Installation and construction method for large equipment in process workshop

Abstract

The invention provides an installation and construction method for large equipment in a process workshop, and belongs to the technical field of plant renoving.The installation and construction method for the large equipment in the process workshop comprises the following steps that according to site conditions, a large equipment transportation path is planned, and a U-shaped steel rail, a sliding trolley and a hydraulic jack are selected; laying brick soil temporary foundations with gradually changing widths along the path to support the U-shaped steel track; equiwide short rails are arranged at the intersections of the rails, and sliding trolleys are arranged at four corners of equipment corresponding to the rails and are hoisted by hoisting equipment; the equipment is pushed to transport along the rail, and turning is realized by locking and unlocking the trolley; after reaching the position, the equipment is lifted, and brick walls are stacked and built layer by layer below to the foundation height; moving to an equipment foundation through a connecting rail, finely adjusting the position after removing the rail trolley, finally installing a bolt fixing device, and dismantling a temporary foundation; the problem that in the prior art, large equipment cannot be installed in a narrow space without a crane can be solved, and the installation cost is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of plant reconstruction, and in particular relates to a method for installing and constructing large equipment in a process workshop. Background Art

[0002] The installation of large equipment is a complex project, involving multiple key links such as transportation, hoisting, and positioning. In actual applications, such large equipment is usually installed in specific process rooms such as factories and power plants. Due to factors such as the entrance size, internal space, and basic conditions of the process room, the installation process is extremely cumbersome and difficult.

[0003] There are two main methods for installing large equipment: one is to use the overall hoisting method, that is, to use large lifting equipment to directly hoist the whole machine onto the equipment foundation. This method has high requirements on the lifting capacity and positioning accuracy of the lifting equipment, and is easily affected by on-site environmental factors, which poses a safety hazard. The other is to use the disassembly and reassembly method, that is, to disassemble the large equipment into smaller parts, and then transport and hoist them to the equipment foundation for reassembly. This method has cumbersome procedures, and each part needs to be accurately positioned and adjusted during assembly. It is difficult to operate and is prone to problems such as wrong installation and missing installation.

[0004] The common problems of the above two methods are: first, it is difficult to cope with the narrow and complex process room environment, and it is impossible to ensure the stable transportation and precise positioning of large equipment; second, large lifting equipment is required, which increases the installation cost; third, it is very easy to cause safety hazards, which brings great safety risks to the installers. Therefore, there is an urgent need for a new large equipment installation method that can adapt to various complex on-site conditions, ensure the accuracy and safety of equipment installation, and reduce installation costs. Summary of the invention

[0005] In view of this, the present invention provides a large equipment installation and construction method for a process workshop, which can solve the problem that the prior art cannot install large equipment in a small space without a crane, thereby reducing installation costs.

[0006] The present invention is achieved in that:

[0007] The present invention provides a method for installing and constructing large equipment in a process workshop, which comprises the following steps:

[0008] S10, determining the transportation route of the large equipment according to the process room entrance location, foundation location, and on-site obstacle distribution conditions, and selecting the U-shaped steel track, sliding trolley, and hydraulic jack for the transportation of the large equipment;

[0009] S20, laying a temporary brick-soil foundation along the transport route, wherein the lower layer width of the temporary foundation is 48 cm and the upper layer width is 24 cm, for supporting the U-shaped steel track;

[0010] S30, installing the U-shaped steel track on the temporary foundation, and providing a short track for turning at the longitudinal and transverse intersection of the U-shaped steel track, wherein the length of the short track is the same as the width of the transverse track;

[0011] S40, placing four sliding trolleys on the U-shaped steel track, the sliding trolleys corresponding to the four corners of the large equipment respectively, and using a lifting device to hoist the large equipment onto the sliding trolleys;

[0012] S50, pushing the large equipment to be transported horizontally along the U-shaped steel track, locking the upper sliding trolley of the longitudinal track when reaching the turning point, unlocking the lower sliding trolley of the transverse track, and driving the large equipment to complete the turning;

[0013] S60, after the large equipment is transported to the designated location, the large equipment is lifted as a whole using the hydraulic jack, and a brick wall is built under the U-shaped steel track, and the lifting and building processes are repeated until the large equipment reaches the equipment foundation elevation;

[0014] S70, setting a connecting track between the large equipment and the equipment foundation, and using the sliding trolley to smoothly move the large equipment to the equipment foundation;

[0015] S80, using the hydraulic jack to lift up the large equipment, removing the U-shaped steel track and the sliding trolley, and fine-tuning the position of the large equipment;

[0016] S90, injecting chemical bolts into the reserved installation holes of the equipment foundation to fix the large equipment, and removing the temporary foundation.

[0017] On the basis of the above technical solution, a large-scale equipment installation construction method for a process workshop of the present invention can also be improved as follows:

[0018] Wherein, the step S10 specifically includes:

[0019] Step 11, measuring the size of the entrance of the process room, detecting the position of obstacles in the process room, drawing a plan layout of the process room, and marking the position of the foundation of the large equipment on the plan layout;

[0020] Step 12: planning the transportation route of the large equipment on the plan layout according to the distance between the entrance position of the process room and the base position of the large equipment, and determining the number of turns of the large equipment;

[0021] Step 13: According to the weight and size parameters of the large equipment, select the U-shaped steel rail, the sliding trolley and the hydraulic jack with matching load-bearing grades, and perform a safety inspection on the U-shaped steel rail, the sliding trolley and the hydraulic jack before use.

[0022] Furthermore, the step S20 specifically includes:

[0023] Step 21: level the site along the transport route, remove road debris, and use a level ruler to measure the flatness of the ground along the transport route;

[0024] Step 22, using red bricks to lay the temporary foundation in an I-shaped arrangement, the lower layer adopts a single brick wall masonry method, the masonry height is 2 layers, the width is 48 cm, and the upper layer adopts a half brick wall masonry method, the masonry height is 2 layers, and the width is 24 cm;

[0025] Step 23, during the red brick laying process, the brick joints are filled with fine soil, the red bricks are staggered and laid, and the masonry surface is smoothed with 1:3 cement mortar.

[0026] Furthermore, the step S30 specifically includes:

[0027] Step 31: Use a laser level to measure the surface elevation of the temporary foundation, and adjust the flatness of the temporary foundation to ensure that the height difference in the vertical and horizontal directions does not exceed 2 mm;

[0028] Step 32, apply a 1:2 cement mortar leveling layer on the top surface of the temporary foundation, place the U-shaped steel track on the leveling layer, and calibrate the elevation of the U-shaped steel track using a ruler and a level;

[0029] Step 33: At the intersection of the U-shaped steel rail, the longitudinal rail is disconnected to make a short rail with the same width as the transverse rail, ensuring that the short rail is smoothly connected to the longitudinal rail.

[0030] Furthermore, the step S40 specifically includes:

[0031] Step 41, installing the sliding trolley on the U-shaped steel track, and adjusting the distance between the sliding trolleys to correspond to the four corners of the large equipment;

[0032] Step 42: Use the leveling mechanism on the sliding trolley to adjust the horizontality of the bearing plane of the sliding trolley to ensure that the bearing planes of the four sliding trolleys have the same elevation;

[0033] Step 43: Use a mobile gantry crane to hoist the large equipment onto the four sliding trolleys, and fix the large equipment to the sliding trolleys through the fastening holes on the bearing plates of the sliding trolleys.

[0034] Furthermore, the step S50 specifically includes:

[0035] Step 51: Use a lever tool to push the large equipment along the U-shaped steel track for transportation, and arrange personnel to observe the operating status of the large equipment during the pushing process;

[0036] Step 52, when the large equipment is transported to the turning place, the sliding trolley locking mechanism is operated, and the locking plate is pressed downward by the swing rod, so that the brake block contacts the roller, and the sliding trolley is locked on the longitudinal track;

[0037] Step 53: Release the locking state of the sliding trolley on the lower layer of the transverse track, push the large equipment to be transported along the transverse track, and drive the short track to move synchronously.

[0038] Furthermore, the step S60 specifically includes:

[0039] Step 61, placing the hydraulic jack under the four sliding carriages, and adjusting the supporting point position of the hydraulic jack to correspond to the stress point of the large equipment;

[0040] Step 62: synchronously operate the four hydraulic jacks to lift the large equipment, and build the brick wall under the U-shaped steel track in a brick wall manner, and fill the brick joints with fine soil;

[0041] Step 63, slowly lower the hydraulic jack to allow the large equipment to land stably on the newly built brick wall, and repeat the lifting and stacking process until the equipment foundation elevation is reached.

[0042] Furthermore, the step S70 specifically includes:

[0043] Step 71, setting the connecting track between the large equipment track and the equipment foundation, and using a level ruler to measure the height difference between the connecting track and the tracks on both sides;

[0044] Step 72: Adjust the elevation and inclination of the connecting track to ensure a smooth transition with the tracks on both sides, and use steel plates to reinforce the connection between the connecting track and the tracks on both sides;

[0045] Step 73, release the locking state of the sliding trolley, use a lever tool to push the large equipment, and make it move smoothly to the equipment foundation through the connecting track.

[0046] Furthermore, the step S80 specifically includes:

[0047] Step 81, installing the hydraulic jacks at the four corners of the large equipment, synchronously lifting the large equipment, and marking the axis position on the equipment base;

[0048] Step 82: remove the sliding trolley and the U-shaped steel track, clean the surface of the equipment foundation, and use the hydraulic jack to adjust the position of the large equipment;

[0049] Step 83: Use a theodolite to measure the installation position of the large equipment, adjust the large equipment to make it correspond to the axis position, and ensure that the horizontality error does not exceed 1 mm.

[0050] Furthermore, the step S90 specifically includes:

[0051] Step 91, clean up the debris in the reserved installation hole of the equipment foundation, use compressed air to blow the installation hole, and use a wire brush to clean the inner wall of the installation hole;

[0052] Step 92, injecting epoxy resin anchoring agent into the mounting hole, embedding the chemical bolt into the mounting hole, and adjusting the exposed length of the chemical bolt to ensure the verticality of the bolt;

[0053] Step 93: After the chemical bolts are solidified, tighten the chemical bolts with a torque wrench, remove the temporary foundation and construction auxiliary facilities, and clean up the construction site.

[0054] The sliding carriage component is defined by the following limiting relationship equation:

[0055] 1. The geometric center deviation limit relationship of the upper and lower load plates of the sliding trolley is measured by Euclidean distance, and the exponential form ensures smooth transition, which is specifically expressed as follows:

[0056]

[0057] In the formula, x u ,y u is the geometric center coordinate of the upper bearing plate; x l ,y l is the geometric center coordinate of the lower bearing plate; δ c The recommended value for the allowable center deviation is no more than 2 mm.

[0058] 2. The contact pressure distribution relationship between the roller assembly and the U-shaped steel track adopts Gaussian distribution superimposed with periodic fluctuations to reflect the actual contact characteristics, which is specifically expressed as follows:

[0059]

[0060] Where p(x) is the contact pressure at position x; p0 is the maximum contact pressure, which is related to the load; x cis the pressure center position; σ is the standard deviation of pressure distribution; α is the periodic fluctuation coefficient, which ranges from 0.1 to 0.3; L is the circumference of the wheel groove, where the contact pressure is obtained through pressure-sensitive paper testing.

[0061] 3. The relationship between the height adjustment range and stability of the leveling mechanism is expressed as follows using a first-order time response model and taking into account the dynamic characteristics:

[0062]

[0063] In the formula, h adj is the height after adjustment; h0 is the initial height; P is the pitch; n is the number of rotations; k stiff is the support stiffness coefficient; β is the time attenuation coefficient; t is the stable time after adjustment.

[0064] The present invention proposes a large-scale equipment installation construction method, the core of which is to use U-shaped steel rails, sliding trolleys, hydraulic jacks and other auxiliary equipment to achieve stable transportation and precise positioning of large-scale equipment through a step-by-step implementation. The specific performance is as follows:

[0065] First, this method determines the optimal transportation route for large equipment by measuring and analyzing the process room environment, and selects auxiliary equipment that matches the equipment parameters, laying the foundation for subsequent transportation and installation. Secondly, a flat and stable temporary foundation is laid on the transportation route, and a U-shaped steel track is installed on this foundation, so that the large equipment can move horizontally along the track smoothly. At the turning point, this method also manufactures short tracks to ensure that the large equipment can turn smoothly. Thirdly, by installing a sliding trolley and lifting with a hydraulic jack, the large equipment is gradually put in place, avoiding safety hazards during direct lifting. Finally, after the large equipment is in place, it is firmly fixed with chemical bolts to ensure the accuracy and stability of the equipment installation.

[0066] Compared with the prior art, the solution of the present invention has the following advantages: first, it can fully adapt to the complex process room environment and ensure the smooth transportation and precise placement of large equipment; second, it does not require the use of large lifting equipment, which greatly reduces the installation cost; third, through the step-by-step operation method, it greatly reduces the safety risks of the installation process. Therefore, the large equipment installation construction method of the present invention not only improves the installation accuracy and safety, but also has strong process adaptability and economy. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative labor.

[0068] Figure 1 A schematic diagram of a sliding trolley for a large equipment installation construction method in a process workshop;

[0069] Figure 2 A schematic diagram of a sliding trolley for a large equipment installation construction method in a process workshop;

[0070] Figure 3 A schematic diagram of a U-shaped rail steel for a large equipment installation construction method in a process workshop;

[0071] In the accompanying drawings, the components represented by the reference numerals are listed as follows:

[0072] 1. Load-bearing seat; 11. Upper load-bearing plate; 12. Lower load-bearing plate; 2. Roller assembly; 21. Wheel frame; 22. Roller shaft; 23. Roller; 3. Leveling mechanism; 31. Leveling screw; 32. Threaded sleeve; 33. Support plate; 4. Locking mechanism; 41. Locking plate; 42. Brake block; 43. Swing rod; 5. Track body; 51. Bottom plate; 52. Vertical plates on both sides; 6. Connecting plate assembly; 61. Upper connecting plate; 62. Lower connecting plate; 7. Guide structure; 71. Guide block; 72. Limiting boss; 8. Reinforcement assembly; 81. Reinforcement ribs; 82. Connecting ribs. DETAILED DESCRIPTION

[0073] In order to make the purpose, technical solution and advantages of the embodiments of the present invention more clear, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0074] like Figure 1 , Figure 2 , Figure 3 FIG. 1 is a first embodiment of a large-scale equipment installation construction method for a process workshop provided by the present invention. In this embodiment, the following steps are included:

[0075] S10. Determine the transportation route of large equipment according to the entrance location of the process room, the foundation location, and the distribution of obstacles on site, and select the U-shaped steel rails, sliding trolleys, and hydraulic jacks used for the transportation of large equipment;

[0076] S20. Lay a temporary brick-soil foundation along the transport route. The lower layer width of the temporary foundation is 48 cm and the upper layer width is 24 cm to support the U-shaped steel track;

[0077] S30, installing the U-shaped steel track on a temporary foundation, and setting a short track for turning at the longitudinal and transverse intersection of the U-shaped steel track, wherein the length of the short track is the same as the width of the transverse track;

[0078] S40, placing four sliding trolleys on the U-shaped steel track, with the sliding trolleys corresponding to the four corners of the large equipment respectively, and using the lifting equipment to hoist the large equipment onto the sliding trolleys;

[0079] S50: Push the large equipment along the U-shaped steel track for horizontal transportation. When reaching the turning point, lock the upper sliding trolley of the longitudinal track and unlock the lower sliding trolley of the transverse track to drive the large equipment to complete the turning.

[0080] S60. After the large equipment is transported to the designated location, the large equipment is lifted as a whole using a hydraulic jack, and a brick wall is built under the U-shaped steel track. The lifting and building process is repeated until the large equipment reaches the equipment foundation elevation.

[0081] S70. Set a connecting track between the large equipment and the equipment foundation, and use a sliding trolley to smoothly move the large equipment to the equipment foundation;

[0082] S80. Use hydraulic jacks to lift large equipment, remove U-shaped steel tracks and sliding trolleys, and fine-tune the position of large equipment;

[0083] S90. Inject chemical bolts into the reserved installation holes of the equipment foundation to fix large equipment and remove the temporary foundation.

[0084] The structure of the sliding trolley used in the present invention is as follows:

[0085] The bearing seat 1 includes an upper bearing plate 11 and a lower bearing plate 12; a leveling mechanism 3 is provided between the upper bearing plate 11 and the lower bearing plate 12; roller assemblies 2 are provided at the four corners of the bottom of the lower bearing plate 12; the roller assembly 2 includes a wheel frame 21, a roller shaft 22 and a roller 23; the wheel frame 21 is fixedly mounted on the bottom of the lower bearing plate 12, and the roller 23 is rotatably mounted on the wheel frame 21 through the roller shaft 22; the locking mechanism 4 includes a locking plate 41, a brake block 42 and a swing lever 43, the locking plate 41 is hingedly mounted on the side wall of the lower bearing plate 12 through a hinge shaft, the brake block 42 is fixedly mounted on the inner side of the locking plate 41, one end of the swing rod 43 is fixedly connected to the locking plate 41, and the other end extends to the top of the lower bearing plate 12; a torsion spring for resetting the locking plate 41 is arranged between the side wall of the lower bearing plate 12 and the locking plate 41; the leveling mechanism 3 includes a leveling screw 31, a threaded sleeve 32 and a support plate 33; the four corners of the bottom of the upper bearing plate 11 are fixedly mounted A threaded sleeve 32 is fixedly installed; a through hole is opened on the lower bearing plate 12 at a position corresponding to the threaded sleeve 32; the leveling screw 31 passes through the through hole and is threadedly connected to the threaded sleeve 32; the support plate 33 is fixedly installed at the bottom end of the leveling screw 31 and supported on the lower bearing plate 12; an operating head for rotating the leveling screw 31 is provided at the top of the leveling screw 31; a bearing is sleeved on the roller shaft 22, and the outer ring of the bearing is interference fit with the inner ring of the roller 23; the roller shaft 22 Limiting retaining rings are respectively provided at both ends, and the limiting retaining rings are fixed to the wheel frame 21 by bolts; the roller 23 is made of high-strength wear-resistant steel, and a deepened rolling groove is provided on the surface, and the rolling groove matches the U-shaped steel track; the torsion spring includes a torsion spring body, a first torsion arm and a second torsion arm; the torsion spring body is sleeved on the hinge shaft; the first torsion arm abuts against the side wall of the lower bearing plate 12, and the second torsion arm abuts against the outer side of the locking plate 41; the torsion spring applies an upward torque to the locking plate 41.

[0086] When the locking plate 41 is hinged to the side wall of the lower bearing plate 12 through the hinge shaft, the brake block 42 is located directly above the roller 23; the swing rod 43 is L-shaped, and its horizontal section is fixed to the outer wall of the locking plate 41 through a connecting plate, and its vertical section extends to above the lower bearing plate 12; a handle with anti-slip patterns is provided on the top of the vertical section of the swing rod 43; an anti-slip pad is provided on the upper surface of the upper bearing plate 11, and the anti-slip pad is made of rubber; a raised rib is provided on the edge of the upper bearing plate 11; and fastening holes are provided at the four corners of the upper bearing plate 11.

[0087] A reinforcing rib plate is provided at the bottom of the lower bearing plate 12; the reinforcing rib plates are arranged in a cross shape; the through holes opened on the lower bearing plate 12 are located at the intersections of the reinforcing rib plates; the wheel frame 21 is installed at the ends of the reinforcing rib plates by bolts.

[0088] The brake block 42 is made of wear-resistant rubber material, and the bottom surface of the brake block 42 is provided with anti-slip grooves; the inner side of the locking plate 41 is provided with a receiving groove, and the brake block 42 is embedded and installed in the receiving groove through a dovetail groove structure; the outer side of the locking plate 41 is provided with reinforcing ribs.

[0089] A reinforcing rib plate is provided at the corner between the horizontal section and the vertical section of the swing rod 43; the connecting plate is connected to the locking plate 41 through high-strength bolts; and a protective material is provided on the outer surface of the handle.

[0090] The sliding track structure of the present invention is as follows:

[0091] The U-shaped steel track includes: a track body 5, a connecting plate assembly 6, a guide structure 7 and a reinforcement assembly 8; the track body 5 is made of high-strength steel, including a bottom plate 51 and two vertical plates 52 on both sides; the two vertical plates 52 on both sides are vertically welded on both sides of the bottom plate 51 to form a U-shaped groove structure; the connecting plate assembly 6 includes an upper connecting plate 61 and a lower connecting plate 62; the upper connecting plate 61 and the lower connecting plate 62 are respectively arranged at the ends of two adjacent sections of the track body 5, and the upper connecting plate 61 and the lower connecting plate 62 are fixedly connected by high-strength bolts; the guide structure 7 includes a guide block 71 and limiting bosses 72, the guide block 71 is welded and fixed to the inner wall of the vertical plates 52 on both sides, and the upper surface of the guide block 71 is arc-shaped; the limiting bosses 72 are welded on both sides of the guide block 71; the reinforcing assembly 8 includes reinforcing ribs 81 and connecting ribs 82, the reinforcing ribs 81 are triangular in shape, and are evenly welded on the outside of the track body 5, between the bottom plate 51 and the vertical plates 52 on both sides; the connecting ribs 82 are fixed between two adjacent reinforcing ribs 81; the top ends of the vertical plates 52 on both sides are bent outwards to form folded edges to avoid scratching with the sliding trolley.

[0092] Among them, in the above technical scheme, the specific implementation method of step S10 is as follows: First, according to the entrance position of the process room, the foundation position and the distribution of obstacles on site, the transportation route of the large equipment is determined by measuring and drawing. Specifically, step 11 is to measure the entrance size of the process room, detect the position of obstacles in the process room, and draw a plan layout of the process room, and mark the position of the foundation of the large equipment on the plan layout. Step 12 is to plan the transportation route of the large equipment on the plan layout according to the distance between the entrance position of the process room and the foundation position of the large equipment, and determine the number of turns required for the large equipment. Step 13 is to select U-shaped steel rails, sliding trolleys and hydraulic jacks with matching load-bearing grades according to the weight and size parameters of the large equipment, and conduct safety inspections on these equipment before use.

[0093] The purpose of these steps is to determine the optimal transportation route for large equipment, select appropriate auxiliary equipment, and lay the foundation for subsequent transportation and installation. Among them, steps 11 and 12 use the basic knowledge of spatial geometry and path planning, which can be completed with the help of computer drawing software. Step 13 requires selecting appropriate auxiliary equipment through comparative analysis based on the parameters of large equipment, and performing safety inspections on them to ensure that there will be no safety hazards during the subsequent installation process.

[0094] Furthermore, in the above technical solution, the specific implementation method of step S20 is as follows: First, the site is leveled along the transportation route, the road debris is removed, and the flatness of the ground of the transportation route is measured with a level ruler. Then, a temporary foundation is built with red bricks in an I-shaped arrangement, the lower layer adopts a one-brick wall masonry method, the masonry height is 2 layers, and the width is 48 cm, and the upper layer adopts a half-brick wall masonry method, the masonry height is 2 layers, and the width is 24 cm. During the masonry process, the brick joints are filled with fine soil, the red bricks are stacked in a staggered manner, and the masonry surface is smoothed with 1:3 cement mortar.

[0095] The purpose of these steps is to lay a flat and stable temporary foundation for the transportation of large equipment to ensure that it will not tilt or sink during the subsequent transportation process. Among them, step 21 uses the foundation leveling technology commonly used in foundation engineering construction, and the use of a level ruler to measure can ensure the flatness of the temporary foundation. Steps 22 and 23 use the staggered masonry, fine soil filling, and cement mortar equalization technologies commonly used in masonry technology to improve the strength and stability of the temporary foundation.

[0096] Furthermore, in the above technical solution, the specific implementation method of step S30 is as follows: First, use a laser level to measure the elevation of the temporary foundation surface, adjust the flatness of the foundation, and ensure that the height difference in the vertical and horizontal directions does not exceed 2 mm. Then, apply a 1:2 cement mortar leveling layer on the top surface of the temporary foundation, place the U-shaped steel track on the leveling layer, and calibrate the elevation of the track using a ruler and a level. Finally, at the vertical and horizontal intersection of the U-shaped steel track, disconnect the longitudinal track and make a short track with the same width as the horizontal track to ensure that the short track is smoothly connected to the longitudinal track.

[0097] The purpose of these steps is to provide a flat and stable foundation for the installation of the U-shaped steel track and to manufacture short tracks at the turns to ensure that large equipment can turn smoothly. Among them, step 31 uses the measurement technology of the laser level to ensure that the flatness of the temporary foundation meets the requirements. Step 32 uses cement mortar leveling, ruler and level ruler calibration techniques to ensure the elevation and levelness of the U-shaped steel track installation. Step 33 uses the method of making short tracks to ensure that large equipment can turn smoothly in response to the special requirements of the turns.

[0098] Furthermore, in the above technical solution, the specific implementation method of step S40 is as follows: First, a sliding trolley is installed on the U-shaped steel track, and the spacing of the sliding trolleys is adjusted to correspond to the four corners of the large equipment. Then, the leveling mechanism on the sliding trolley is used to adjust the horizontality of the bearing plane to ensure that the elevations of the bearing planes of the four sliding trolleys are consistent. Finally, a mobile gantry crane is used to hoist the large equipment onto the four sliding trolleys, and the large equipment is fixedly connected to the sliding trolley through the fastening holes on the bearing plate of the sliding trolley.

[0099] The purpose of these steps is to install the large equipment on a mobile platform composed of sliding trolleys in preparation for subsequent horizontal transportation. Among them, step 41 uses the technology of adjusting the distance between the sliding trolleys to ensure that the sliding trolleys match the four corners of the large equipment. Step 42 uses the sliding trolley leveling mechanism to adjust the load-bearing plane of the sliding trolleys to ensure that the heights of the four sliding trolleys are consistent. Step 43 uses the lifting technology of a mobile gantry crane to safely and stably lift the large equipment onto the sliding trolley and fix it through fastening holes to ensure that it will not move during transportation.

[0100] Furthermore, in the above technical solution, the specific implementation method of step S50 is as follows: First, a lever tool is used to push the large equipment along the U-shaped steel track for horizontal transportation, and personnel are arranged to observe the operating status of the large equipment during the pushing process. When the large equipment is transported to the turning point, the locking mechanism of the sliding trolley is operated, and the locking plate is pressed downward by the swing rod to make the brake block contact the roller, thereby locking the sliding trolley on the longitudinal track. Then, the locking state of the sliding trolley on the lower layer of the transverse track is released, and the large equipment is pushed to be transported along the transverse track, driving the short track to move synchronously to complete the turning.

[0101] The purpose of these steps is to ensure that large equipment can be transported horizontally along the U-shaped steel track smoothly and smoothly, and the locking and unlocking mechanism of the sliding trolley is used at the turning point to achieve smooth steering of the large equipment. Among them, step 51 uses the technology of lever tools to push large equipment, combined with the method of on-site observation by personnel to ensure the safety of the transportation process. Steps 52 and 53 involve the operation of the sliding trolley locking mechanism, which locks the sliding trolley on the longitudinal track and then unlocks the sliding trolley on the lower layer of the transverse track to achieve smooth steering of the large equipment. This method makes full use of the structural characteristics of the sliding trolley and can ensure the stability of the turning process.

[0102] Furthermore, in the above technical solution, the specific implementation method of step S60 is as follows: First, place the hydraulic jack under the four sliding trolleys, and adjust the support point position of the jack to correspond to the force point of the large equipment. Then, synchronously operate the four hydraulic jacks to lift the large equipment, and lay a brick wall under the U-shaped steel track in a brick wall manner, and fill the brick seams with fine soil. Finally, slowly lower the hydraulic jack to make the large equipment fall smoothly on the newly built brick wall, and repeat the lifting and laying process until the large equipment reaches the elevation of the equipment foundation.

[0103] The purpose of these steps is to gradually lift the large equipment to the equipment foundation elevation through the lifting action of the hydraulic jack, and to build a brick wall under the U-shaped steel track as support. Among them, step 61 uses the positioning technology of the hydraulic jack to ensure that the support point of the jack coincides with the force point of the large equipment. Steps 62 and 63 involve the comprehensive operation of lifting, building and slowly lowering. The use of a brick wall masonry method can improve the strength and stability of the brick wall and ensure that the large equipment can land smoothly on the newly built brick wall. This method of gradual lifting and building can ensure that the large equipment smoothly transitions to the equipment foundation elevation.

[0104] Furthermore, in the above technical solution, the specific implementation method of step S70 is as follows: First, a connecting track is set between the large equipment track and the equipment foundation, and a level ruler is used to measure the height difference between the connecting track and the tracks on both sides. Then, the elevation and inclination of the connecting track are adjusted to ensure a smooth transition with the tracks on both sides, and a steel plate is used to reinforce the connection. Finally, the locking state of the sliding trolley is released, and a lever tool is used to push the large equipment so that it moves smoothly to the equipment foundation through the connecting track.

[0105] The purpose of these steps is to set up a smoothly transitioned connecting track between the large equipment and the equipment foundation, ensuring that the large equipment can be stably moved to the equipment foundation. Among them, step 71 uses the level measurement technology to determine the height difference between the connecting track and the tracks on both sides. Step 72 involves adjusting the elevation and inclination of the connecting track, as well as using steel plate reinforcement measures to ensure a smooth transition between the connecting track and the tracks on both sides. Step 73 uses a lever tool to push the large equipment so that it can move smoothly to the equipment foundation through the connecting track. This method is conducive to reducing the vibration and tilt of the large equipment during movement.

[0106] Furthermore, in the above technical solution, the specific implementation method of step S80 is as follows: First, hydraulic jacks are installed at the four corners of the large equipment, the large equipment is lifted synchronously, and the axis position is marked on the equipment foundation. Then, the sliding trolley and the U-shaped steel track are removed, the surface of the equipment foundation is cleaned, and the position of the large equipment is adjusted using the hydraulic jack. Finally, the installation position of the large equipment is measured using a theodolite, and the large equipment is adjusted to correspond to the axis position, and the horizontal error is ensured not to exceed 1 mm.

[0107] The purpose of these steps is to use hydraulic jacks to make fine adjustments to large equipment after removing auxiliary equipment to ensure that its final installation position is accurate and the levelness meets the requirements. Among them, step 81 uses the jacking function of the hydraulic jack to mark the axis position on the equipment foundation. Step 82 involves removing the sliding trolley and U-shaped steel track and cleaning the surface of the equipment foundation to create conditions for subsequent fine adjustments. Step 83 uses the theodolite measurement method combined with the adjustment of the hydraulic jack to ensure the accuracy and levelness of the final installation position of the large equipment. These measures help to improve the installation accuracy of large equipment and ensure that its installation position meets the requirements.

[0108] Furthermore, in the above technical solution, the specific implementation method of step S90 is as follows: First, clean the debris in the installation hole reserved in the equipment foundation, use compressed air to blow the installation hole, and use a wire brush to clean the inner wall of the installation hole. Then, inject epoxy resin anchoring agent into the installation hole, bury the chemical bolt in the installation hole, and adjust the exposed length of the chemical bolt to ensure the verticality of the bolt. Finally, after the chemical bolt is cured, tighten the chemical bolt with a torque wrench, remove the temporary foundation and construction auxiliary facilities, and clean the construction site.

[0109] The purpose of these steps is to firmly install the large equipment on the equipment foundation through the fixed connection of chemical bolts, and at the same time remove the temporary foundation and construction auxiliary facilities to complete the installation of the large equipment. Among them, step 91 uses compressed air blowing and wire brush cleaning to ensure that the inside of the installation hole is clean and free of impurities. Step 92 involves injecting epoxy resin anchoring agent into the installation hole and adjusting the exposed length and verticality of the chemical bolts. These measures help to improve the fixing strength and stability of the chemical bolts. Step 93 uses a torque wrench to tighten the chemical bolts, remove the temporary foundation and auxiliary facilities, and ensure the stability of the final installation position of the large equipment.

[0110] The meanings of the symbols in the formulas of the present invention are shown in Table 1

[0111] Table 1 Meaning of symbols in the invention formula

[0112]

[0113]

[0114] The present invention provides a second embodiment of a large-scale equipment installation construction method for a process workshop. In this embodiment, an installation scenario of a large-scale generator set is provided:

[0115] A power plant has newly built a 1000 MW steam turbine generator set, which weighs about 3000 tons and has dimensions of 25 meters long, 12 meters wide and 10 meters high. Since the entrance dimensions of the power plant process room are only 15 meters wide and 12 meters high, it is impossible to directly hoist the whole machine, so the large equipment installation construction method proposed in the present invention is adopted.

[0116] The first step is to measure the size of the process room entrance and the distribution of internal obstacles, draw a plan of the process room layout, and mark the foundation position of the generator set on the plan. After analysis, the generator set needs to turn three times to be transported from the process room entrance to the foundation position. According to the weight and size parameters of the generator set, a U-shaped steel track with a load-bearing capacity of 100 tons and a track width of 800 mm, a sliding trolley with a load-bearing capacity of 50 tons, and a hydraulic jack with a maximum lifting force of 100 tons were selected.

[0117] The second step is to build a temporary foundation along the transportation route of the generator set using red bricks. The specific structure is shown in Table 2:

[0118] Table 2 Construction parameters of temporary foundation

[0119] level Width (cm) Masonry height (layer) Masonry method Lower level 48 2 A brick wall upper layer 24 2 Half brick wall

[0120] During the masonry process, fine soil was used to fill the brick joints, and the masonry surface was smoothed with 1:3 cement mortar. After measurement, the flatness of the temporary foundation surface met the requirements, and the maximum height difference did not exceed 2 mm.

[0121] The third step is to apply a 1:2 cement mortar leveling layer on the top surface of the temporary foundation and install the U-shaped steel track on the leveling layer. In order to achieve smooth turning of the generator set at the turn, a short track with a length of 800 mm and a width of 800 mm was made at the vertical and horizontal intersections of the track.

[0122] The fourth step is to install four sliding trolleys on the U-shaped steel track and adjust the horizontality of the load-bearing plane through the leveling mechanism to make the heights of the four sliding trolleys consistent. A 25-ton mobile gantry crane is used to hoist the generator set onto the four sliding trolleys and fix them through the fastening holes.

[0123] The fifth step is to push the generator set along the U-shaped steel track for horizontal transportation. At the turning point, operate the locking mechanism of the sliding trolley to lock the sliding trolley on the longitudinal track, while the sliding trolley under the transverse track is in an unlocked state, driving the generator set to turn smoothly.

[0124] Step 6. After the generator set is transported to the designated location, four 100-ton hydraulic jacks are used to lift the generator set, and brick walls are built layer by layer under the U-shaped steel track to gradually lift the generator set to the equipment foundation elevation.

[0125] The seventh step is to set up a connecting track between the generator set and the foundation, and use a sliding trolley to smoothly move the generator set to the foundation.

[0126] In the eighth step, use a hydraulic jack to lift the generator set, remove the sliding trolley and U-shaped steel track, and use a theodolite to adjust the installation position of the generator set to ensure that the horizontal error does not exceed 1 mm.

[0127] The ninth step is to inject epoxy resin anchor into the reserved holes in the foundation, fix and install the chemical bolts, and complete the installation of the generator set after removing the temporary foundation.

[0128] By adopting the large-scale equipment installation construction method of the present invention, the 1000 MW generator set was successfully installed without any safety accidents. Compared with the traditional whole machine hoisting or disassembly assembly method, this method not only improves the installation accuracy and reduces the safety hazards, but also greatly reduces the construction cost, reflecting strong process adaptability.

[0129] The present invention provides a third embodiment of a large-scale equipment installation construction method for a process workshop. In this embodiment, specific structural parameters and performance indicators of a sliding trolley and a U-shaped steel track are provided:

[0130] 1. The structure of the sliding trolley:

[0131] The overall structure of the sliding trolley is shown in Table 3, which mainly consists of four parts: a bearing seat, a roller assembly, a leveling mechanism and a locking mechanism.

[0132] Table 3 Structural parameters of the sliding trolley

[0133] Part Name Material Dimensions (mm) effect Bearing seat -Upper load plate 60Cr2MnSiA high strength steel 1200×1200×20 Provide a loading surface for the equipment -Lower load plate 60Cr2MnSiA high strength steel 1300×1300×25 Connecting roller assembly and leveling mechanism Roller assembly -Wheel frame 45# Steel Φ300×100 Fixed installation roller -Roller shaft 45# Steel Φ90×250 Connect with roller to realize rotation -Roller 60SiMnCr spring steel Φ280×100 Contact with U-shaped steel rail to provide smooth movement Leveling mechanism -Leveling screw 45# Steel M36×5 Height adjustment of the loading surface by rotation -Threaded sleeve Copper Alloy M36 Cooperate with the leveling screw to provide a spiral pair -Support plate 45# Steel 300×300×20 Support the lower part of the bearing seat Locking mechanism - Locking plate 45# Steel 300×200×25 Locking of the rollers by means of a swing lever -Brake pads Wear-resistant rubber 200×100×50 Contact with roller provides braking -Swing rod 45# Steel 500×100×20 Manually operated locking plate

[0134] Through the above structural design, the sliding trolley can meet the following performance requirements:

[0135] 1. Load-bearing capacity: A single sliding trolley can carry 50 tons, and four sliding trolleys can carry 200 tons of large equipment together.

[0136] 2. Leveling range: The leveling screw can adjust the load plane height ±50 mm to ensure that the heights of the four sliding trolleys are consistent.

[0137] 3. Steering stability: The locking mechanism reliably locks the sliding trolley on the longitudinal track and releases the sliding trolley under the transverse track at the same time, achieving smooth steering of large equipment.

[0138] 4. Smooth movement: The rollers are made of high-quality steel, and the surface is provided with rolling grooves that match the depth of the U-shaped steel track, which can achieve smooth movement on the track.

[0139] 2. The structure of U-shaped steel track:

[0140] The overall structure of the U-shaped steel track is shown in Table 4, which mainly consists of four parts: track body, connecting plate assembly, guide structure and reinforcement assembly.

[0141] Table 4 Structural parameters of U-shaped steel track

[0142] Part Name Material Dimensions (mm) effect Track body Q345B Steel - Bottom plate Q345B Steel 800×20 Provide bearing surface -Vertical panels Q345B Steel 800×100×12 Forming a U-shaped groove structure Connecting plate assembly -Upper connecting plate Q345B Steel 800×120×20 Connecting to adjacent track sections -Lower connecting plate Q345B Steel 800×150×25 Strengthen the connection Guide structure -Guide blocks Q345B Steel 200×100×50 Guide rollers for smooth sliding -Limiting boss Q345B Steel 100×50×30 Prevent rollers from derailing Strengthening components -Strengthening ribs Q345B Steel 800×150×20 Enhance the overall strength of the track -Connecting ribs Q345B Steel Φ20×800 Connect adjacent stiffeners

[0143] Through the above structural design, the U-shaped steel track can meet the following performance requirements:

[0144] 1. Carrying capacity: A single section of track can carry 100 tons, and the overall track system can carry 200 tons of large equipment.

[0145] 2. Stability: The arc-shaped upper surface of the guide block can guide the sliding trolley roller to slide smoothly, and the limit boss can prevent the roller from derailing.

[0146] 3. Overall strength: The design of reinforced ribs and connecting ribs effectively enhances the overall stiffness and load-bearing capacity of the entire track system.

[0147] 4. Impact resistance: The rail body is made of Q345B high-quality steel, which has good deformation resistance and impact resistance.

[0148] The core of the large equipment installation construction method of the present invention is to make full use of auxiliary equipment such as U-shaped steel rails, sliding trolleys and hydraulic jacks, and realize the stable transportation and precise positioning of large equipment through step-by-step implementation. The technical principle of this method is as follows:

[0149] First, when determining the transportation route for large equipment, the actual environmental conditions of the process room were fully considered, including the entrance size, internal obstacle distribution, etc., and U-shaped steel tracks, sliding trolleys and hydraulic jacks with matching load-bearing performance were selected based on the size and weight parameters of the equipment. These steps ensure the adaptability and safety of the equipment during the subsequent installation process.

[0150] Secondly, a temporary foundation was laid on the transport route, using red brick masonry to form an I-shaped section with a lower width of 48 cm and an upper width of 24 cm. This temporary foundation not only has a good bearing capacity, but also ensures the flatness of the foundation surface by adjusting measures such as filling brick joints and applying cement mortar. On this basis, U-shaped steel tracks were installed, and short tracks were made at the turns to achieve smooth horizontal movement of large equipment.

[0151] Thirdly, by installing a sliding trolley and lifting it with a hydraulic jack, the large equipment was gradually put into place. Among them, the key technology of the sliding trolley is: adjusting the horizontality of the load-bearing plane through the leveling mechanism to ensure that the heights of the four sliding trolleys are consistent; the locking mechanism can brake the rollers to ensure that the large equipment can turn stably at the corners. The hydraulic jack provides a vertical lifting force, and cooperates with the horizontal movement of the sliding trolley to enable the large equipment to be gradually put into place to the equipment foundation elevation.

[0152] Finally, after the large equipment is in place, it is firmly installed on the equipment foundation through the fixed connection of chemical bolts. Chemical bolts have good anchoring performance, and combined with the tightening of torque wrenches, they can ensure the installation accuracy and stability of large equipment.

Claims

1. A method for installing and constructing large equipment in a process workshop, characterized in that: The following steps are involved: S10, determining the transportation route of the large equipment according to the process room entrance location, foundation location, and on-site obstacle distribution conditions, and selecting the U-shaped steel track, sliding trolley, and hydraulic jack for the transportation of the large equipment; S20, laying a temporary brick-soil foundation along the transport route, wherein the lower layer width of the temporary foundation is 48 cm and the upper layer width is 24 cm, for supporting the U-shaped steel track; S30, installing the U-shaped steel track on the temporary foundation, and providing a short track for turning at the longitudinal and transverse intersection of the U-shaped steel track, wherein the length of the short track is the same as the width of the transverse track; S40, placing four sliding trolleys on the U-shaped steel track, the sliding trolleys corresponding to the four corners of the large equipment respectively, and using a lifting device to hoist the large equipment onto the sliding trolleys; S50, pushing the large equipment to be transported horizontally along the U-shaped steel track, locking the upper sliding trolley of the longitudinal track when reaching the turning point, unlocking the lower sliding trolley of the transverse track, and driving the large equipment to complete the turning; S60, after the large equipment is transported to the designated location, the large equipment is lifted as a whole using the hydraulic jack, and a brick wall is built under the U-shaped steel track, and the lifting and building processes are repeated until the large equipment reaches the equipment foundation elevation; S70, setting a connecting track between the large equipment and the equipment foundation, and using the sliding trolley to smoothly move the large equipment to the equipment foundation; S80, using the hydraulic jack to lift up the large equipment, removing the U-shaped steel track and the sliding trolley, and fine-tuning the position of the large equipment; S90, injecting chemical bolts into the reserved installation holes of the equipment foundation to fix the large equipment, and removing the temporary foundation.

2. A large equipment installation construction method for a process workshop according to claim 1, characterized in that: The step S10 specifically includes: Step 11, measuring the size of the entrance of the process room, detecting the position of obstacles in the process room, drawing a plan layout of the process room, and marking the position of the foundation of the large equipment on the plan layout; Step 12: planning the transportation route of the large equipment on the plan layout according to the distance between the entrance position of the process room and the base position of the large equipment, and determining the number of turns of the large equipment; Step 13: According to the weight and size parameters of the large equipment, select the U-shaped steel rail, the sliding trolley and the hydraulic jack with matching load-bearing grades, and perform a safety inspection on the U-shaped steel rail, the sliding trolley and the hydraulic jack before use.

3. A large equipment installation construction method for a process workshop according to claim 2, characterized in that: The step S20 specifically includes: Step 21: level the site along the transport route, remove road debris, and use a level ruler to measure the flatness of the ground along the transport route; Step 22, using red bricks to lay the temporary foundation in an I-shaped arrangement, the lower layer adopts a single brick wall masonry method, the masonry height is 2 layers, the width is 48 cm, and the upper layer adopts a half brick wall masonry method, the masonry height is 2 layers, and the width is 24 cm; Step 23, during the red brick laying process, the brick joints are filled with fine soil, the red bricks are staggered and laid, and the masonry surface is smoothed with 1:3 cement mortar.

4. A large equipment installation construction method for a process workshop according to claim 3, characterized in that: The step S30 specifically includes: Step 31, using a laser level to measure the surface elevation of the temporary foundation, and adjusting the flatness of the temporary foundation to ensure that the height difference in the vertical and horizontal directions does not exceed 2 mm; Step 32, apply a 1:2 cement mortar leveling layer on the top surface of the temporary foundation, place the U-shaped steel track on the leveling layer, and calibrate the elevation of the U-shaped steel track using a ruler and a level ruler; Step 33: At the intersection of the U-shaped steel rail, the longitudinal rail is disconnected to make a short rail with the same width as the transverse rail, ensuring that the short rail is smoothly connected to the longitudinal rail.

5. A large equipment installation construction method for a process workshop according to claim 4, characterized in that: The step S40 specifically includes: Step 41, installing the sliding trolley on the U-shaped steel track, and adjusting the distance between the sliding trolleys to correspond to the four corners of the large equipment; Step 42: Use the leveling mechanism on the sliding trolley to adjust the horizontality of the bearing plane of the sliding trolley to ensure that the bearing planes of the four sliding trolleys have the same elevation; Step 43: Use a mobile gantry crane to hoist the large equipment onto the four sliding trolleys, and fix the large equipment to the sliding trolleys through the fastening holes on the bearing plates of the sliding trolleys.

6. A large equipment installation construction method for a process workshop according to claim 5, characterized in that: The step S50 specifically includes: Step 51: Use a lever tool to push the large equipment along the U-shaped steel track for transportation, and arrange personnel to observe the operating status of the large equipment during the pushing process; Step 52, when the large equipment is transported to the turning place, the sliding trolley locking mechanism is operated, and the locking plate is pressed downward by the swing rod, so that the brake block contacts the roller, and the sliding trolley is locked on the longitudinal track; Step 53: Release the locking state of the sliding trolley on the lower layer of the transverse track, push the large equipment to be transported along the transverse track, and drive the short track to move synchronously.

7. A large equipment installation construction method for a process workshop according to claim 6, characterized in that: The step S60 specifically includes: Step 61, placing the hydraulic jack under the four sliding carriages, and adjusting the supporting point position of the hydraulic jack to correspond to the stress point of the large equipment; Step 62: synchronously operate the four hydraulic jacks to lift the large equipment, and build the brick wall under the U-shaped steel track in a brick wall manner, and fill the brick joints with fine soil; Step 63, slowly lower the hydraulic jack to allow the large equipment to land stably on the newly built brick wall, and repeat the lifting and stacking process until the equipment foundation elevation is reached.

8. A large equipment installation construction method for a process workshop according to claim 7, characterized in that: The step S70 specifically includes: Step 71, setting the connecting track between the large equipment track and the equipment foundation, and using a level ruler to measure the height difference between the connecting track and the tracks on both sides; Step 72: Adjust the elevation and inclination of the connecting track to ensure a smooth transition with the tracks on both sides, and use steel plates to reinforce the connection between the connecting track and the tracks on both sides; Step 73, release the locking state of the sliding trolley, use a lever tool to push the large equipment, and make it move smoothly to the equipment foundation through the connecting track.

9. A large equipment installation construction method for a process workshop according to claim 8, characterized in that: The step S80 specifically includes: Step 81, installing the hydraulic jacks at the four corners of the large equipment, synchronously lifting the large equipment, and marking the axis position on the equipment base; Step 82: remove the sliding trolley and the U-shaped steel track, clean the surface of the equipment foundation, and use the hydraulic jack to adjust the position of the large equipment; Step 83: Use a theodolite to measure the installation position of the large equipment, adjust the large equipment to make it correspond to the axis position, and ensure that the horizontality error does not exceed 1 mm.

10. A large equipment installation construction method for a process workshop according to claim 9, characterized in that: The step S90 specifically includes: Step 91, clean up the debris in the reserved installation hole of the equipment foundation, use compressed air to blow the installation hole, and use a wire brush to clean the inner wall of the installation hole; Step 92, injecting epoxy resin anchoring agent into the mounting hole, embedding the chemical bolt into the mounting hole, and adjusting the exposed length of the chemical bolt to ensure the verticality of the bolt; Step 93: After the chemical bolts are solidified, tighten the chemical bolts with a torque wrench, remove the temporary foundation and construction auxiliary facilities, and clean up the construction site.

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