orifice at the bottom is extended out of the equipment by 3.5m. Therefore, when the equipment is manufactured for delivery and transportation, the large connecting pipe at the bottom of the equipment cannot face to the right lower side. When the equipment is hoisted, the equipment needs to be overturned at high altitude, so that the pipe orifice at the bottom of the equipment is vertically downwards, and then the reactor is hoisted in place.
2. When the reactor is hoisted and overturned, a combined balance beam, a sling, a shackle and a pulley are required to be used, so that the hoisting process is ensured to be safe and stable, and the equipment body is prevented from being scratched by the steel wire rope or the steel wire rope is prevented from being damaged.
3. The reactor equipment is turned over by the offset weight generated by the large D/H/F connecting pipe (dead weight 30 t) at the bottom of the equipment.
4. The equipment has large volume and weight, the net weight of the reactor is 301150kg, the weight of the cactus component is removed to 36567kg, the on-site hoisting weight is about 264583kg, and the equipment installation elevation is higher (16.15 m), so the hoisting difficulty is higher.
Disclosure of Invention
In order to solve the problems, the invention provides the aerial overturning construction method for the large horizontal reactor, which can ensure smooth and steady overturning of the large horizontal reactor, and has the advantages of simple working procedure, low labor intensity, short operation period of a crane and high safety.
The invention relates to an aerial overturning construction method of a large horizontal reactor, which specifically comprises the following steps:
s1, crane approach and assembly: after the main crane and the auxiliary crane enter the field, carrying out station positioning and assembly according to a hoisting plan;
s2, equipment entering and unloading: the large-scale horizontal reactor equipment is manufactured, and is transported to a specified position for hoisting by a transportation unit, and particularly enters by a hoisting planning line, and the loading is required to be oriented according to the requirement;
S3, checking and accepting the equipment foundation, preparing sizing blocks, and confirming that equipment installation conditions are met for the next step;
s4, symmetrically arranging two reinforcing rings arranged along the circumference of the large horizontal reactor on the large horizontal reactor, arranging two main crane lugs on the same reinforcing ring, and correspondingly arranging the main crane lugs on the two reinforcing rings;
Two annular rope baffle plates are arranged in the middle of the large horizontal reactor, an auxiliary lifting lug is arranged on each rope baffle plate, and the projection of the main crane lug and the auxiliary lifting lug on the axial section of the large horizontal reactor meets the following relation:
the main crane lugs and the auxiliary lifting lugs are respectively positioned at two sides of the shaft section, and the two main crane lugs are symmetrically arranged about the shaft section passing through the auxiliary lifting lugs;
Checking the welding quality of the lifting lug, if the lifting lug is unqualified, strictly forbidden to lift and timely notifying related departments of treatment, and carrying out the next step after the lifting lug is qualified;
S5, warning pulling and setting: a warning area is arranged before the equipment is hoisted, a striking warning line is arranged around the equipment, and no personnel are forbidden to enter the equipment;
s6, checking the station position of the crane: after the main crane and the auxiliary crane stand according to the specified positions, the main crane and the auxiliary crane are confirmed by the quality and technicians according to a common check confirmation table;
S7, selecting and checking hoisting rigging: selecting proper rigging according to the weight and the specification and the size of the equipment and combining the existing rigging condition and the rigging performance;
S8, checking the pre-stress of the sling: after each preparation work is finished, a connecting lifting hook at one end of a lifting appliance of the main crane is respectively connected with two main crane lugs on the same reinforcing ring, two ends of the lifting appliance on the auxiliary crane are respectively connected with two auxiliary lifting lugs, and the main crane and the auxiliary crane start to slowly lift under the signals of lifting command, so that the slings are stressed, and whether the slings are uniformly stressed is checked;
S9, test hanging: hoisting by a main crane and an auxiliary crane to separate the large horizontal reactor from the saddle by 100mm, then jointly checking the stress conditions of the sling and the lifting lug before hoisting the mechanical operation conditions, and signing and confirming the mechanical operation conditions to perform formal hoisting;
S10, formally hoisting: under the signals of a lifting command, the main crane and the auxiliary crane lift the large horizontal reactor, the lower end of the large horizontal reactor is kept at 500mm or below from the ground all the time, the main crane slowly lifts the top of the large horizontal reactor, the auxiliary crane is matched with a falling hook, a lifting appliance steel wire rope on the main crane and a lifting appliance steel wire rope on the auxiliary crane are tightly attached to a reinforcing ring and a rope baffle plate respectively, in the overturning process, the lifting appliance steel wire rope on the main crane is gradually separated from the reinforcing ring of the large horizontal reactor by a rope part on the outer side of the large horizontal reactor, the attaching length of the lifting appliance steel wire rope on the auxiliary crane with the reinforcing ring is gradually increased until the overturning of the reactor is completed, after the large horizontal reactor realizes the turning over of an aerial body, the auxiliary overturning crane is unhooked, the main crane is independently lifted vertically, the main crane slewing arm lever slowly lifts the equipment to the position right above a reactor frame base, the equipment is confirmed to slowly fall back to the frame base, and after the axis position and elevation of the equipment are preliminarily adjusted, and the anchor bolts are fastened;
s11, unhooking a crane: after the installation team finishes equipment alignment and fixation, the crane command main crane returns to the hook to separate the steel wire rope from the lifting lug, the main crane lifts the hook, then the main crane rotates, the hoisting rigging is retracted, and the hoisting work is finished.
Preferably, reinforcing rings are also arranged at two ends of the large horizontal reactor, grooves are formed between the reinforcing rings and the large horizontal reactor and between the reinforcing rings and the main crane lugs, and then polishing and welding are carried out, and the welding seam is full welding.
Preferably, a supporting balance beam is arranged on a main crane, the length of the supporting balance beam is 900mm and 500t, a steel wire rope is connected with a lifting hook by adopting 1 pair of steel wire rope buckles with the diameter of 120mm multiplied by 25m, then 1 shackle is respectively hung on rope buckles below the steel wire rope with the diameter of 120mm multiplied by 25m on two sides of the balance beam, 2 flat shackles with the length of 500t are adopted, 2 matched 200t pulleys are used simultaneously, the pulleys are arranged on shackle pin shafts, and steel plate baffle rings with certain thickness are arranged between two sides of the pulleys and the shackle body and are used for limiting the pulleys to generate axial movement along the pin shafts;
The main crane sling and the main crane lug are connected by adopting a pressing steel wire rope buckle with the diameter of 120mm multiplied by 30m, which is connected with a 120 t-level shackle.
Preferably, the auxiliary crane is also provided with a supporting balance beam, the length of the balance beam is 3000mm, the grade of 200t, and the balance beam is connected with the auxiliary lifting lug by adopting a steel wire rope buckle with the diameter of 65mm multiplied by 30m and a grade of 120t shackle.
Preferably, the main crane is an 800t crawler crane and the auxiliary crane is a 260t crawler crane.
Preferably, the foundation of the main crane is set by the following method: firstly, digging 1200mm of the ground by using an excavator, compacting the excavated foundation trench, then adopting rubble/sheet stone layering backfilling and tamping, wherein the thickness of each layer is not more than 500mm, the total thickness is 1100mm, finally paving slag stones with the thickness of 200mm on the surface layer, adopting a 25t road roller for vibration compaction, and requiring the specific pressure of grounding to be more than 0.15MPa.
The invention adopts two cranes, can realize continuous completion of equipment unloading, overturning and hoisting at one time, has advanced and reliable technology, is easy to operate, is economical and efficient, and has higher popularization and application values.
The invention can realize smooth and steady overturning, has simple working procedure, small labor intensity, short operation period of the crane and high safety, and can greatly save the production cost.
Drawings
Fig. 1 is a schematic view of the hoisting of the present invention.
Fig. 2 is a schematic diagram of the flipping process of the present invention.
FIG. 3 is a schematic diagram showing the stress of the reactor in the initial state of the inversion.
Fig. 4 is a schematic diagram showing stress of the turnover completion state of the reactor.
Reference numerals: 1-main lifting lug, 2-auxiliary lifting lug, 3-reinforcing ring, 4-rope baffle plate and 5-large horizontal reactor.
Detailed Description
The invention relates to an aerial overturning construction method of a large horizontal reactor, which specifically comprises the following steps:
s1, crane approach and assembly: after the main crane and the auxiliary crane enter the field, carrying out station positioning and assembly according to a hoisting plan;
S2, equipment entering and unloading: the large horizontal reactor 5 is manufactured, and is transported to a specified position for hoisting by a transportation unit, and is driven in by a hoisting planning line, and the loading is required to be oriented according to the requirement;
S3, checking and accepting the equipment foundation, preparing sizing blocks, and confirming that equipment installation conditions are met for the next step;
S4, symmetrically arranging two reinforcing rings 3 on the large horizontal reactor 5 along the circumferential direction of the large horizontal reactor 5, wherein two main lifting lugs 1 are arranged on the same reinforcing ring 3, and the main lifting lugs 1 on the two reinforcing rings 3 are correspondingly arranged;
Two annular rope baffle plates 4 are arranged in the middle of the large horizontal reactor 5, an auxiliary lifting lug 2 is arranged on each rope baffle plate 4, and the projections of the main lifting lug 1 and the auxiliary lifting lug 2 on the axial section of the large horizontal reactor 5 meet the following relation:
The main lifting lug 1 and the auxiliary lifting lug 2 are respectively positioned at two sides of the axial section, and the two main lifting lugs 1 are symmetrically arranged about the axial section passing through the auxiliary lifting lug 2;
Checking the welding quality of the lifting lug, if the lifting lug is unqualified, strictly forbidden to lift and timely notifying related departments of treatment, and carrying out the next step after the lifting lug is qualified;
S5, warning pulling and setting: a warning area is arranged before the equipment is hoisted, a striking warning line is arranged around the equipment, and no personnel are forbidden to enter the equipment;
s6, checking the station position of the crane: after the main crane and the auxiliary crane stand according to the specified positions, the main crane and the auxiliary crane are confirmed by the quality and technicians according to a common check confirmation table;
S7, selecting and checking hoisting rigging: selecting proper rigging according to the weight and the specification and the size of the equipment and combining the existing rigging condition and the rigging performance;
S8, checking the pre-stress of the sling: after each preparation work is finished, a connecting lifting hook at one end of a lifting appliance of a main crane is respectively connected with two main lifting lugs 1 on the same reinforcing ring 3, two ends of the lifting appliance on an auxiliary crane are respectively connected with two auxiliary lifting lugs 2, the main crane and the auxiliary crane start to slowly lift under the signals of a lifting command, so that slings are stressed, and whether the slings are uniformly stressed is checked;
S9, test hanging: hoisting by a main crane and an auxiliary crane, so that the large horizontal reactor 5 is separated from the saddle by 100mm, then, carrying out joint inspection on stress conditions of a sling and a lifting lug before hoisting on mechanical operation conditions, and signature confirmation, and then, carrying out formal hoisting;
S10, formally hoisting: under the signals of a lifting command, the main crane and the auxiliary crane lift the large horizontal reactor 5, the lower end of the large horizontal reactor 5 is kept at 500mm or below from the ground all the time, the main crane slowly lifts the top of the large horizontal reactor 5, the auxiliary crane is matched with a falling hook, a lifting appliance steel wire rope on the main crane and a lifting appliance steel wire rope on the auxiliary crane are respectively tightly attached to the reinforcing ring 3 and the rope baffle 4, in the overturning process, the lifting appliance steel wire rope on the main crane is gradually separated from the reinforcing ring 3 on the large horizontal reactor 5 by a rope part on the outer side of the large horizontal reactor 5, the attaching length of the lifting appliance steel wire rope on the auxiliary crane to the reinforcing ring 3 can be gradually increased until the overturning of the large horizontal reactor 5 is completed, the auxiliary overturning crane unhooks, the equipment is independently lifted by the main crane, the main crane slewing arm rod slowly lifts the equipment to the position right above the reactor frame base, the equipment is slowly fallen to the frame base, the axis position of the equipment is preliminarily adjusted, and after the anchor bolts are fastened;
s11, unhooking a crane: after the installation team finishes equipment alignment and fixation, the crane command main crane returns to the hook to separate the steel wire rope from the lifting lug, the main crane lifts the hook, then the main crane rotates, the hoisting rigging is retracted, and the hoisting work is finished.
Reinforcing rings 3 are also arranged at two ends of the large horizontal reactor 5, grooves are formed between the reinforcing rings 3 and the large horizontal reactor 5 and between the reinforcing rings 3 and the main lifting lugs 1, and then polishing and welding are carried out, and the welding seam is full welding.
The main crane is provided with a supporting balance beam, the length of the supporting balance beam is 900mm and 500t, a steel wire rope is connected with a lifting hook by adopting 1 pair of steel wire rope buckles with the diameter of 120mm multiplied by 25m, then 1 shackle is respectively hung on rope buckles below the steel wire rope with the diameter of 120mm multiplied by 25m on two sides of the balance beam, 2 flat shackles with the length of 500t are adopted for the shackle, 2 matched pulleys with the standard pulley with the length of 200t are simultaneously used, the pulleys are arranged on shackle pin shafts, and steel plate baffle rings with certain thickness are arranged between two sides of the pulleys and the shackle body and are used for limiting the pulleys to generate axial movement along the pin shafts;
the main crane sling and the main lifting lug 1 are connected by adopting a pressing steel wire rope buckle with the diameter of 120mm multiplied by 30m, which is connected with a 120 t-level shackle.
The auxiliary crane is also provided with a supporting balance beam, the length of the balance beam is 3000mm and 200t, and the balance beam is connected with the auxiliary lifting lug 2 by adopting a steel wire rope buckle with the diameter of 65mm multiplied by 30m and a 120 t-level shackle.
The main crane is an 800t crawler crane, and the auxiliary crane is a 260t crawler crane.
The foundation of the main crane is set by adopting the following method: firstly, digging 1200mm of the ground by using an excavator, compacting the excavated foundation trench, then adopting rubble/sheet stone layering backfilling and tamping, wherein the thickness of each layer is not more than 500mm, the total thickness is 1100mm, finally paving slag stones with the thickness of 200mm on the surface layer, adopting a 25t road roller for vibration compaction, and requiring the specific pressure of grounding to be more than 0.15MPa.
The invention adopts two cranes, can realize continuous completion of equipment unloading, overturning and hoisting at one time, has advanced and reliable technology, is easy to operate, is economical and efficient, and has higher popularization and application values.
The invention can realize smooth and steady overturning, has simple working procedure, small labor intensity, short operation period of the crane and high safety, and can greatly save the production cost.
Construction principle
1. Before the large horizontal reactor 5 is in place, in consideration of convenience in transportation, equipment is not suitable for entering a site to be immediately lifted in transportation, a certain angle of turning over is needed for the large horizontal reactor 5 to be lifted at a proper angle, that is, a turning over process is needed to be realized in the process of lifting the large horizontal reactor 5.
2. The overturning method needs a sling system combining a steel wire rope, a balance beam, a shackle and a pulley, so that the equipment and the sling are relatively fixed during overturning, and the surface of the equipment and the steel wire rope are not damaged due to relative sliding.
3. In the process of lifting equipment and overturning, the main crane bears the weight of the main body of the equipment, and the auxiliary crane bears the weight of the unbalanced part of the equipment or the friction force between the pulley and the shaft in the process of overturning the equipment. The process realizes stable overturning of equipment, achieves the position of in-place hoisting, and then the main crane is hooked again to hoist in place. According to the process, a group of fixed pulleys or rope protection wheels are added to the end parts of the balance beams, so that the function of the pulleys is achieved on one hand, the function of rope protection is achieved on the other hand, the protection of a hoisting rope is enhanced, the bending coefficient of a steel rope is increased, the equipment is stable and safe in the hoisting and overturning process, and dynamic load is hardly generated; besides the normal choice of the main crane, the small crane for auxiliary hoisting machinery reduces the hoisting cost.
Construction process flow
1. Hoisting process
The main crane adopts 1 crawler crane with 800t, the auxiliary crane adopts 1 crawler crane with 260t, and the work of hanging super-lifting counterweight displacement hoisting rigging, laying roadbed plates, transporting and the like adopts 1 truck crane with 80t, and the overturning of the large horizontal reactor 5 is carried out by using the offset generated by the large connecting pipe (self weight 30 t) at the bottom of the equipment.
2. Reactor hoisting process and control
The 800t crawler crane adopts one supporting balance beam, the length is 9000mm,500t grade, and the steel wire rope is connected with the lifting hook by adopting a pair of pressed steel wire rope buckles with the diameter of 120mm multiplied by 25m above the balance beam. Then, the shackles are respectively hung on the rope buckles below the steel wire ropes with the diameters of 120mm multiplied by 25m on the two sides of the balance beam, the shackles adopt 2 flat shackles of 500t level, 2 pulleys of 200t level which are matched and customized are used simultaneously, the pulleys are arranged on the shackle pin shaft, and steel plate baffle rings with certain thickness are arranged between the two sides of the pulleys and the shackle body, so that the pulleys can be limited to generate axial movement along the pin shaft, and the overturning and hoisting process of the reactor is stable. Then, 1 pair of pressed wire rope buckles with the diameter of 120mm multiplied by 30m are adopted to connect the 500 t-level flat shackle with 2 pulleys and 4 main lifting lugs 1 of the reactor, and 4 120 t-level shackles with the diameter of 120mm multiplied by 30m are adopted to connect the wire rope buckles with the main lifting lugs 1.
The auxiliary overturning crane adopts one supporting balance beam, the length is 3000mm and 200t, a pair of steel wire rope buckles with the diameter of 65mm multiplied by 30m are adopted, and 2 steel wire ropes are connected with the auxiliary plate type lifting lugs for overturning the reactor by adopting 120 t-level shackles.
(2) Lifting test crane
The large-scale horizontal reactor 5 is manufactured, is responsible for being transported to a designated position of the western side hoisting of the reaction frame by a transportation unit, and is driven in a reverse way from the south to the north by a hoisting planning line, and the large-scale horizontal reactor is required to be oriented before being loaded. Firstly, hanging a sling system on the equipment according to the scheme requirement, slowly lifting the equipment by an 800t crawler crane, and simultaneously slowly lifting the equipment by 260t crawler crane to enable the equipment to leave 100mm of the transport vehicle, keeping a hovering state and carrying out joint inspection, and comprehensively inspecting the conditions of bearing sinking of a lifting foundation, the state of a lifted object, the working state of a crane, the stress of a lifting sling and a lifting lug and the like.
(3) Reactor unloading vehicle
After the test hanging inspection is carried out, the 800t crawler crane and the 260t crawler crane are simultaneously hooked, the hooking is stopped after the lower plane of the equipment leaves 300mm of the transport vehicle, the transport vehicle drives away, and the pipeline on the side surface of the equipment does not collide with the transport vehicle when the equipment leaves the transport vehicle.
(4) Reactor inversion
Under the command of a lifting signal, the 800t crawler crane and the auxiliary 260t crawler crane slowly lift the hook at the same time, and the 260t crawler crane slowly drops the hook, so that the reactor rotates 60 degrees around the horizontal axis until the equipment is rotated rightly.
(5) Reactor is hoisted in place
After the reactor is turned over in place, the 260t crawler crane is unhooked, the 800t crawler crane lifts the reactor until the lower opening plane of the reactor pipeline exceeds 500mm of the 16.15m platform, the 800t crawler crane rotates the main arm and walks to adjust the position, and after the installer confirms the positioning direction of the reactor, the 800t crawler crane falls off the hook to lift the equipment to the positioning position.
(6) Unhooking finish
The 800t crawler crane hook is about 2m, a 25 automobile crane lifts the hanging basket to lift the crane to the position of the main lifting lug 1 of the reactor, the 120t shackle is removed one by one, and the equipment is separated from the crane.
4. Lifting lug diagram design
4 Plate-type lifting lugs are symmetrically arranged at the lower positions of support reinforcing rings 3 on two sides of a cactus connecting pipe at the top of the reactor, a lifting lug main plate is welded firstly, then a reinforcing rib plate and a lifting lug rib plate of equipment are welded, the lifting lug and the reinforcing rings 3 are welded into a whole, and the reinforcing rings 3 are additionally provided with the rib plates to locally reinforce lifting points.
In the overturning process of the reactor, the main crane and the auxiliary steel wire rope can be tightly attached to the reinforcing ring 3, the rope portion of the main crane steel wire rope, which is close to the outer side of the equipment, is gradually separated from the reinforcing ring 3, the attaching length of the auxiliary steel wire rope and the reinforcing ring 3 can be gradually increased until the reactor is overturned to be unhooked, so that the situation that the steel wire rope suddenly slides from the outer peripheral surface of the reinforcing ring 3 is prevented, balance beams are arranged on the main crane and the auxiliary crane in the scheme, and meanwhile, baffles are welded at proper positions on two sides of the reinforcing ring 3, which are in overturning contact with the auxiliary steel wire rope, so that the steel wire rope cannot slide out of the reinforcing ring 3 in the overturning process is ensured.
5. Hoisting process calculation
(1) Lug stress accounting
Main lug 1 intensity calculation:
Lifting lug parameters: lifting lug material Q345R;
Allowable stress: ；
Fillet weld coefficient: ；
comprehensive influence coefficient: taking the factors of hoisting impact, uneven load distribution of a plurality of lifting lugs and the like into consideration, and taking K=1.65
L=900mm、S=80mm、S1=20mm、R=210mm、D=140mm、D1=350mm，
Reactor lifting quality 275t, single lifting lug maximum lifting weight W L =275/4=69 t
Because the main crane lifting hook and the auxiliary crane lifting hook both use balance beams, the transverse included angle between the steel wire rope and the equipment is always kept at 0 degrees.
And (5) lifting lug stress analysis: the 4 plate lifting lugs are positioned at the lower positions of the support reinforcing rings 3 on the two sides of the cactus, the auxiliary force is maximum (the stress of the auxiliary lifting lugs 2 is maximum) in the initial state of equipment overturning, and the stress of the main lifting lug 1 in the state when the equipment overturning is completed is maximum.
Sling direction load: f L= K*WL =1.65×69=114 t (1.65 for the integrated safety factor)
Maximum tensile stress of the lifting lug plate holes is calculated conservatively as:
safety;
Maximum shear stress in the lifting lug plate sling direction is calculated conservatively as:
safety.
(2) Auxiliary force accounting for reactor upset initial state
When the auxiliary force of the reactor is maximum, the reactor is in an initial overturning state, the stress analysis is carried out by CAD, the tail sliding sling is tightly attached to the outer circumference of the hoop, the sling is vertically upwards, the sling can be regarded as a tangent position point of F max and the outer hoop, which is shown in the figure, and the main crane sling is arranged on the outer side of the reactor in the same way as the steel wire rope T 2. The specific accounting is as follows:
The hoisting mass g=g1+g2=245 t+30t=275 t= 275000kg of the large horizontal reactor 5,
The diameter of the reactor outer hoop is D Hoop ring =9.15m
The lower pipe orifice of the equipment has the mass of 30 tons, the lower pipe orifice is inclined towards the ground when being loaded, an included angle of 30 degrees is formed between the lower pipe orifice and the ground, the gravity center position deviates from the vertical center line 5.278m of the barrel body of the equipment, the stress of the main crane rope balance beam on the outer side of the equipment is shown as a diagram T 2, and the stress of the main crane rope balance beam on the inner side of the equipment is shown as a diagram T 1,T1 and an included angle of 79 degrees between the main crane rope balance beam and the horizontal line.
The torque balance principle is adopted:
G1L1+G2L2=FmaxD Hoop ring +T1v（D Hoop ring /2）+T1h（D Hoop ring /2）
T1v=T1sin79°,T1h=T1cos79°
the steel wire ropes at two sides of the fixed pulley connected by the snap ring below the balance beam of the main crane are stressed equally, namely T 2=T1,
And: g 1+G2=Fmax+T1v+T2=Fmax+T1sin79°+T2
Substituting the numerical value to obtain the maximum value of the auxiliary force of the reactor: f max =130t and,
Initial main crane cable stress of reactor overturn: diagram T 2=T1 = 86.2T, then turn over the initial single lug sling direction tension = T 2/2 = 43.1T.
(3) Stress accounting for complete state of reactor turnover
When the overturning of the reactor is completed, the stress state diagram is as follows, the stress of the main lifting lug 1 is the largest, and the component force of the single lifting lug in the vertical direction is; t 1vmax=G/4=T1max sin73 °, g= 275000T, then T 1max = 71.39T, is the main crane rigging maximum stress.
(4) Crane load accounting
QUY260 type 260t crawler crane, 24m main arm, 8m working radius, rated load 176.9t, sling weight about 10t, load factor is: 140/176.9t=79.1% <100%;260t of crawler crane load meets the requirements.
Rigging stress accounting
2 Pressed steel wire ropes with the diameter of 120mm multiplied by 30m are configured; the middle part of the folded steel wire rope is tied and hung at the position of a 500T clamping ring below the balance beam, so that the steel wire rope is folded and reduced at the position of the 500T clamping ring, the maximum pulling force T 1max = 71.39T, R = D/D, D = 165mm, D = 120mm, R = D/D = 165/120 = 1.375 +.6, and the obtained product is substituted into the formula E= (100-50/R 0.5)%, so as to obtain E = 57.4%
The main crane steel wire rope receives 123t multiplied by 2 strands multiplied by 0.574=282t >275t;
The main crane cable meets the hoisting safety requirement.
800T crawler crane hoisting station area foundation treatment
The self weight of the 800t crawler crane is about 550 tons, the super-lifting weight is 250 tons, the specification of a special road base plate of the 800t crawler crane is 2.3m multiplied by 6m, each crawler belt is 12m long, the road base plates are horizontally placed, 5 road base plates (7t.5.2=70t) are needed for each crawler belt, and the total pressure to the ground is 1170 tons.
According to GB/T51384-2019 technical Standard for treating foundation of petrochemical engineering large-scale equipment hoisting field, the comprehensive coefficient of unbalanced load and dynamic load is 1.35, and the requirement of a roadbed plate on the ground pressure when the crawler crane hoisting equipment is 800T is as follows:
P = (1170×1.35) / (2.3×6×5×2) =11.45t/m2
After the station foundation of the 800t main crane locomotive is excavated to the depth of 1.2m, 4 points are increased to be over excavated for 1m, and the foundation treatment method is determined by checking the condition of a silt layer.
For an 800t crawler crane used for 8 reactor hoisting operation areas, firstly, an excavator is used for digging 1200mm of the ground, the dug foundation pit is compacted, then, rubble/sheet stone is adopted for layered backfilling and tamping, the thickness of each layer is not more than 500mm, the total thickness is 1100mm, finally, a surface layer is paved with slag stones with the thickness of 200mm, and a 25t road roller is adopted for vibration compaction. The specific ground pressure is required to be greater than 0.15MPa.
Claims (6)
1. The aerial overturning construction method of the large horizontal reactor is characterized by comprising the following steps of:
s1, crane approach and assembly: after the main crane and the auxiliary crane enter the field, carrying out station positioning and assembly according to a hoisting plan;
s2, equipment entering and unloading: the large-scale horizontal reactor equipment is manufactured, and is transported to a specified position for hoisting by a transportation unit, and particularly enters by a hoisting planning line, and the loading is required to be oriented according to the requirement;
S3, checking and accepting the equipment foundation, preparing sizing blocks, and confirming that equipment installation conditions are met for the next step;
S4, symmetrically arranging two reinforcing rings arranged along the circumference of the large horizontal reactor on the large horizontal reactor, arranging two main lifting lugs on the same reinforcing ring, and correspondingly arranging the main lifting lugs on the two reinforcing rings;
two annular rope baffle plates are arranged in the middle of the large-scale horizontal reactor, an auxiliary lifting lug is arranged on each rope baffle plate, and the projection of the main lifting lug and the auxiliary lifting lug on the axial section of the large-scale horizontal reactor meets the following relation:
The main lifting lugs and the auxiliary lifting lugs are respectively positioned at two sides of the shaft section, and the two main lifting lugs are symmetrically arranged about the shaft section passing through the auxiliary lifting lugs;
Checking the welding quality of the lifting lug, if the lifting lug is unqualified, strictly forbidden to lift and timely notifying related departments of treatment, and carrying out the next step after the lifting lug is qualified;
S5, warning pulling and setting: a warning area is arranged before the equipment is hoisted, a striking warning line is arranged around the equipment, and no personnel are forbidden to enter the equipment;
s6, checking the station position of the crane: after the main crane and the auxiliary crane stand according to the specified positions, the main crane and the auxiliary crane are confirmed by the quality and technicians according to a common check confirmation table;
S7, selecting and checking hoisting rigging: selecting proper rigging according to the weight and the specification and the size of the equipment and combining the existing rigging condition and the rigging performance;
S8, checking the pre-stress of the sling: after each preparation work is finished, a connecting lifting hook at one end of a lifting appliance of a main crane is respectively connected with two main lifting lugs on the same reinforcing ring, two ends of the lifting appliance on an auxiliary crane are respectively connected with two auxiliary lifting lugs, the main crane and the auxiliary crane start to slowly lift under the signals of a lifting command, so that slings are stressed, and whether the slings are uniformly stressed is checked;
S9, test hanging: hoisting by a main crane and an auxiliary crane to separate the large horizontal reactor from the saddle by 100mm, then jointly checking the stress conditions of the sling and the lifting lug before hoisting the mechanical operation conditions, and signing and confirming the mechanical operation conditions to perform formal hoisting;
S10, formally hoisting: under the signals of a lifting command, the main crane and the auxiliary crane lift the large horizontal reactor, the lower end of the large horizontal reactor is kept at 500mm or below from the ground all the time, the main crane slowly lifts the top of the large horizontal reactor, the auxiliary crane is matched with a falling hook, a lifting appliance steel wire rope on the main crane and a lifting appliance steel wire rope on the auxiliary crane are tightly attached to a reinforcing ring and a rope baffle plate respectively, in the overturning process, the lifting appliance steel wire rope on the main crane is gradually separated from the reinforcing ring of the large horizontal reactor by a rope part on the outer side of the large horizontal reactor, the attaching length of the lifting appliance steel wire rope on the auxiliary crane with the reinforcing ring is gradually increased until the overturning of the reactor is completed, after the large horizontal reactor realizes the turning over of an aerial body, the auxiliary overturning crane is unhooked, the main crane is independently lifted vertically, the main crane slewing arm lever slowly lifts the equipment to the position right above a reactor frame base, the equipment is confirmed to slowly fall back to the frame base, and after the axis position and elevation of the equipment are preliminarily adjusted, and the anchor bolts are fastened;
s11, unhooking a crane: after the installation team finishes equipment alignment and fixation, the crane command main crane returns to the hook to separate the steel wire rope from the lifting lug, the main crane lifts the hook, then the main crane rotates, the hoisting rigging is retracted, and the hoisting work is finished.
2. The method for constructing the large horizontal reactor by turning over the large horizontal reactor in the air according to claim 1, wherein reinforcing rings are arranged at two ends of the large horizontal reactor, grooves are formed between the reinforcing rings and the large horizontal reactor and between the reinforcing rings and the main lifting lugs, the large horizontal reactor and the main lifting lugs are polished and welded, and the welding seam is full welding.
3. The aerial overturning construction method of the large horizontal reactor as claimed in claim 2, wherein a supporting balance beam is arranged on the main crane, the lengths of the supporting balance beam and the lifting hook are 900mm and 500t, a steel wire rope is connected with a lifting hook by adopting 1 pair of steel wire rope buckles with the diameters of 120mm multiplied by 25m, then 1 shackle is respectively hung on rope buckles below the steel wire rope with the diameters of 120mm multiplied by 25m on two sides of the balance beam, 2 flat shackles with the diameters of 500t are adopted for the shackle, 2 matched pulleys with 200t are used, the pulleys are arranged on shackle pin shafts, and steel plate baffle rings with certain thickness are arranged between two sides of the pulleys and the shackle body and are used for limiting the pulleys to generate axial movement along the pin shafts;
The main crane sling and the main lifting lug are connected by adopting a pressing steel wire rope buckle with the diameter of 120mm multiplied by 30m, which is connected with a 120 t-level shackle.
4. The aerial turnover construction method of a large horizontal reactor as set forth in claim 3, wherein the auxiliary crane is also provided with a supporting balance beam, the length of the balance beam is 3000mm, the grade of 200t, and the balance beam is connected with the auxiliary lifting lug by adopting a steel wire rope buckle with the diameter of 65mm multiplied by 30m and a grade of 120t shackle.
5. The aerial turnover construction method of a large horizontal reactor as set forth in claim 4, wherein said main crane is an 800t crawler crane and said auxiliary crane is a 260t crawler crane.
6. The aerial turnover construction method of a large horizontal reactor as set forth in claim 5, wherein the foundation of the main crane is set by the following method: firstly, digging 1200mm of the ground by using an excavator, compacting the excavated foundation trench, then adopting rubble/sheet stone layering backfilling and tamping, wherein the thickness of each layer is not more than 500mm, the total thickness is 1100mm, finally paving slag stones with the thickness of 200mm on the surface layer, adopting a 25t road roller for vibration compaction, and requiring the specific pressure of grounding to be more than 0.15MPa.
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| Application Number | Priority Date | Filing Date | Title |
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