Construction method of in-band cone non-standard tank

Abstract

The application discloses a modular construction method of a non-standard tank with an inner cone, and the tank is divided into three modules according to the main structure of a tar-ammonia separation tank, wherein the first module is a lower half of the tank, the second module is an upper half of the tank, and the third module is the inner cone. The three modules are prefabricated and assembled respectively, the inner cone small modules are prefabricated outside the pipe respectively, then the inner cone small modules of the third module are hoisted into the first module for assembly, the second module is hoisted above the first module, then the annular seam between the two modules is welded, and finally the assembled inner cone is lifted to a specified position and welded. The modular construction process of the non-standard tank with the inner cone provided by the application transplants high-altitude operation of traditional construction to the ground, adopts a suitable structure combination as a module unit, and performs modular hoisting after prefabrication and assembly, so that the work efficiency is improved, the construction cost and safety risk are reduced, and the installation precision is greatly improved.

Description

Technical Field

[0001] This method is applicable to the on-site fabrication and installation of non-standard equipment in chemical plants, especially for construction methods involving non-standard tanks with internal cones. Background Technology

[0002] During the coking process, the emitted gases are mostly highly corrosive and toxic. If coke oven gas is released directly into the air without treatment, it will result in a serious waste of resources and severe environmental pollution. Currently, because my country prioritizes ecological and environmental development, gas purification systems must be constructed and put into operation simultaneously with the construction of coke ovens.

[0003] The tar-ammonia-water separation unit in the coal gas purification process relies on the difference in specific gravity between ammonia and tar to separate them in a tar-ammonia-water separation tank, thereby obtaining coal tar products. The tar-ammonia-water separation tank, as the main equipment for tar-ammonia-water separation, has a complex structure with an inner cone inside. A single tank has up to 50 pipe openings and three sets of regulating devices. Due to the inner cone inside the tank, traditional construction methods can only be carried out using the direct installation method, requiring the erection of external scaffolding after the main structure is completed for the installation of overflow pipes and pipe openings. Traditional construction methods involve a lot of work at heights, resulting in low worker efficiency, long construction periods, and high construction costs. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a modular construction method for non-standard tanks with internal cones, so as to improve the efficiency of workers and machinery, reduce the risk of working at heights, and shorten the construction cycle.

[0005] To solve the above technical problems, the technical solution adopted by the present invention is as follows:

[0006] A modular construction method for non-standard tanks with internal cones includes the following steps:

[0007] Step 1: Divide the tank modules;

[0008] Based on the main structural form of the tar-ammonia-water separation tank, it is divided into three modules: Module 1 is the lower half of the tank, including the bottom plate, the upper contact wall plate of the inner cone, and several wall plates at the bottom; Module 2 is the upper half of the tank, including the top ring wall plate and its lower wall plate, the internal overflow channel, the foam baffle, the tank top plate, the tank top central ring, the edge angle steel ring, and the tank top purlin; Module 3 is the inner cone, which includes the top inner cone, the bottom inner cone, and several small inner cone modules.

[0009] Step 2: Prefabrication and assembly of the three modules

[0010] Module 1 Prefabrication and Assembly: First, lay the bottom plate of the tank and weld it together. Then, use the inverted assembly method to assemble and weld each wall panel. After assembly, weld the bottom wall panel to the bottom plate.

[0011] Module 2 Prefabrication and Assembly: First, the top ring wall panels are assembled and welded, and then each wall panel is assembled and welded using the inverted method. At the same time, the overflow trough and foam baffle inside the tank are installed.

[0012] Module 3 Prefabrication and Assembly: Each section of the inner cone module is prefabricated outside the tank, and then the inner cone modules of Module 3 are hoisted into Module 1 for assembly.

[0013] Step 3: Assemble Module 2 and Module 1

[0014] Module 2 is hoisted above Module 1, and then the circumferential seam between the two modules is welded.

[0015] Step 4, Inner cone lifting installation

[0016] After the welding of Module 1 and Module 2 is completed, the inner cone assembled in Step 2 is lifted to the designated position and welded. Then, the top inner cone and the bottom inner cone are installed.

[0017] Furthermore, in Module 1, there are four wall panels from bottom to top. When assembling and welding the wall panels, first assemble and weld the longitudinal seam of the fourth wall panel. After the assembly and welding is completed, lift the fourth wall panel. Then, assemble and weld the longitudinal seam of the third wall panel. After the assembly and welding is completed, lower the fourth wall panel and weld the circumferential seam with the third wall panel. Repeat the above steps until the circumferential seam of the second wall panel and the first wall panel is completed. Then, weld the seam between the first wall panel and the bottom plate and the reserved seam on the bottom plate. Finally, install the pipe openings on the tank wall.

[0018] Furthermore, in step two, during the prefabrication and installation of module one, an electric hoist is used for lifting.

[0019] Furthermore, Module 2 includes a sixth strip wall panel as the top ring wall panel and a fifth strip wall panel below it. During the prefabrication and assembly of Module 2, after the sixth strip wall panel is assembled and welded, the edge angle steel, the tank top center ring, and the tank top purlin are installed. Then, the longitudinal seam of the fifth strip wall panel is welded, and then the circumferential seam between the sixth strip wall panel and the fifth strip wall panel is welded. Finally, the prefabricated tank top plate is assembled and welded with the tank top center ring and the edge angle steel ring.

[0020] Furthermore, in step two, during the prefabrication and installation of module two, a truck crane is used for lifting.

[0021] Furthermore, in step two, the inner cone is prefabricated in 9 sections. The 9th inner cone is the top inner cone, and the angle between the 9th inner cone and the tank wall is 30°. The angle between the 1st to 8th inner cones and the wall is 45°. The tank is prefabricated in sections outside the tank. The 2nd to 4th inner cones are one inner cone module, the 5th to 6th inner cones are one inner cone module, and the 7th to 8th inner cones are one inner cone module. The 1st inner cone is the bottom inner cone and serves as the inner cone adjustment section.

[0022] Furthermore, in step three, the inner cone sections 2-4 of module three are first hoisted into module one. After they are in place, the inner cones are supported by channel steel. Then, the inner cone sections 5-6 are hoisted into module one and assembled and welded with the inner cone sections 2-4. Next, the inner cone sections 7-8 are hoisted into module one and assembled and welded with the inner cone sections 2-6.

[0023] Furthermore, in step four, after the welding of modules one and two is completed, several manual hoists are evenly arranged on the top of the tank, and lifting lugs are welded on the inner cone. After the 2nd to 8th sections of the inner cone are lifted to the designated position using the manual hoists, the inner cone is officially supported and welded. Then, the 9th section of the inner cone is installed in sections, and finally, the 1st section of the inner cone is processed and installed according to the bottom dimensions.

[0024] The modular construction process for non-standard tanks with inner cones provided by this invention transplants the traditional high-altitude construction work to the ground. It uses suitable structural combinations as modular units, prefabricates and assembles them, and then performs modular hoisting. This not only improves work efficiency but also reduces construction costs and safety risks, while also significantly improving installation accuracy. Attached Figure Description

[0025] The accompanying drawings, which are provided to further illustrate the invention and form part of this application, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention.

[0026] Figure 1 This is a schematic diagram of the main structure and module division of the tar-ammonia-water separation tank;

[0027] Figure 2 This is a general unified flowchart of the method described in this invention;

[0028] Figure 3 This is a prefabrication flowchart of module one of the present invention;

[0029] Figure 4 This is a flowchart of the prefabrication process for module two of the present invention;

[0030] Figure 5 This is a flowchart of the prefabrication process for module three of this invention.

[0031] In the diagram, 1-first wall panel, 2-second wall panel, 3-third wall panel, 4-fourth wall panel, 5-fifth wall panel, 6-sixth wall panel, 7-top plate, 8-bottom plate. Detailed Implementation

[0032] To enable those skilled in the art to better understand the present invention, the present invention will be further described clearly and completely below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other.

[0033] This embodiment provides a construction method for a tar-ammonia water separation tank. The tar-ammonia water separation tank is a non-standard tank with an inner cone, including a tank bottom plate, several tank wall sections, a tank top, several inner cone sections, and several pipe openings.

[0034] Tank Module Division

[0035] Based on the main structural form of the tar-ammonia-water separation tank, the tank is divided into three modules for prefabrication and installation.

[0036] Module 1 is the lower half of the tank, including a bottom plate 8, an upper contact wall plate of the inner cone, and several lower wall plates, totaling four wall plates. The upper contact wall plate of the inner cone is the fourth wall plate 4, and the others from top to bottom are the third wall plate 3, the second wall plate 2, and the first wall plate 1.

[0037] Module 2 is the upper half of the tank, including the top ring wall panel and its lower wall panel, the tank top plate 7, the tank top center ring, the edge angle steel ring, and the tank top purlin. Among them, the top ring wall panel is the sixth band wall panel 6, and the lower part of the top ring wall panel is the fifth band wall panel 5.

[0038] Module 3 is the inner cone, which includes a top inner cone, a bottom inner cone, and several smaller inner cone modules. In this embodiment, the inner cone has a total of 9 segments. The top inner cone is the 9th segment, the bottom inner cone is the 1st segment, and the middle part, segments 2-8, are divided into three smaller inner cone modules.

[0039] Three modules are prefabricated and assembled simultaneously

[0040] Module 1: First, lay and weld the tank bottom plate 8. Then, assemble and weld the longitudinal seam of the fourth wall plate 4. After the assembly welding is completed, use an electric hoist to lift the fourth wall plate 4 using the inverted method, and then perform the assembly welding of the longitudinal seam of the third wall plate 3. After the assembly welding is completed, lower the fourth wall plate 4 and perform the circumferential weld with the third wall plate 3. Repeat the above steps until the circumferential weld of the second wall plate 2 and the first wall plate 1 is completed. Then, weld the weld between the first wall plate 1 and the bottom plate 8, as well as the weld reserved on the bottom plate 8, and install the pipe openings on the tank wall.

[0041] Module Two: The top ring wall panel (sixth strip wall panel 6) is assembled and welded. After completion, the edge angle steel, tank top center ring, and tank top purlins are installed. Then, the prefabricated tank top panel 7 is assembled and welded with the tank top center ring and edge angle steel ring. The longitudinal seam of the fifth strip wall panel 5 is welded using a truck crane inverted assembly method, and then the circumferential seam between the sixth strip wall panel 6 and the fifth strip wall panel 5 is welded.

[0042] Module 3: The inner cone is prefabricated in 9 sections. The angle between the 9th section of the inner cone and the tank wall is 30°, and the angle between the 1st to 8th sections of the inner cone and the wall is 45°. These sections are prefabricated externally to the tank, with small modules for sections 2-4, 5-6, and 7-8 hoisted into the tank for installation. Inner cone section 1 serves as an adjustment section; after inner cones 2-9 are installed, it will be machined and installed in place according to the actual dimensions.

[0043] Module 3 is constructed using a segment-by-segment direct assembly method. Sections 2-8 of the inner cone from Module 3 are hoisted into Module 1 for installation. First, sections 2-4 from Module 3 are hoisted into Module 1, and after positioning, the inner cones are supported using channel steel. Then, sections 5-6 are hoisted into Module 1 and assembled and welded with sections 2-4 of the inner cone. Finally, sections 7-8 are hoisted into Module 1 and assembled and welded with sections 2-6 of the inner cone.

[0044] Assembly of Module 2 and Module 1

[0045] Use a truck crane to lift module two onto top of module one, and then weld the circumferential seam between the two modules.

[0046] Inner cone lifting installation

[0047] After the welding of modules one and two is completed, several manual hoists are evenly arranged on the top of the tank. Lifting lugs are welded onto the inner cone. Using the manual hoists, sections 2-8 of the inner cone are lifted to the designated position, and the welding of the inner cone support is completed. Then, the 9th inner cone is installed in sections. Finally, according to the bottom dimensions, the 1st inner cone is machined and installed.

[0048] The scope of protection claimed by this invention is not limited to the specific embodiments described above. For those skilled in the art, this invention can have various modifications and alterations. Any modifications, improvements, and equivalent substitutions made within the concept and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A modular construction method for non-standard tanks with internal cones, characterized in that, include: Step 1: Divide the tank modules; Based on the main structural form of the tar-ammonia-water separation tank, it is divided into three modules: Module 1 is the lower half of the tank, including the bottom plate, the upper contact wall plate of the inner cone, and several lower wall plates; Module 2 is the upper half of the tank, including the top ring wall plate and its lower wall plate, the tank top plate, the tank top central ring, the edge angle steel ring, and the tank top purlin; Module 3 is the inner cone, which includes the top inner cone, the bottom inner cone, and several small inner cone modules. Step 2: Prefabrication and assembly of the three modules Module 1 Prefabrication and Assembly: First, lay the bottom plate of the tank and weld it together. Then, use the inverted assembly method to assemble and weld each wall panel. After assembly, weld the bottom wall panel to the bottom plate. In Module 1, there are four wall panels from bottom to top. When assembling and welding the wall panels, first assemble and weld the longitudinal seam of the fourth wall panel. After the fourth wall panel is assembled and welded, lift the fourth wall panel. Then, assemble and weld the longitudinal seam of the third wall panel. After the third wall panel is assembled and welded, lower the fourth wall panel and weld the circumferential seam with the third wall panel. Repeat the above steps until the circumferential seam of the second wall panel and the first wall panel is assembled and welded. Then weld the seam between the first wall panel and the bottom plate and the reserved seam on the bottom plate. Finally, install the pipe openings on the tank wall. Module 2 Prefabrication and Assembly: First, the top ring wall panels are assembled and welded, and then the wall panels of each belt are assembled and welded using the inverted assembly method; Module 2 includes a sixth strip wall panel that serves as the top ring wall panel and a fifth strip wall panel below it. During the prefabrication and assembly of Module 2, after the sixth strip wall panel is assembled and welded, the edge angle steel, the tank top center ring, and the tank top purlins are installed. Then, the longitudinal seam of the fifth strip wall panel is welded, and then the circumferential seam between the sixth strip wall panel and the fifth strip wall panel is welded. Finally, the prefabricated tank top plate is assembled and welded with the tank top center ring and the edge angle steel ring. Module 3 Prefabrication and Assembly: Each inner cone module is prefabricated outside the tube, and then the inner cone modules of Module 3 are hoisted into Module 1 in sections for assembly. The inner cone is prefabricated in 9 sections. The 9th section is the top inner cone, with a 30° angle between it and the tank wall. The angles between the 1st to 8th sections and the tank wall are 45°. The tank is prefabricated in sections outside the tank. Sections 2-4, 5-6, and 7-8 form a small inner cone module. The 1st section is the bottom inner cone and serves as an adjustment section. First, hoist the inner cone sections 2-4 of Module 3 into Module 1. After positioning, use channel steel to support the inner cones. Then, hoist the inner cone sections 5-6 into Module 1 and assemble and weld them with the inner cone sections 2-4. Next, hoist the inner cone sections 7-8 into Module 1 and assemble and weld them with the inner cone sections 2-6. Step 3: Assemble Module 2 and Module 1 Module 2 is hoisted above Module 1, and then the circumferential seam between the two modules is welded. Step 4, Inner cone lifting installation After the welding of Module 1 and Module 2 is completed, the inner cone assembled in Step 2 is lifted to the designated position and welded. Then, the top inner cone and the bottom inner cone are installed.

2. The method according to claim 1, characterized in that: In step two, when module one is prefabricated and installed, an electric hoist is used for lifting.

3. The method according to claim 1 or 2, characterized in that: In step two, during the prefabrication and installation of module two, a truck crane is used for lifting.

4. The method according to claim 3, characterized in that: In step four, after the welding of modules one and two is completed, several manual hoists are evenly arranged on the top of the tank. Lifting lugs are welded on the inner cone. After the manual hoists lift the inner cone sections 2-8 to the designated positions, the inner cone is officially supported and welded. Then, the 9th inner cone section is installed in sections. Finally, the 1st inner cone section is processed and installed according to the bottom dimensions.

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