A corrugated compensator repair device and repair method thereof

Abstract

The present invention provides a bellows compensator repair device and a repair method thereof, comprising an old bellows arranged between a hot blast furnace and a hot blast main pipe, the old bellows comprising a bellows section and a straight section, characterized in that the old bellows is provided with a repair pipe formed by connecting at least two tube lobes, each tube lobe comprising a straight tube lobe placed on the periphery of the bellows section of the old bellows, and a bellows lobe placed on the periphery of the straight section of the old bellows. The planned outage time of the blast furnace can be utilized, and the repair pipe can be coated on the faulty old bellows in only 24-48 hours without having to remove it, greatly shortening the repair time. The existing technology requires 8-10 days to replace a new bellows compensator. Furthermore, the coated repair pipe has good high-temperature resistance, pressure resistance, and fatigue resistance, and can be tightly integrated with the old bellows, saving costs, and not affecting the hot blast furnace's normal supply of high-temperature hot air to the blast furnace, thereby maintaining normal smelting in the blast furnace.

Description

Technical Field

[0001] The present invention relates to a repair device and method, in particular to a repair device and method for a corrugated compensator, and belongs to the technical field of pipeline transportation. Background Art

[0002] A bellows compensator is a flexible, thin-walled, transversely corrugated expansion and contraction component. Its expansion element is primarily a stainless steel bellows. During pipeline transportation, the bellows' expansion and bending provide axial, radial, and angular compensation for the pipeline. Its operating principle is that when power and thermal pipes expand due to temperature and pressure fluctuations within the fluid, the bellows absorb the pipe deformation energy, thereby compensating for the energy and preventing pipe cracking and even leakage caused by rigid deformation. Consequently, bellows compensators are widely used in industry. However, in actual production applications, particularly in the metallurgical industry, such as on the hot blast branch pipes of blast furnaces, bellows compensators must absorb not only the axial displacement energy of the hot blast branch pipes, but also their own thermal expansion and the radial displacement energy of the branch pipe expansion. Axial displacement of the branch pipe compresses the refractory brickwork within the pipe, while radial displacement can shear the brickwork, which can be detrimental to the brickwork structure. Furthermore, when the hot blast furnace is firing and delivering air, the air temperature inside the hot blast branch pipe fluctuates greatly, which can easily damage the refractory bricks inside the hot blast branch pipe. This is especially true when the radial displacement of the hot blast branch pipe compensator is large. If this is not promptly and effectively addressed, the hot blast branch pipe compensator can break and leak air, forcing production to be suspended to repair or replace the damaged hot blast branch pipe compensator. This not only affects normal production, but also requires the removal of refractory bricks to weld cracks and holes, and then the replacement of refractory bricks. This is obviously extremely inefficient and takes a long time to repair, with replacement taking about 10 days, resulting in economic losses for the company. Therefore, it is necessary to improve the existing technology. Summary of the Invention

[0003] The technical problem to be solved by the invention is: how to repair the corrugated compensator on the hot blast branch pipe that has failed or is about to fail online in a shorter time and at a faster speed in a temporary wind-off state, so as not to affect the normal supply of high-temperature hot air to the blast furnace by the hot blast stove and maintain blast furnace smelting.

[0004] The first object of the present invention is to provide a corrugated compensator repair device.

[0005] The second object of the present invention is to provide a method for repairing a corrugated compensator based on the corrugated compensator repair device.

[0006] The first object of the present invention is achieved through the following technical solutions: a bellows compensator repair device, comprising an old bellows arranged between a hot blast stove and a hot blast main pipe, the old bellows comprising a bellows section and a straight pipe section, characterized in that the old bellows is provided with a repair pipe formed by connecting at least two tube lobes, each tube lobe comprising a straight tube lobe placed on the periphery of the bellows section of the old bellows, and a bellows lobe placed on the periphery of the straight pipe section of the old bellows, so that the repair pipe formed by connecting at least two tube lobes can be quickly covered on the old bellows that has failed or is about to fail, thereby completing online repair, thereby not affecting the hot blast stove to normally provide high-temperature hot air to the blast furnace and maintain blast furnace smelting.

[0007] The bellows petal is provided with at least one outwardly protruding corrugation, and reinforcements are provided on both sides of the corrugation. The reinforcements are hollow reinforcement tubes through which cooling medium passes, or solid reinforcement tubes, so as to increase the strength of the bellows petal and improve its service life.

[0008] The at least two pipe petals are connected to form a repair pipe through the axial flanges thereon and the bolts and nuts on the axial flanges.

[0009] The at least two tube petals are axially welded to form a repaired tube.

[0010] The inner wall of the tube flap is provided with an insulation layer, which is made of high-temperature resistant insulation material with a thickness of 30-60 mm, so as to increase the service life of the tube flap and tightly wrap around the old corrugated pipe.

[0011] The thermal insulation materials are aluminum silicate fiber cotton and aerogel insulation felt, wherein the aluminum silicate fiber cotton is arranged on the inner wall of the straight tube valve, and the aerogel insulation felt is arranged on the inner wall of the corrugated tube valve, and each layer of thermal insulation material is tied with steel wire to prevent the thermal insulation material from being dislocated.

[0012] The two ends of the repair pipe are respectively connected to the corresponding flanges of the hot blast stove and the hot blast main pipe through radial flanges and bolts and nuts thereon, or the two ends of the repair pipe are respectively connected to the hot blast stove and the hot blast main pipe through radial welding.

[0013] A plurality of axial adjustable pull rods are provided between the hot blast furnace and the hot blast main pipe along the circumferential direction. The adjustable pull rods include a first and a second connecting screw respectively fixed to the hot blast furnace and the hot blast main pipe, and a sleeve with an internal thread connected to the first and the second connecting screws, and the internal threads at both ends of the sleeve have opposite spiral directions, so that the sleeve can be rotated forward to bring the first and the second connecting screws closer to complete the tightening of the pull rod, and vice versa to move the first and the second connecting screws away to complete the loosening of the pull rod.

[0014] The second object of the present invention is achieved through the following technical solution: a method for repairing a corrugated compensator based on the corrugated compensator repair device, characterized by comprising the following steps:

[0015] A. Install multiple adjustable tie rods along the circumferential direction between the hot blast furnace and the hot blast main pipe. Adjust the multiple adjustable tie rods to axially tighten the old corrugated pipe between the hot blast furnace and the hot blast main pipe, and at the same time, compress the refractory bricks inside the old corrugated pipe;

[0016] B. Cover the old corrugated pipe with a layer of thermal insulation material;

[0017] C. Wrap at least two tube petals on the insulation material layer of the old bellows, and place the straight tube petal of each tube petal on the periphery of the bellows section of the old bellows, and the bellows petal on the periphery of the straight tube section of the old bellows. The old bellows is clamped into the insulation layer through the insulation material layer to prevent the tube petals and the old bellows from moving relative to each other, and displacement compensation is completed through the bellows petals;

[0018] D. Connect and fix at least two pipe petals to form a repair pipe through the axial flange of each pipe petal and the bolts and nuts thereon, or axially weld at least two pipe petals to form a repair pipe;

[0019] E. Install hollow reinforcement tubes with cooling medium inside on both sides of each corrugated tube of the repaired pipe to cool each corrugated tube of the repaired pipe and improve its anti-deformation strength; or install solid reinforcement tubes to improve the anti-deformation strength of each corrugated tube of the repaired pipe;

[0020] F. The two ends of the repair pipe are connected to the corresponding flanges of the hot blast stove and the hot blast main pipe through radial flanges and their bolts and nuts, or the two ends of the repair pipe are connected to the hot blast stove and the hot blast main pipe through radial welding;

[0021] G. Adjust the multiple adjustable pull rods in step A to loosen the tension on the hot blast furnace and the hot blast main pipe, thereby completing the repair of the old corrugated pipe. The repaired pipe can compensate for thermal expansion and contraction, reducing the stress on the hot blast main pipe.

[0022] The thermal insulation material layer of step B is specifically:

[0023] B1. Wrap the old corrugated pipe section with multiple layers of aluminum silicate fiber cotton, and tie each layer of aluminum silicate fiber cotton with steel wire;

[0024] B2. Wrap the straight pipe section of the old corrugated pipe with multiple layers of aerogel insulation felt, and tie each layer of aerogel insulation felt with steel wire.

[0025] When the two ends of the repair pipe in step F are respectively connected to the hot air furnace and the hot air main pipe, two interfaces connected to the outside are left, and the two interfaces are respectively connected to the inlet and outlet pipes so that protective argon gas can be introduced into the repair pipe through the inlet and outlet pipes and the corresponding interfaces, which facilitates the safe connection of the repair pipe and serves as the inlet and outlet pipe interfaces for air tightness testing.

[0026] The repair pipe can withstand a maximum pressure of 0.6 MPa, a maximum temperature of 350°C, a maximum axial displacement of 30 mm, a maximum radial displacement of 50 mm, an axial stiffness of 1051 N / mm, a radial stiffness of 1256 N / mm, and a fatigue life of up to 3,000 times. As long as the internal brickwork is not severely damaged, its service life is equivalent to that of a newly replaced compensator.

[0027] Compared with the prior art, the present invention has the following advantages and effects: by adopting the above technical scheme, the repair tube formed by connecting at least two tube petals can be conveniently covered on the old corrugated tube that has failed or is about to fail without removing it, making full use of the planned shutdown time of the blast furnace, and realizing online repair of the old corrugated tube in only 24-48 hours, greatly shortening the repair time, while the prior art requires 8-10 days to replace the new corrugated compensator. At the same time, the covered repair tube has higher resistance to high temperature, pressure and fatigue, and can be tightly combined with the old corrugated tube, saving costs, and does not affect the normal supply of high-temperature hot air to the blast furnace by the hot blast furnace, thereby maintaining normal smelting of the blast furnace. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a top view of the structure of the present invention;

[0029] Figure 2 for Figure 1 A partial enlarged view of

[0030] Figure 3 for Figure 1 The adjustable pull rod structure diagram. DETAILED DESCRIPTION

[0031] The present invention will be further described below with reference to the embodiments given in the accompanying drawings. Example 1

[0032] The bellows compensator repair device provided by the present invention includes an old bellows 4 arranged between a hot blast furnace 1 and a hot blast main pipe 3, wherein the old bellows 4 includes a bellows section 41 and a straight section 42, wherein: the old bellows 4 is provided with a repair pipe 2 formed by connecting two tube petals, each tube petal including two straight tube petals 21 placed on the periphery of the bellows section 41 of the old bellows 4, and two bellows petals 22 placed on the periphery of the straight section 42 of the old bellows 4;

[0033] Each section of the bellows 22 is provided with an outwardly protruding corrugation, and reinforcement members 6 are provided on both sides of the corrugation. The reinforcement members 6 are hollow reinforcement tubes through which the cooling medium is passed, so as to increase the strength of the bellows and improve the service life.

[0034] The two tube petals are connected to form a repair pipe by the axial flange 24 and the bolts and nuts 25 on the axial flange 24; obviously, the two tube petals can also be axially welded to form a repair pipe;

[0035] The inner wall of the tube flap is provided with a heat-insulating layer 23, which is made of conventional high-temperature resistant heat-insulating material with a thickness of 30-60 mm, so as to increase the service life of the tube flap and tightly wrap around the old corrugated tube 4;

[0036] The thermal insulation material is aluminum silicate fiber cotton and aerogel insulation felt, wherein the aluminum silicate fiber cotton is arranged on the inner wall of the straight tube flap 21, and the aerogel insulation felt is arranged on the inner wall of the corrugated tube flap 22, and each layer of thermal insulation material is tied with steel wire to prevent the thermal insulation material from being displaced;

[0037] The two ends of the repair pipe are connected to the corresponding flanges of the hot blast stove 1 and the hot blast main pipe 3 respectively through the radial flanges and the bolts and nuts on the radial flanges; obviously, the two ends of the repair pipe can also be connected to the hot blast stove 1 and the hot blast main pipe 3 respectively through radial welding;

[0038] A plurality of axially adjustable pull rods 5 are provided between the hot blast furnace 1 and the hot blast main pipe 3 along the circumferential direction. The adjustable pull rods 5 include a first and a second connecting screw rods 51 and 52 respectively fixed to the hot blast furnace and the hot blast main pipe, and a sleeve 53 with an internal thread connected to the first and the second connecting screw rods 51 and 52, and the internal threads at both ends of the sleeve 53 have opposite spiral directions, so that the sleeve can be rotated in the forward direction to bring the first and the second connecting screw rods 51 and 52 closer to complete the tightening of the pull rod, and vice versa to move the first and the second connecting screw rods 51 and 52 away from each other to complete the loosening of the pull rod. Example 2

[0039] The method for repairing a corrugated compensator based on the corrugated compensator repair device of the present invention comprises the following steps:

[0040] A. Install multiple adjustable tie rods 5 along the circumferential direction between the hot blast furnace 1 and the hot blast main pipe 3. Adjust the multiple adjustable tie rods 5 to axially tighten the old corrugated pipe 4 between the hot blast furnace 1 and the hot blast main pipe 3, and at the same time, compress the refractory bricks inside the old corrugated pipe 4;

[0041] B. Wrap the old corrugated pipe 4 with a layer of heat-insulating material, as follows:

[0042] B1. Wrap the bellows section 41 of the old bellows 4 with multiple layers of aluminum silicate fiber cotton, and tie each layer of aluminum silicate fiber cotton with steel wire;

[0043] B2. Wrap the straight pipe section 42 of the old corrugated pipe 4 with multiple layers of aerogel insulation felt, and tie each layer of aerogel insulation felt with steel wire;

[0044] C. Wrap the two tube petals on the insulation layer of the old bellows 4, and place the straight tube petal 21 of each tube petal on the periphery of the bellows section 41 of the old bellows 4, and the bellows petal 22 on the periphery of the straight tube section 42 of the old bellows 4. Clamp the old bellows 4 into the insulation layer through the insulation layer to prevent the bellows petal 22, the straight tube petal 21, and the old bellows 4 from moving relative to each other, and complete displacement compensation through the bellows petals.

[0045] D. Connect and fix the two tube petals to form a repair pipe through the axial flange 24 of each tube petal and the bolts and nuts 25 thereon. Obviously, the two tube petals can also be axially welded to form a repair pipe;

[0046] E. Install hollow reinforcement tubes with cooling medium inside on both sides of each bellows of the repaired pipe to cool each bellows of the repaired pipe while improving its anti-deformation strength. Obviously, solid reinforcement tubes can also be installed to improve the anti-deformation strength of each bellows of the repaired pipe;

[0047] F. The two ends of the repair pipe are connected to the corresponding flanges of the hot blast furnace 1 and the hot blast main pipe 3 through radial flanges and the bolts and nuts thereon. Obviously, the two ends of the repair pipe can also be connected to the hot blast furnace 1 and the hot blast main pipe 3 respectively through radial welding. At the same time, when the two ends of the repair pipe are connected to the hot blast furnace 1 and the hot blast main pipe 3 respectively, two interfaces 71 and 72 for communication with the outside are reserved. The two interfaces 71 and 72 are connected to the inlet and outlet pipes respectively, so that protective argon gas can be introduced into the repair pipe through the inlet and outlet pipes and the corresponding interfaces 71 and 72, which facilitates the safe connection of the repair pipe and serves as the inlet and outlet pipe interfaces for air tightness testing.

[0048] G. Adjust the multiple adjustable pull rods 5 in step A to loosen the tension on the hot blast furnace 1 and the hot blast main pipe 3, thereby completing the repair of the old corrugated pipe 4. The repaired pipe can compensate for thermal expansion and contraction, reducing the stress on the hot blast main pipe.

[0049] The repair pipe provided by the present invention can withstand a maximum pressure of 0.6 MPa, a maximum temperature of 350°C, a maximum axial displacement of 30 mm, a maximum radial displacement of 50 mm, an axial stiffness of 1051 N / mm, a radial stiffness of 1256 N / mm, and a fatigue life of up to 3000 times. As long as the internal brickwork is not severely damaged, the service life is equivalent to that of a newly replaced compensator.

Claims

1. A method for repairing a corrugated compensator based on a corrugated compensator repair device, characterized in that The following steps are involved: The bellows compensator repair device includes an old bellows arranged between the hot blast furnace and the hot blast main pipe, the old bellows including a bellows section and a straight section, and is characterized in that a repair pipe formed by connecting at least two tube petals is provided on the old bellows, each tube petal including a straight tube petal placed on the periphery of the bellows section of the old bellows, and a bellows petal placed on the periphery of the straight section of the old bellows; A plurality of axial adjustable pull rods are provided between the hot blast furnace and the hot blast main pipe, the adjustable pull rods comprising a first and a second connecting screw respectively fixed to the hot blast furnace and the hot blast main pipe, and a sleeve with an internal thread connected to the first and second connecting screws, wherein the internal threads at both ends of the sleeve have opposite spiral directions; The repair method comprises the following steps: A. Install multiple adjustable tie rods along the circumferential direction between the hot blast furnace and the hot blast main pipe. Adjust the multiple adjustable tie rods to axially tighten the old corrugated pipe between the hot blast furnace and the hot blast main pipe, and at the same time, compress the refractory bricks inside the old corrugated pipe; B. Cover the old corrugated pipe with a layer of thermal insulation material; C. Wrap at least two tube petals on the insulation material layer of the old bellows, and place the straight tube petals of each tube petal on the periphery of the bellows section of the old bellows, and the bellows petals on the periphery of the straight tube section of the old bellows, to prevent the tube petals and the old bellows from moving relative to each other, and complete displacement compensation through the bellows petals; D. Connect and fix at least two pipe petals to form a repair pipe through the axial flange of each pipe petal and the bolts and nuts thereon, or axially weld at least two pipe petals to form a repair pipe; E. Install hollow reinforcement tubes with cooling medium inside on both sides of each corrugated tube of the repaired pipe to cool each corrugated tube of the repaired pipe and improve its anti-deformation strength; or install solid reinforcement tubes to improve the anti-deformation strength of each corrugated tube of the repaired pipe; F. The two ends of the repair pipe are connected to the corresponding flanges of the hot blast stove and the hot blast main pipe through radial flanges and their bolts and nuts, or the two ends of the repair pipe are connected to the hot blast stove and the hot blast main pipe through radial welding; G. Adjust the multiple adjustable pull rods in step A to loosen the tension on the hot blast furnace and the hot blast main pipe, thereby completing the repair of the old corrugated pipe. The repaired pipe can compensate for thermal expansion and contraction, reducing the stress on the hot blast main pipe.

2. The method for repairing a corrugated compensator based on a corrugated compensator repair device according to claim 1, characterized in that The bellows petal is provided with at least one outwardly protruding corrugation, and reinforcement members are respectively provided on both sides of the corrugation. The reinforcement members are hollow reinforcement tubes through which cooling medium flows, or solid reinforcement tubes.

3. The method for repairing a corrugated compensator based on a corrugated compensator repair device according to claim 1, characterized in that The thermal insulation material layer of step B is specifically: B1. Wrap the old corrugated pipe section with multiple layers of aluminum silicate fiber cotton, and tie each layer of aluminum silicate fiber cotton with steel wire; B2. Wrap the straight pipe section of the old corrugated pipe with multiple layers of aerogel insulation felt, and tie each layer of aerogel insulation felt with steel wire.

4. The method for repairing a corrugated compensator based on a corrugated compensator repair device according to claim 1 is characterized in that When the two ends of the repair pipe in step F are connected to the hot air furnace and the hot air main pipe respectively, two interfaces for connecting to the outside are reserved, and the two interfaces are respectively connected to the inlet and outlet pipes.

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