A verticality control method for modular prefabricated installation of super-large equipment

Abstract

The application discloses a verticality control method for modular prefabrication and installation of super-large equipment, which comprises the following steps: prefabricating a module by adopting a vertical method, adjusting the roundness of the upper port and the lower port of the module, reinforcing the module, marking 0°, 90°, 180° and 270° mark points on the module by four equal divisions, determining the lower end surface of the module as a horizontal reference surface, introducing an upper reference line and a lower reference line on the module, installing inner and outer parts on the module where the inner and outer parts are needed, installing the module one on the installation base, further taking the module one as a reference, sequentially installing the remaining modules in a bottom-up order, and finally welding an upper head on the upper end of the module located at the top. The method is convenient to operate, high in efficiency and precision, and the working principle is that, for the large equipment installed by modular prefabrication in a vertical state, the verticality of the super-large equipment is controlled by adopting a specific operation mode according to the concentric circle principle.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of pressure vessel and non-standard chemical equipment manufacturing and installation, and particularly relates to a verticality control method for modular prefabrication and installation of super-large equipment. BACKGROUND

[0002] For steel super-large pressure vessels and non-standard chemical equipment (collectively referred to as equipment) with a diameter of dozens of meters and a height of up to or more than 100 meters, due to the large diameter and height, the modular prefabrication and installation has become a trend due to the limitations of road transportation, hoisting and other factors. The large-scale equipment brings great difficulty to the control of prefabrication and installation size, especially the control of installation verticality. If the installation verticality exceeds the allowable value specified in the specification, it will not only affect the levelness control of the inner part installation, but also affect the safe operation of the equipment. However, there is no more accurate and effective method for controlling the verticality when using modular prefabrication and installation to install super-large equipment in the prior art. SUMMARY

[0003] The technical problem to be solved by the present application is to provide a verticality control method for modular prefabrication and installation of super-large equipment, which is convenient to operate, efficient and accurate.

[0004] The technical scheme adopted by the present application to solve the above technical problem is: a verticality control method for modular prefabrication and installation of super-large equipment, the super-large equipment comprising a plurality of cylindrical modules, the verticality control method for modular prefabrication and installation of the super-large equipment comprising the following steps:

[0005] 1) prefabrication

[0006] 1.1) placing a plurality of piers on an operation platform, adjusting the levelness of the top surface of the plurality of piers to be less than 5mm, and prefabricating a plurality of modules on the plurality of piers in a vertical manner under the support of the plurality of piers;

[0007] 1.2) after each module is prefabricated, adjusting the roundness of the upper port and the lower port of each module, and controlling the roundness of the upper port and the lower port of each module to be within 5mm respectively;

[0008] 1.3) using a steel pipe to reinforce the upper port and the lower port of each module in a "micron type" to ensure that the ovality of the module is not enlarged in the transportation, hoisting and installation links;

[0009] 1.4) equally dividing the upper port and the lower port of each module into four parts, and sequentially marking 0°, 90°, 180° and 270° mark points in clockwise order, with the 0° mark point in front, the 90° mark point on the right, the 180° mark point behind, and the 270° mark point on the left;

[0010] 1.5) Check whether the lower end surface of each module is horizontal. If not, adjust the supporting piers to adjust the levelness of the lower end surface of each module. After confirming that the lower end surface of each module is horizontal, draw a circle of lower reference line parallel to the lower end surface on the inner wall and outer wall of the module at 100mm-150mm above the lower end surface, and draw a circle of upper reference line parallel to the lower end surface on the inner wall and outer wall of the module at 100mm-150mm below the upper end surface of each module, taking the lower end surface of each module as the horizontal reference surface;

[0011] 1.6) Install the inner and outer parts on the module where the inner and outer parts are needed, and the elevation size of all the installed inner and outer parts is subject to the upper reference line or the lower reference line;

[0012] 2) Installation

[0013] 2.1) Determine that the levelness of the installation foundation of the equipment meets the design requirements, and mark 0°, 90°, 180°, 270° azimuth lines on the installation foundation in clockwise order, with the 0° azimuth line in front, the 90° azimuth line on the right, the 180° azimuth line in back, and the 270° azimuth line on the left;

[0014] 2.2) Number the modules in sequence. First, place the module one vertically on the installation foundation. The inner side of the module one is pre-installed with a lower head, so that the 0°, 90°, 180°, 270° mark points of the module one are respectively aligned with the 0°, 90°, 180°, 270° azimuth lines on the installation foundation. Then measure the levelness of the upper reference line of the module one, and adjust it with the skirt pad iron until the upper reference line of the module one is level. Then fix the module one on the installation foundation through the anchor bolt;

[0015] 2.3) Place the module two vertically on the module one, so that the 0°, 90°, 180°, 270° mark points of the module two are respectively aligned with the 0°, 90°, 180°, 270° mark points of the module one. Measure the distance between the upper reference line of the module one and the lower reference line of the module two, at least symmetrically measure the distance values A1, A2, A3, A4 at four places, take adjustment measures to ensure that A1=A2=A3=A4, and then weld the lower end of the module two with the upper end of the module one.

[0016] 2.4) Use the method of step 2.3) to install the remaining modules in sequence from bottom to top. Finally, weld the upper head on the upper end of the module located at the top.

[0017] The method controls the tolerance of the 90° angle between the measured element and the reference element, wherein the measured element is the vertical line of the center of the circle of the arbitrary horizontal section of the module to the horizontal reference surface, the reference element is the horizontal reference surface, and the high-precision control of the perpendicularity of the super large equipment is realized according to the concentric circle principle.

[0018] As preferred, the adjusting measure is adjusting the gap size between the adjacent modules or cutting the port of the module. In the module installation process, when the horizontal degree of the port of the module deviates due to the cumulative error caused by prefabrication, welding shrinkage and other factors, according to the deviation condition, the gap size between the adjacent modules can be adjusted to ensure the horizontal reference line, and when the gap between the adjacent modules is too large to meet the welding process requirement, the port of the module can be properly cut to ensure the horizontal upper end surface or lower end surface of the module.

[0019] Compared with the prior art, the method has the following advantages: the method of the application first prefabricates the module by using the vertical method, adjusts the roundness of the upper port and the lower port of the module, reinforces the module, then marks the 0°, 90°, 180° and 270° mark points on the module by four equal parts, determines the lower end surface of the module as the horizontal reference surface and introduces the upper reference line and the lower reference line on the module, then installs the inner and outer parts on the module where the inner and outer parts are needed, then installs the module one on the installation base, further takes the module one as the reference, and installs the remaining modules in sequence from bottom to top, and finally welds the upper head on the upper end of the module located at the top. The verticality control method of the modular prefabrication and installation of the super large equipment is convenient to operate, high in efficiency and precision, and the working principle is that for the large equipment installed by the modular prefabrication in the vertical state, the verticality of the super large equipment is controlled by using the specific operation mode according to the concentric circle principle. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 It is a schematic diagram of the prefabricated module (taking the prefabrication of the module five as an example);

[0021] Figure 2 It is a schematic diagram of the installation effect of the module one after being installed on the installation base;

[0022] Figure 3 It is a schematic diagram of the installation of the module two;

[0023] Figure 4 It is a schematic diagram of the installation of the module five;

[0024] Figure 5 It is a schematic diagram of the installation of the super large equipment in the embodiment;

[0025] Figures 1-5 The specific reference signs are as follows:

[0026] 1-pier, 2-steel pipe, 3-horizontal reference plane, 4-lower reference line, 5-upper reference line, 61-support ring, 62-liquid downcomer, 63-liquid receiving tray, 64-tray, 7-installation foundation, 71-skirt pad iron, 72-anchorage bolt, 8-lower head, 9-upper head, 10-upper end face of module five, 11-upper end port of module five, 12- vertical line of the center of the circle in which any horizontal section of the module is located and the horizontal reference plane 3. DETAILED DESCRIPTION

[0027] The application will be described in further detail below with reference to the embodiments and the accompanying drawings.

[0028] Taking a super large equipment with a height of 100 meters and a diameter of 10 meters as an example, according to the comprehensive factors of processing and manufacturing capacity, road transportation, hoisting and the like, the equipment is divided into an upper head, a lower head and nine cylindrical modules for prefabrication and installation, and the verticality control is performed by using the method of the application, and the specific steps are as follows:

[0029] 1) prefabrication

[0030] 1.1) referring to Figure 1 , a plurality of piers 1 are placed on the operation platform, the levelness of the top surface of the plurality of piers 1 is adjusted to be less than 5 mm, and a plurality of modules are prefabricated on the plurality of piers 1 by using a vertical method under the support of the plurality of piers 1;

[0031] 1.2) after the prefabrication of each module is completed, the roundness of the upper port and the lower port of each module is adjusted, and the roundness of the upper port and the lower port of each module is controlled to be within 5 mm respectively;

[0032] 1.3) the upper port and the lower port of each module are respectively reinforced by using a steel pipe 2 in the form of “mizi”;

[0033] 1.4) the upper port and the lower port of each module are respectively quartered, and are sequentially marked with 0°, 90°, 180° and 270° mark points in clockwise order, with the 0° mark point in front, the 90° mark point on the right, the 180° mark point behind and the 270° mark point on the left;

[0034] 1.5) Check whether the lower end surface of each module is horizontal. If not, adjust the supporting pier 1 to adjust the levelness of the lower end surface of each module. After confirming that the lower end surface of each module is horizontal, take the lower end surface of each module as the horizontal reference surface 3, draw a circle of lower reference line 4 parallel to the lower end surface on the inner wall and outer wall of the module at 120 mm above the lower end surface, and draw a circle of upper reference line 5 parallel to the lower end surface on the inner wall and outer wall of the module at 120 mm below the upper end surface of each module;

[0035] 1.6) Install the internal and external parts such as support ring 61, liquid downcomer plate 62, liquid receiving disc 63, and tray 64 on the module where the internal and external parts are needed. The elevation size of all internal and external parts is subject to the upper reference line 5 or the lower reference line 4;

[0036] 2) Installation

[0037] 2.1) Determine that the levelness of the installation foundation 7 of the equipment meets the design requirements, and mark the 0°, 90°, 180°, and 270° azimuth lines on the installation foundation 7 in clockwise order, with the 0° azimuth line in front, the 90° azimuth line on the right, the 180° azimuth line in back, and the 270° azimuth line on the left;

[0038] 2.2) Number the multiple modules in sequence. First, place module one (in this embodiment, module one is actually a skirt) vertically on the installation foundation 7. The inner side of module one is prefabricated with a lower head 8, so that the 0°, 90°, 180°, and 270° mark points of module one are respectively aligned with the 0°, 90°, 180°, and 270° azimuth lines on the installation foundation 7. Then measure the levelness of the upper reference line 5 of module one, and adjust it using the skirt pad iron 71 until the upper reference line 5 of module one is level. After that, fix module one on the installation foundation 7 through the anchor bolt 72. The effect diagram of module one after installation on the installation foundation 7 is shown in Figure 2

[0039] 2.3) Then place module two vertically on module one, as shown in Figure 3 , so that the 0°, 90°, 180°, and 270° mark points of module two are respectively aligned with the 0°, 90°, 180°, and 270° mark points of module one. Measure the distance between the upper reference line 5 of module one and the lower reference line 4 of module two. At least measure the distance values A1, A2, A3, and A4 at four symmetrical positions, take adjustment measures to ensure that A1=A2=A3=A4, and then weld the lower end of module two with the upper end of module one.

[0040] 2.4) Use the method of step 2.3) to install the remaining modules in sequence from bottom to top. Finally, weld the upper head 9 on the upper end of the module located at the top, as shown in Figure 5

[0041] ​​The adjustment measure used in the above step 2.3) is to adjust the gap size between adjacent modules or to trim the port of the module. In the process of module installation, due to the cumulative error caused by prefabrication, welding shrinkage and other factors, when the levelness of the port of the module deviates, according to the deviation, one is to adjust the gap size between adjacent modules to ensure the horizontal level of the reference line, when the gap between adjacent modules is too large to meet the welding process requirements, the port of the module can be trimmed appropriately to ensure the horizontal level of the upper end face or the lower end face of the module. Figure 4 The installation of module five is shown in the figure, from Figure 4 It can be seen that the upper end face 10 of module five is not horizontal, and trimming off the black part 11 on the upper port can make the upper end face of module five horizontal. Figure 4 The upper end face of module five is not horizontal, and trimming off the black part 11 on the upper port can make the upper end face of module five horizontal.

[0042] The above method controls the tolerance of the 90° angle between the measured element and the reference element, where the measured element is the vertical line 12 from the center of the circle of any horizontal section of the module to the horizontal reference surface 3, and the reference element is the horizontal reference surface 3, and the high-precision control of the perpendicularity of the super large equipment is realized according to the concentric circle principle. The concentric circle principle is that when the vertical line through the center of the circle of any horizontal section of the module is perpendicular to the horizontal reference surface 3, then the center of the circle of any horizontal section and the center of the circle of the horizontal reference surface 3 must be concentric.

Claims

1. A method for controlling the perpendicularity of a super large equipment modular prefabricated installation, characterized in that, The super large equipment comprises a plurality of cylindrical modules, and a verticality control method for modular prefabrication and installation of the super large equipment comprises the following steps: 1) prefabrication 1.1) placing a plurality of piers on an operation platform, adjusting the top surface of the plurality of piers to have a levelness of less than 5 mm, and prefabricating a plurality of modules on the plurality of piers in a vertical manner under the support of the plurality of piers; 1.2) after each module is prefabricated, adjusting the roundness of the upper end and the lower end of each module, and controlling the roundness of the upper end and the lower end of each module to be within 5 mm respectively; 1.3) using a steel pipe to reinforce the upper end and the lower end of each module in a "mu type" manner respectively; 1.4) equally dividing the upper end and the lower end of each module into four parts, and sequentially marking 0°, 90°, 180° and 270° mark points in a clockwise order, with the 0° mark point in front, the 90° mark point on the right, the 180° mark point in back and the 270° mark point on the left; 1.5) checking whether the lower end surface of each module is horizontal, and if not, adjusting the levelness of the lower end surface of each module by adjusting the pier; after confirming that the lower end surface of each module is horizontal, taking the lower end surface of each module as a horizontal reference surface, drawing a circle of lower reference lines parallel to the lower end surface on the inner wall and the outer wall of the module located 100-150 mm above the lower end surface, and drawing a circle of upper reference lines parallel to the lower end surface on the inner wall and the outer wall of the module located 100-150 mm below the upper end surface of each module; 1.6) installing inner and outer parts on the module where the inner and outer parts are needed, and the elevation size of all the installed inner and outer parts is based on the upper reference line or the lower reference line; 2) installation 2.1) determining that the levelness of the installation foundation of the equipment meets the design requirements, and marking 0°, 90°, 180° and 270° azimuth lines on the installation foundation in a clockwise order, with the 0° azimuth line in front, the 90° azimuth line on the right, the 180° azimuth line in back and the 270° azimuth line on the left; 2.2) sequentially numbering the plurality of modules, placing the module one vertically on the installation foundation, prefabricating and installing a lower head on the inner side of the module one, aligning the 0°, 90°, 180° and 270° mark points of the module one with the 0°, 90°, 180° and 270° azimuth lines on the installation foundation respectively, then measuring the levelness of the upper reference line of the module one, and adjusting the levelness of the upper reference line of the module one until the upper reference line of the module one is horizontal by using a skirt pad iron, and then fixing the module one on the installation foundation by using foundation bolts; 2.3) placing the module two vertically on the module one, aligning the 0°, 90°, 180° and 270° mark points of the module two with the 0°, 90°, 180° and 270° mark points of the module one respectively, measuring the distance between the upper reference line of the module one and the lower reference line of the module two, at least symmetrically measuring four distance values A1, A2, A3 and A4, taking adjustment measures to ensure that A1=A2=A3=A4, and then welding the lower end of the module two with the upper end of the module one; 2.4) sequentially installing the remaining modules in a top-down order by using the method of step 2.3), and finally welding an upper head on the upper end of the module located at the top.

2. The method of claim 1, wherein, The adjustment measure is adjusting the size of the gap between adjacent modules or trimming the port of the module. The adjustment measure is adjusting the size of the gap between adjacent modules or trimming the port of the module. The adjustment measure is adjusting the size of the gap between adjacent modules or trimming the port of

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