Assembly process of blast furnace top five-way ball

Abstract

The application discloses a kind of assembly process of blast furnace top five ball, it is related to metallurgical iron and steel iron-making blast furnace system installation technical field, the assembly process of the blast furnace top five ball of the present application includes S1: determining the design ball of five ball;S2: structure assembly platform;S3: five ball center and five hole size positioning;S4: assemble five ball ball;S5: five ball ball welding;S6: riser center, intersecting line, riser short pipe, downcomer elbow pipe, downcomer straight section welding;S7: anticorrosion coating.The assembly process of blast furnace top five ball described above adopts plugboard assembly method to avoid cumulative error, selects correct welding assembly sequence, determines riser and downcomer positioning center line, angle, intersecting line, controls insertion depth, positioning precision, riser and downcomer short section four direction angle, etc., dynamically monitors welding five ball manufacturing precision, to improve welding quality, while it can reduce construction amount, reduce the generation of waste.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of metallurgical steel iron-making blast furnace system installation, and particularly relates to a high furnace top five-way ball assembling process suitable for new construction, reconstruction and extension, intelligent upgrading and reconstruction engineering of a metallurgical steel iron-making blast furnace system. BACKGROUND

[0002] The development of the steel industry is an important symbol of the national industrial civilization. China has become a steel power after 70 years of wind and rain. With the adjustment of national steel policy, the adjustment of industrial layout, the adjustment of product structure, the intelligent upgrading, the capacity upgrading and reconstruction, and the green development, another round of high-speed development of the steel industry is promoted. In these large metallurgical industrial projects, the super large blast furnace project is indispensable. The high furnace top five-way ball is an important equipment connecting the riser and the downcomer in the high furnace top five-way ball. The gas acting force of the downcomer is buffered to achieve balance. The highest point of the five-way ball is provided with a gas diffuser valve to achieve overpressure protection and diffusing gas during the rest period. The medium conveyed by the five-way ball is high furnace gas, and the connection form adopts welding. The circumferential weld and the connecting weld of the ball node are required to be 100% ultrasonic flaw detection, and the welding quality is required to be high.

[0003] In the existing literature, CN109913599B discloses a high furnace five-way ball field assembling and installing method. The five-way ball is assembled and installed on a steel pipe type assembling platform. The five-way ball is welded by rotating and adjusting the angle of the five-way ball. After welding, the welding hole of the riser and the downcomer is adjusted, and then welded and assembled. In the above-mentioned installation method, the control point of each plate is to rotate and adjust the angle of the five-way ball through the steel pipe type assembling platform, and then realize fine adjustment. However, this installation method has high requirements for the manufacturing precision of the assembling platform. The five-way ball is cut into holes of the riser, the downcomer and the diffuser pipe from a complete structure, which increases the material and labor for the production of the five-way ball. Moreover, the holes are completely formed by field cutting, which has a large amount of construction and generates a large amount of waste. SUMMARY

[0004] In order to overcome the shortcomings of the prior art, the present application provides a high furnace top five-way ball assembling process, which adopts a plug-in plate assembling method to avoid cumulative error, selects a correct welding and assembling sequence, determines the positioning center line, angle, intersecting line, control insertion depth, positioning precision and four direction angles of the riser and the downcomer short section, dynamically monitors the welding five-way ball manufacturing precision, improves the welding quality, reduces the construction amount and reduces the generation of waste.

[0005] The present application adopts the following technical solutions:

[0006] A high furnace top five-way ball assembling process comprises the following steps:

[0007] S1: determining the design sphere of the five-pass ball

[0008] The force analysis and mechanical demonstration of the five-pass ball sphere are determined by design, and the sphere is divided into upper polar zone, lower polar zone and equatorial zone.

[0009] S2: constructing an assembly platform

[0010] The assembly platform is treated by pouring and hardening C30 concrete, the thickness of the concrete is 200 mm, the levelness requirement is 2 / 1000, the positioning center, longitudinal and transverse center lines and settlement observation points meet the installation requirements, a δ=30 mm steel plate is paved as the assembly platform, and a special assembly jig is made according to the parameters of the five-pass ball using profiled steel;

[0011] S3: positioning the center of the five-pass ball and the size of the five-pass hole

[0012] According to the positioning of the pipe hole of the descending pipe of the five-pass ball, the pipe hole of the ascending pipe is calculated, the center of the four ascending pipe holes is calculated according to the center of one descending pipe hole; the distance from the four equally divided points of the pipe hole of the intersecting line of the descending pipe to the center of the five-pass ball is found out on the drawing, and the angle is calculated; then the horizontal size of the four points of the pipe hole of the descending pipe is projected on the assembly platform; the center line of the blast furnace from 0° to 180° is found out according to the arc length, and the center of the blast furnace is determined, and a lifting lug is welded vertically above the center;

[0013] S4: assembling the five-pass ball sphere

[0014] According to the following assembly sequence: five-pass ball→ascending pipe center, intersecting line→ascending pipe short pipe→descending pipe elbow→descending pipe straight section, the five-pass ball is assembled;

[0015] S5: welding of the five-pass ball sphere

[0016] S6: welding of the ascending pipe center, intersecting line, ascending pipe short pipe, descending pipe elbow and descending pipe straight section

[0017] S7: corrosion protection coating

[0018] The five-pass ball sphere is coated with a projection corrosion protection coating process.

[0019] Further, in step S1, the upper polar zone, the lower polar zone and the equatorial zone are provided in a petal-shaped structure.

[0020] Further, the upper polar zone and the lower polar zone are each divided into two petals, and the equatorial zone is divided into eight petals.

[0021] Further, in step S4, the specific assembly steps are:

[0022] S41: The center point of the five-way ball is aligned with the center line of the equatorial plate of the five-way ball; the distance between the four positioning points on each shell plate and the center of the five-way ball is measured; the shell plates are hoisted, and the cross center line is drawn on the upper and lower sections of the shell plates, and the positioning blocks are welded on the sections at an interval of 800 mm; the shell plates are assembled from the top and the bottom simultaneously; the four shell plates at the type steel are hoisted, and the positioning blocks are welded; the first shell plate with a column head is fixed by using a fixture, and a gap of 2-3 mm is reserved;

[0023] S42: The positioning lines of the upper and lower flange plates are aligned with the web by using the inclined support, and then the hydraulic jacks are used to tighten;

[0024] S43: The CO2 gas protection welding is used for bottom welding;

[0025] S44: The second, third and fourth shell plates with type steel legs are hoisted; the shell plates at the non-type steel are hoisted in sequence, and are inserted between the equatorial bands of the two type steel legs until the entire equatorial band is closed;

[0026] S45: The H-type steel is placed on a special welding jig; the center line of the five-way ball, the center lines of the four riser pipes, the downcomer pipe, the diffuser pipe and the pipe edge control line are painted on the assembly platform, and the paint marks are made; the center point is marked by using a sample punch; at the same time, the four equal division lines of the riser pipe, the downcomer pipe and the diffuser pipe are drawn on the assembly platform; the total station instrument and the line hammer are used to check and verify the assembly size; the jack and the hand-operated hoist are used to adjust the assembly; the assembly fixture is used to fix and adjust the gap.

[0027] Further, in step S45, the special welding jig comprises a triangular support and a wedge-shaped platform arranged at the bottom of the inclined surface of the triangular support, and the inclined surface of the wedge-shaped platform is perpendicular to the inclined surface of the triangular support.

[0028] Further, in step S45, the horizontal error of the equatorial line of each shell plate is not greater than 4 mm; the horizontal error of the equatorial line of any two adjacent shell plates is not greater than 5 mm; and the horizontal error of the equatorial line of any two shell plates is not greater than 8 mm.

[0029] Further, in steps S5 and S6, the welding principle is as follows: (1) first longitudinal welding and then circumferential welding; first outer welding and then inner welding; first discontinuous welding and then continuous welding; (2) first equatorial band longitudinal welding and then upper and lower band longitudinal welding, and then equatorial band circumferential welding; the five-way ball circumferential welding is performed, and attention is paid to the opposite welding directions inside and outside the ball; (3) first welding of the weld with a large groove, and then welding of the weld with a small groove after cleaning; (4) longitudinal welding, large groove welding is completed, small groove welding is performed after cleaning the reverse side, and segmented trailing welding is adopted, and each segment of weld is welded completely without stopping in the middle; (5) uniform welding, the welding parameters of current, voltage and welding speed are consistent, and the welding is strictly performed according to the process card.

[0030] Further, in step S7, the specific steps of the anticorrosive coating are: spraying or projection - primer coating - intermediate coating - top coating - on-site installation - touch-up painting.

[0031] Compared with the prior art, the application has the beneficial effects that:

[0032] The assembling process of the blast furnace top five-way ball of the application adopts the plug-in assembling method to avoid cumulative error, selects correct welding assembling sequence, determines the positioning center line, angle, intersecting line of the ascending and descending pipes, controls the insertion depth, positioning precision and four-direction angle of the ascending and descending pipe short sections, and dynamically monitors the welding five-way ball manufacturing precision to improve the welding quality, while reducing the construction amount and waste generation. DETAILED DESCRIPTION

[0033] Hereinafter, the application will be further described in conjunction with specific embodiments, and it should be noted that the following described embodiments or technical features can be combined arbitrarily to form new embodiments without conflict.

[0034] An assembling process of a blast furnace top five-way ball, comprising the following steps:

[0035] S1: determining the design ball of the five-way ball

[0036] The force analysis and mechanical demonstration of the five-way ball are determined by design, and the ball is divided into upper polar zone, lower polar zone and equatorial zone, wherein the upper polar zone, the lower polar zone and the equatorial zone are provided in petal-shaped structure, the upper polar zone and the lower polar zone are each divided into two petals, and the equatorial zone is divided into eight petals.

[0037] In one embodiment, the upper polar zone and the lower polar zone are assembled in a "cross-shaped" structure.

[0038] In other embodiments, the butt welds in each petal of the upper polar zone, the lower polar zone and the equatorial zone are in a 600X type groove, and the oxidation slag is removed, and there is no unevenness, oil stain, burr, oxide, slag, paint, rust, etc., and the groove position of the factory is sealed with plastic tape.

[0039] S2: constructing an assembling platform

[0040] The assembling platform is treated by pouring and hardening C30 concrete, the concrete thickness is 200mm, the levelness is 2 / 1000, the positioning center, longitudinal and transverse center lines and settlement observation points meet the installation requirements, a δ=30mm steel plate is laid as the assembling platform, and a special assembling jig is made according to the parameters of the five-way ball.

[0041] Understandably, the structure of the special assembling jig is similar to that of the five-way ball, so as to improve the convenience of assembling.

[0042] S3: Positioning of five-hole ball center and five-hole size

[0043] The specific steps are:

[0044] Because the five-hole ball has opened the pipe hole of the descending pipe when approaching, the pipe hole of the ascending pipe is positioned according to the opening of the pipe hole of the descending pipe, and the centers of the four pipe holes of the ascending pipe are more accurately calculated from the center of one pipe hole of the descending pipe. The distances from the four equally divided points of the pipe hole of the intersecting line of the descending pipe to the center of the five-hole ball are found out on the drawing, and the angles are calculated at the same time. Then the horizontal dimensions of the four points of the pipe hole of the descending pipe are projected on the assembling platform. The center of the blast furnace is determined according to the arc length of the center line of the blast furnace from 0° to 180°, and a lifting lug is welded vertically above the center for the subsequent lifting and fixing of the five-hole ball.

[0045] S4: Assembling the five-hole ball body

[0046] When the concrete strength reaches the design strength, the five-hole ball is assembled on the special assembling jig, the lower plate is hoisted on the assembling jig according to the layout and pipe hole orientation, and the five-hole ball is assembled according to the following assembly sequence: five-hole ball→ascending pipe center, intersecting line→ascending pipe short pipe→descending pipe elbow→descending pipe straight section. When assembling, the gap and misalignment between the ball shell plates are adjusted by using a jack, a hand-operated hoist and a tool holder.

[0047] The specific steps are:

[0048] S41: The center point of the five-hole ball to the center line of the equatorial plate of the five-hole ball is laid out; the distance from the four positioning points on each ball shell plate to the center of the five-hole ball is measured; the equatorial strip steel plate of the five-hole ball shell body should not be spliced, the ball body strip plate is hoisted, the cross center line is drawn on the upper and lower two sections of the ball body plate in advance, the positioning block for assembly is welded at an interval of 800 mm, and the upper and lower sections are assembled at the same time from the center; the four ball body strip plates at the type steel position are hoisted, the assembly positioning block is welded, the first ball body plate with a column head is fixed after being hoisted in place, and a gap of 2-3 mm is reserved during assembly;

[0049] S42: After the positioning lines of the upper and lower flange plates are aligned with the web plate by using inclined supports, the hydraulic jack is used to tighten;

[0050] S43: CO2 gas shielded welding is used for bottom sealing and welding.

[0051] S44: The second, third and fourth ball body plates at the type steel leg position are continuously hoisted, and the purpose of the type steel leg is to fix the weight of the equatorial strip; the one, two, three and four ball body plates at the non-type steel position are sequentially hoisted and inserted between the equators of the two strip columns, and attention is paid to control the assembly gap of the equatorial strip; until the entire equatorial strip is closed.

[0052] S45: The H-shaped steel is placed on the special welding fixture; the center lines of the five-way ball, four riser center lines, the downcomer center line, the diffuser center line, the pipe edge control edge line, the paint powder line, and the pop-up line are painted on the assembly platform, and the paint marks are made; the center point is marked with a sample punch; at the same time, the four equal division lines of the riser, the downcomer, and the diffuser are popped out on the assembly platform to facilitate assembly control; the total station instrument and the line hammer are used to check and verify the size during the process; the jack and the hand-operated hoist are used to adjust the assembly during the assembly process; the assembly fixture is used to fix and adjust the gap; the equatorial line horizontal error of each ball shell plate should not be greater than 4mm; the equatorial line horizontal error of adjacent two ball shell plates should not be greater than 5mm; the equatorial line horizontal error of any two ball shell plates should not be greater than 8mm. In order to facilitate the subsequent use of the special welding fixture for submerged arc welding.

[0053] In one embodiment, the special welding fixture includes a triangular support and a wedge-shaped table provided at the bottom of the inclined surface side of the triangular support, and the inclined surface of the wedge-shaped table is perpendicular to the inclined surface of the triangular support.

[0054] S5: Five-way ball welding

[0055] The equatorial belt is the reference for the entire five-way ball assembly and installation, and it is crucial for the entire ball assembly quality, so careful adjustment is made to ensure that the maximum and minimum diameter deviation, the upper and lower chord horizontality, the gap between the openings, the edge misalignment, and the corner angle meet the specifications before point welding. The total station instrument detects the size shrinkage and deformation of the upper and lower openings of the equatorial belt throughout the welding process.

[0056] S6: Welding of the riser center, the intersecting line, the riser short pipe, the downcomer elbow pipe, and the downcomer straight section

[0057] According to the center line, the hole center line, and the intersecting line, the welding assembly support is assembled, and then the hole is opened and the riser short pipe is installed and welded after the theodolite and the line hammer are verified to be correct. The downcomer is assembled by symmetrical welding and fixing the flange. The four equal division lines of the riser, the downcomer, and the diffuser are inspected and detected on the assembly platform.

[0058] In one embodiment, the assembly is cut off and then assembled and welded, the reserved insertion depth, positioning accuracy, and the four direction angles of the riser and the downcomer short section and the ball are adjusted by the jack and the hand-operated hoist when necessary.

[0059] In one embodiment, the welding principle is: (1) first longitudinal and then circumferential, first outer and then inner, first broken and then full; (2) first longitudinal welding of the equatorial band to the upper and lower band, and then circumferential welding of the equatorial band, and welding of the five-way ball ring, with attention to the opposite welding directions inside and outside the ball; (3) first welding of the weld with a large groove, and then welding of the weld with a small groove after cleaning; (4) longitudinal welding, welding of a large groove is completed, and then welding of a small groove after cleaning of the reverse side, with segmented trailing welding, each weld is welded completely without stopping in the middle; (5) uniform welding, the welding parameters of current, voltage and welding speed are consistent, and welding is strictly performed according to the process card. Before hoisting, the five-way ball welding angle steel support is paved with an aluminum jumping plate to facilitate installation. During welding, the accuracy is monitored in real time to improve the welding quality.

[0060] S7: anticorrosion coating

[0061] The five-way ball is coated by adopting a projection anticorrosion coating process.

[0062] In one embodiment, the specific steps of anticorrosion coating are: spraying or projection - primer coating - intermediate coating - top coating - on-site installation - supplementary painting.

[0063] Compared with the prior art, the plugboard assembly method is adopted to avoid cumulative errors, correct welding assembly sequences are selected, the positioning center line, angle, intersecting line of the ascending and descending pipes are determined, the insertion depth, positioning accuracy and four-direction angle of the ascending and descending pipe short sections are determined, and the manufacturing accuracy of the welded five-way ball is dynamically monitored.

[0064] The above-described embodiments are only preferred embodiments of the present application, and cannot be used to limit the scope of protection of the present application, and any non-essential changes and replacements made by those skilled in the art on the basis of the present application are within the scope of protection of the present application.

Claims

1. A process for assembling a top five-port ball of a blast furnace, characterized in that, It comprises the following steps: S1: determining the design of the five-way ball The force analysis of the five-way ball is determined by design, which divides the ball into upper and lower polar zones and equatorial zone; S2: constructing an assembly platform The assembly platform is made of C30 concrete with a thickness of 200mm and a levelness of 2 / 1000. The positioning center, longitudinal and transverse center lines, and settlement observation points meet the installation requirements. A δ=30mm steel plate is laid as the assembly platform. The special assembly jig is made according to the parameters of the five-way ball; S3: positioning the center of the five-way ball and the size of the five-way hole According to the positioning of the pipe hole of the descending pipe, the pipe hole of the ascending pipe is opened. The center of the four pipe holes of the ascending pipe is calculated inversely. The distance from the four points of the pipe hole of the descending pipe to the center of the five-way ball is found out on the drawing. The angle is calculated. The horizontal size of the four points of the pipe hole of the descending pipe is projected on the assembly platform. The center line of the blast furnace from 0° to 180° is found out according to the arc length. The center of the blast furnace is determined. A lifting lug is welded vertically above the center. S4: assembling the five-way ball According to the following assembly sequence: five-way ball→ascending pipe center, intersecting line→ascending pipe short pipe→descending pipe elbow→descending pipe straight section, the five-way ball is assembled. S5: welding the five-way ball S6: welding the ascending pipe center, intersecting line, ascending pipe short pipe, descending pipe elbow, and descending pipe straight section S7: corrosion protection The five-way ball is coated with a projection corrosion protection process.

2. The assembly process of a top five-port ball of a blast furnace according to claim 1, characterized in that, In step S1, the upper and lower polar zones and the equatorial zone are provided in a petal-shaped structure.

3. The assembly process of a top five-port ball of a blast furnace according to claim 2, characterized in that, Each of the upper and lower polar zones is divided into two petals, and the equatorial zone is divided into eight petals.

4. The assembly process of a top five-port ball of a blast furnace according to claim 1, characterized in that, In step S4, the specific assembly steps are as follows: S41: the center of the five-way ball is aligned with the center line of the equatorial plate. The distance from the four positioning points on each shell plate to the center of the five-way ball is determined. The shell plates are hoisted and assembled. The cross center line is drawn on the upper and lower sections of the shell plate in advance. The positioning blocks are welded at an interval of 800mm. The first shell plate with a column head is hoisted and fixed with a fixture. A gap of 2-3mm is reserved. S42: the positioning lines of the upper and lower flange plates are aligned with the web plate using inclined supports. The hydraulic jacks are used to tighten them. S43: CO2 gas shielded welding is used for bottom sealing and welding. S44: the second, third, and fourth shell plates with H-shaped steel legs are hoisted. The shell plates at non-H-shaped steel locations are hoisted in sequence. They are inserted between the equators of the two shell plates with legs until the entire equatorial zone is closed. S45: the H-shaped steel is placed on the special welding jig. The center line of the five-way ball, the center line of the four ascending pipes, the center line of the descending pipe, the center line of the diffuser pipe, and the edge control line of the pipe are painted on the assembly platform. The center point is marked with a sample punch. The four equal division lines of the ascending pipe, the descending pipe, and the diffuser pipe are also projected on the assembly platform. The total station and the line hammer are used to check and verify the assembly size during the process. The jack and the hand-operated hoist are used to adjust the assembly during the assembly process. The assembly fixture is used to fix and adjust the gap.

5. The assembly process of a top five-port ball of a blast furnace according to claim 4, characterized in that, In step S45, the special welding fixture comprises a triangular support and a wedge-shaped platform arranged at the bottom of the inclined surface of the triangular support, and the inclined surface of the wedge-shaped platform is perpendicular to the inclined surface of the triangular support.

6. The assembly process of a top five-port ball of a blast furnace according to claim 4, characterized in that, In step S45, the equator line horizontal error of each spherical shell plate is not greater than 4mm; the equator line horizontal error of two adjacent spherical shell plates is not greater than 5mm; and the equator line horizontal error of any two spherical shell plates is not greater than 8mm.

7. The assembly process of a top five-port ball of a blast furnace according to claim 1, characterized by, In steps S5 and S6, the welding principle is as follows: (1) first longitudinal and then circumferential; first outer and then inner; first discontinuous and then continuous; (2) first equator band to upper and lower level band longitudinal weld, and then equator band circumferential weld; five-way spherical ring seam welding, and attention is paid to the opposite welding direction of the inside and outside of the sphere; (3) first weld the weld with large groove, and then weld the weld with small groove after cleaning; (4) longitudinal seam welding, large groove welding is finished, small groove welding is performed after the reverse side is cleaned, and segmented trailing welding is adopted, each segment of weld is welded completely, and pause is not allowed in the middle; (5) uniform welding, the welding parameters of current, voltage and welding speed are kept consistent, and welding is strictly performed according to the process card.

8. The assembly process of a top five-port ball of a blast furnace according to claim 1, characterized in that, In step S7, the specific steps of the anticorrosion coating are as follows: spraying or projection - primer coating - intermediate coating - top coating - on-site installation - supplementary painting.