Installation and construction method of internal components of hydrogenation reactor

Abstract

This invention discloses a method for installing internal components of a hydrogenation reactor. Within confined working conditions, personnel and materials enter from the top of the reactor to complete large-scale, high-precision installation. A circular suspended basket is used to seal the bottom pipe openings of the equipment, and the outlet diffuser is assembled and installed around the basket. The box-type distribution panel is installed using a piece-by-piece adjustment method, with the final piece installed with high precision by varying the thickness of the asbestos rope. During scaffolding dismantling, prefabricated ladders are used for segmented assembly to ensure normal personnel access.

Description

Technical Field

[0001] This invention relates to the field of installation technology for hydrogenation reactors, and more specifically, to a method for installing internal components of a hydrogenation reactor. Background Technology

[0002] The hydrotreating reactor is the core component of the wax oil hydrotreating unit. It is equipped with an outlet diffuser and an inlet diffuser. The internal components of the hydrotreating reactor consist of three layers. The third and second layers have identical internal components, including a box-type distribution plate, a quench ring, and a catalyst support system. The first layer only contains the box-type distribution plate. Traditionally, the internal components are installed on the ground onto the hydrotreating reactor, and then the entire unit is hoisted into place. However, in cases of slow internal component manufacturing and delivery delays, the internal components must be installed after the hydrotreating reactor is fully installed, which presents significant installation difficulties and high safety risks. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a method for installing internal components of a hydrogenation reactor, so as to reduce the difficulty of construction and improve the efficiency of construction.

[0004] To solve the above technical problems, the technical solution adopted by the present invention is as follows:

[0005] A method for installing internal components of a hydrogenation reactor includes the following steps:

[0006] Step 1: Install the outlet diffuser;

[0007] The outlet diffuser is installed at the bottom of the hydrogenation reactor and is disassembled into eight assemblies, which are connected by bolts. A circular basket is made, and a top-frame monorail crane is used to lower the personnel in the circular basket from the top of the hydrogenation reactor to the bottom installation position.

[0008] The eight assembly pieces of the outlet diffuser are hoisted into the equipment one by one and assembled around the circular basket. After the overall assembly is completed, a monorail crane is used to move the basket out of the center of the bottom opening, and then a monorail crane is used to hoist the outlet diffuser and bolt it to the main body of the hydrogenation reactor.

[0009] Step two, install the internal components of the third bed layer;

[0010] The second bed internals include a box-type distribution plate, a quench ring, and a catalyst support system;

[0011] (1) Installation of box-type distribution plate: The scaffolding inside the hydrogenation reactor equipment is fully erected from bottom to top. All scaffolding materials are transported from the top of the hydrogenation reactor equipment to the bottom of the equipment by a monorail crane. The top of the scaffolding is fully covered with planks as a construction platform. Workers are transported to the construction platform by a circular basket. The box-type distribution plate is installed by socketing. Local leveling is done with asbestos rope. First, the parts close to the inner wall of the hydrogenation reactor equipment are installed. Then, the middle part of the box-type distribution plate is installed. The last box-type distribution plate is finely adjusted using asbestos rope.

[0012] (2) Installation of the quench ring;

[0013] The quench ring is installed using a pre-installed box-type distribution panel as an installation platform. First, the bottom support system of the quench ring is bolted to the hydrogenation reactor equipment. After the bottom support system of the quench ring is completed, the quench bed is installed on top of the bottom support system. The quench bed is installed in multiple sections. First, the part connected to the hydrogenation reactor equipment is installed using bolt fastening. The cold hydrogenation pipeline is installed on the upper part of the quench bed.

[0014] (3) Installation of catalyst support system;

[0015] The catalyst support system consists of four components, each installed separately. Lifting lugs are installed at both ends of each component. A crane with a secondary boom is used to lift one end of the component and lower it into the hydrogenation reactor. After the hook enters the equipment, the crane's wire rope slowly descends along the top edge. Once the component is 300-500mm from the cold hydrogen pipeline, personnel are lifted into the equipment using a circular basket suspended by a monorail crane. Using the pre-installed rapid cooling bed as a platform, the monorail crane hook is attached to the lifting lug at the other end of the component. The monorail crane is then raised, and simultaneously the crane hook is slowly lowered to level the component, allowing it to be moved horizontally to its installation position.

[0016] Step 3: Install the inner components of the second bed layer;

[0017] The second bed internals include a box-type distribution plate, a quench ring, and a catalyst support system;

[0018] The installation shall be carried out using the same methods as in step two, namely (1) installation of the box-type distribution plate, (2) installation of the quench ring and (3) installation of the catalyst support system;

[0019] Step 4: Install the inner components of the first bed layer;

[0020] The first bed layer internals include a distribution panel; it is installed using the same method as the box-type distribution panel installation in step two (1);

[0021] Step 5: Install thermocouples and install the inlet diffuser after removing all scaffolding.

[0022] Furthermore, in step one, the circular suspended platform includes a circular pipe, with lifting lugs welded around the outer wall of the circular pipe, a baffle plate at the bottom of the circular pipe, and openings and ladders in the side wall of the circular pipe.

[0023] Furthermore, in step two, the box-type distribution plates near the hydrogenation reactor equipment are temporarily fixed after installation. After all the box-type distribution plate components near the equipment are installed, the installation gaps are adjusted, and the flatness of the two adjacent groups is checked. In subsequent installations, the flatness of each group is checked by comparing it with the previous group after installation.

[0024] Furthermore, in step two, the bottom support system of the quench ring includes multiple horizontal square components and multiple vertical square components.

[0025] Furthermore, in step five, when dismantling the scaffolding, ladders are erected inside the hydrogenation reactor for personnel to move up and down.

[0026] Furthermore, in step five, the ladder is divided into multiple sections, which are connected by pins; the scaffolding is dismantled from top to bottom, and the ladder extends downward as the scaffolding is dismantled.

[0027] Furthermore, in step five, when dismantling the scaffolding, compressed air is introduced into multiple points inside the hydrogenation reactor equipment.

[0028] Furthermore, in step five, after the inlet diffuser is assembled on the ground, it is hoisted and installed in place using a monorail crane. After the gap is adjusted to meet the requirements, the top cover of the hydrogenation reactor is installed.

[0029] The technical solution provided by this invention allows personnel and materials to enter from the top of the hydrogenation reactor within a confined working environment, enabling large-scale, high-precision installation. A circular suspended basket is used to seal the bottom pipe openings of the equipment, and the assembly and installation of the outlet diffuser is completed around the basket. The box-type distribution panel is installed using a piece-by-piece adjustment method, with the final piece achieving high-precision installation by varying the thickness of the asbestos rope. During scaffolding dismantling, a prefabricated ladder-based segmented assembly method ensures normal personnel access. Attached Figure Description

[0030] 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.

[0031] Figure 1 This is a schematic diagram of the outlet diffuser described in this invention;

[0032] Figure 2 This is a schematic diagram of the structure of the circular suspended basket described in this invention;

[0033] Figure 3This is a schematic diagram of the catalyst support system described in this invention;

[0034] Figure 4 This is a schematic diagram of the ladder connection described in this invention.

[0035] In the diagram, 1-exit diffuser, 2-pipe, 3-lifting lug, 4-baffle, 5-hole, 6-first component, 7-second component, 8-third component, 9-fourth component, 10-steel ladder, 11-inner pin. Implementation

[0036] This embodiment takes the hydrogenation reactor (2107-R-1001), the core equipment in a certain wax oil hydrogenation treatment device, as an example. The hydrogenation reactor weighs 1471 tons, with an inner diameter of 5400mm*49339mm; the wall thickness is 234mm; the maximum design temperature is 450℃, and the maximum working pressure is 15.0Mpa. The hydrogenation reactor has a total of 7 layers of internal components weighing 127.1 tons.

[0037] 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.

[0038] The accessories of the aforementioned hydrogenation reactor are installed sequentially from bottom to top, starting with the outlet diffuser 1. There are three layers of internal components. The third bed of internal components is installed first, followed by the second bed, and finally the first bed. The third bed of internal components is identical to the second bed, including a box-type distribution plate, a quench ring, and a catalyst support system, and these are installed sequentially. Only the box-type distribution plate is installed in the first bed. Finally, the thermocouples are installed, the scaffolding is removed, and the inlet diffuser is installed.

[0039] Installation of Diffuser 1 at the Exit

[0040] In this embodiment, as Figure 1 As shown, the outlet diffuser 1 is installed at the bottom of the hydrogenation reactor. It is made up of eight parts, which are assembled inside the hydrogenation reactor equipment before installation. The total weight of the outlet diffuser 1 is 1.1 tons. The various components of the outlet diffuser are connected by bolts, and after connection, they are bolted to the main body of the equipment.

[0041] The inner diameter of the top opening of the equipment is 900mm, allowing personnel to enter and exit. The inner diameter of the bottom opening is 588mm. The external connecting pipe at the bottom opening has a 90° elbow welded to the equipment body. Personnel cannot enter the equipment from the bottom 90° elbow and must enter the equipment from the top of the hydrogenation reactor.

[0042] like Figure 2As shown, a circular suspended platform is fabricated on-site, using DN700 pipe 2 for welding, with lifting lugs 3 welded around the perimeter, and baffle 4 welded to the bottom. Holes 5 are opened in the side wall of the circular pipe and a ladder is installed. All welds must be ultrasonically tested before use.

[0043] Using a circular suspended basket, a top-frame monorail crane lowered personnel from the top of the hydrogenation reactor to the bottom installation position. Due to the weight of the outlet diffuser 1, its eight individual assemblies, each weighing approximately 150 kg, were hoisted into the equipment one by one and then assembled inside. After all diffuser assemblies were in place, the circular suspended basket was placed at the bottom of the hydrogenation reactor, and its bottom opening was sealed. The outlet diffuser 1 has an inner diameter of 800 mm. The eight diffuser assemblies were assembled around the circular suspended basket. After overall assembly, a monorail crane was used to move the circular suspended basket out of the center of the bottom opening, and then the monorail crane was used to hoist the outlet diffuser 1 and bolt it to the equipment body, completing the installation of the outlet diffuser 1.

[0044] Internal component installation

[0045] 1. Box-type VLT (top-lift) distribution panel installation

[0046] The key points for the box-type VLT (top-lift) distribution plate are: flatness of installation ≤5mm, asbestos rope sealing inspection, socket installation, and local leveling with asbestos rope; the box-type VLT (top-lift) distribution plate weighs 7.2 tons and is installed at +17200mm.

[0047] Because there is no working platform inside the hydrogenation reactor equipment, scaffolding is erected from the bottom up. All scaffolding materials are transported from the top 50m high to the bottom of the equipment by a monorail crane. The top of the scaffolding is fully covered with planks at an elevation of +16700 to serve as a construction platform for personnel. Workers are transported to the construction platform using a circular suspended basket.

[0048] First, install the components near the inner wall of the hydrogenation reactor. Temporarily secure them after installation. Once all components near the main body are installed, adjust the gaps between each part. Check the flatness of adjacent groups. During subsequent installations, check the flatness of each group after installation, comparing it to the previous group. For the internal components in the middle section, tighten the single-headed bolts after socket installation (the bottom has an internal thread). Use 10mm wide asbestos rope for sealing. The center has a 1200*1000mm manhole plate for direct bolt installation. During construction, check the flatness of each piece against the previous one. If the last piece does not meet the standards, use asbestos rope for final minor adjustments.

[0049] The installation methods for the box-type VLT (top-lift type) distribution panels of the third, second, and first beds are the same; scaffolding and other equipment shall be erected in accordance with the construction requirements.

[0050] 2. Installation of quench ring

[0051] When installing the quench ring, the pre-installed box-type distribution plate is used as the installation platform. The bottom support system of the quench ring consists of 6 horizontal square components and 12 vertical square components, which are used as the support system for the quench ring. The entire support system of the quench ring is bolted to the equipment.

[0052] After the quench ring support system is completed, a quench bed is installed on top of the quench ring support system. The installation is carried out in 25 sections. The part that connects to the hydrogenation reactor equipment is installed first, and the installation is carried out by bolt fastening.

[0053] Install cold hydrogenation pipes (maximum operating temperature 100℃) on the upper part of the quenching bed. Assemble the cold hydrogenation pipes using prefabricated components. After assembling and fixing the cold hydrogenation pipes, apply constant torque to all cold hydrogenation flange connections. Then conduct a water pressure test on the equipment with a test pressure of 23.25 MPa. Once the test pressure is qualified, the quenching ring installation is considered complete.

[0054] The installation method for the quench rings in the third and second beds is the same.

[0055] 3. Catalyst support system installation

[0056] The catalyst support system focuses on the installation of support components, which are installed with high precision by entering the interior through the DN900 top port of the hydrogenation reactor equipment.

[0057] The catalyst support system has a total weight of 25 tons, such as Figure 3 As shown, there are four main components, with the largest components being the first and second components, each weighing 8 tons. They are installed horizontally inside the equipment. Once the first and second components are installed, the installation of the remaining components is relatively easy.

[0058] The maximum distance between the first component and the edge of the hydrogenation reactor inlet is 15mm. The first component is installed first, followed by personnel to observe and direct the installation. The first step in installing the first component is to fabricate lifting lugs at both ends. These lugs are welded using M60 double-ended bolts made of 25Cr2MoVA material and 30mm thick Q235B steel plates. A 70mm hole is made in the steel plate, through which the bolts are fully inserted. 35CrMoA nuts are used as anti-loosening devices for lifting. The second step involves using a 130-ton crane with a secondary boom to lift one end of the first component and insert it into the hydrogenation reactor. After the hook enters the equipment, the wire rope is slowly lowered along the top edge. Personnel are then lowered into the equipment using a circular basket suspended by a monorail crane to direct the installation, preventing excessive descent of the component from damaging the quenching system. The third step in installing the first component: After the component is hoisted to a position 300-500mm from the cold hydrogenation pipeline, personnel enter the equipment and use the installed rapid cooling bed as a construction platform. The monorail crane hook is attached to the second lifting lug at the other end of the first component, and the monorail crane is raised while the crane hook is slowly lowered to level the component. The component is then moved horizontally and installed in the appropriate position, completing the installation of the first component. The remaining second, third, and fourth components are all installed using the same method.

[0059] The installation methods for the catalyst support systems of the third and second beds are the same.

[0060] 4. Thermocouple installation

[0061] During thermocouple installation, the bending of the thermocouples and the installation positions of each measuring point should be carefully checked. The hydrogenation reactor has nine thermocouples at diameters of 8100mm, 12650mm, 17200mm, 20560mm, 25110mm, 30180mm, 33020mm, 37610mm, and 43540mm; each thermocouple has six measuring points.

[0062] Before installation, move the scaffolding platform to the thermocouple installation position. During installation, check the RJ flange face and gasket. After the thermocouple is installed inside the equipment, mark the bending part of the thermocouple and use a small tube bender to bend the thermocouple to ensure that the detection endpoints are installed in the positions required by the drawings. After all 6 temperature measuring points of the thermocouple are installed, use fixing clips to install and fix them.

[0063] All thermocouples are tested for production conditions. A thermocouple will show a qualified temperature at 6 points. The bolts of the thermocouple are tightened to a constant torque during the heating process. The temperature display at 6 points is confirmed to be normal in the cabinet, and the thermocouple installation is qualified.

[0064] 5. Inlet diffuser installation:

[0065] Before installing the inlet diffuser, the scaffolding of the reactor needs to be removed.

[0066] 6. Scaffolding dismantling

[0067] The key to scaffolding removal is to completely dismantle the scaffolding while maintaining high temperatures, making it impossible for personnel to leave the reactor normally. After three days of ventilation, the temperature inside the hydrogenation reactor will be 42℃-45℃. Personnel will enter the equipment in batches for dismantling, strictly controlling the working time per shift to no more than 1.5 hours. Compressed air will be introduced into the equipment at five points on-site.

[0068] The hydrogenation reactor equipment is divided into four sections from top to bottom by its internal platform. The first section of scaffolding consists of a straight ladder erected from the top opening to the first bed, with a height of 4 meters. After the scaffolding is dismantled, materials can be pulled out through the internal manhole, but personnel cannot enter or exit. Therefore, based on the limitation of working hours, a prefabricated ladder-based segmented assembly method is adopted to ensure normal personnel access.

[0069] The prefabricated ladder consists of three sections, each individually fixed. The ladder is assembled from multiple steel sections (10 sections each) to prevent excessive weight; the longest ladder has eight sections. Figure 4 As shown, each steel ladder section is 2 meters long. Two steel ladder sections 10 are connected by an inner pin 11. A 100mm gap is reserved at both ends of the steel ladder 10. The footboard spacing of the steel ladder 10 is 300mm. DN25*2.77 is used as the inner pin. The two ends of the steel ladder 10 and the inner pin are all drilled with 10mm holes to connect the two ends of the adjacent steel ladder 10. A total of 8 M8*55 single-headed bolts are used to connect each section of the steel ladder.

[0070] All ladders are secured using scaffolding, with the internal platform serving as the load-bearing point. The scaffolding is erected in a grid pattern to support the ladders. Platforms are built at the second and third sections. As the scaffolding is dismantled, the ladders extend towards the bottom of the equipment. Once all personnel and materials have been moved to the top platform, the scaffolding dismantling is complete.

[0071] 7. Overall installation of the inlet diffuser

[0072] The inlet diffuser arrived in bulk and, after being assembled on the ground, weighed a total of 0.9 tons. It was then hoisted and installed in place using a monorail crane. After adjusting the gap at the top opening to ensure it was within acceptable limits, the top cover of the hydrogenation reactor was installed.

[0073] 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 method of installing a hydrogenation reactor internal, characterized by, The method comprises the following steps: Step one, outlet diffuser installation; The outlet diffuser is installed at the bottom of the hydrogenation reactor, and is divided into eight assembly units which are connected by bolts; a circular basket is made, and personnel in the circular basket are lifted from the top of the hydrogenation reactor to the bottom installation position by using a top frame monorail crane; The eight assembly units of the outlet diffuser are hoisted into the equipment interior one by one, and are assembled around the circular basket; after the overall assembly is completed, the basket is moved out of the bottom center position by using the monorail crane, and then the outlet diffuser is hoisted and bolted with the hydrogenation reactor body by using the monorail crane; Step two, installation of the third bed layer internals; The third bed layer internals comprise box-type distribution trays, quench rings and catalyst support systems; (1) Box-type distribution tray installation; a scaffold is fully erected from the bottom to the top in the interior of the hydrogenation reactor, the scaffold material is sent to the bottom of the hydrogenation reactor from the top of the hydrogenation reactor by using a monorail crane, a jump board is fully laid on the top of the scaffold to serve as a construction platform, and personnel are sent to the construction platform by using a circular basket; the box-type distribution trays are installed by using a socket type, are leveled by using asbestos rope, are installed from the parts close to the inner wall of the hydrogenation reactor to the middle parts of the box-type distribution trays, and the last box-type distribution tray is finely adjusted by using asbestos rope; (2) Quench ring installation; The quench ring installation uses the box-type distribution tray which has been installed as an installation platform, the bottom support system of the quench ring is first bolted with the hydrogenation reactor part; after the bottom support system of the quench ring is constructed, a quench bed is installed on the top of the bottom support system of the quench ring, the quench bed is installed in multiple parts, the part connected with the hydrogenation reactor is first installed, and is installed by using a bolt fastening mode; a cold hydrogenation pipeline is installed on the upper part of the quench bed; (3) Catalyst support system installation; The catalyst support system comprises four components which are respectively installed; lifting lugs are arranged at two ends of each component, a hoist is selected, a vice lever is added, one end of the component is first hoisted and hoisted into the interior of the hydrogenation reactor, the hook is entered into the equipment, and the steel wire rope of the hoist is slowly lowered along the top edge; after the component is hoisted into the position 300-500 mm away from the cold hydrogen pipeline, personnel enter the interior of the equipment by using a circular basket hoisted by a monorail crane and use the installed quench bed as a construction platform, a hook of the monorail crane is hung on the lifting lug at the other end of the component, the monorail crane is lifted, and the hoist hook is slowly lowered, so that the component is leveled and is horizontally moved to be installed at the installation position; Step three, installation of the second bed layer internals; The second bed layer internals comprise box-type distribution trays, quench rings and catalyst support systems; The same method as in step two, (1) box-type distribution tray installation, (2) quench ring installation and (3) catalyst support system installation is used for installation; Step four, installation of the first bed layer internals; The first bed layer internals comprise distribution trays; The same method as in step two, (1) box-type distribution tray installation is used for installation; Step five, installation of thermocouples, and installation of an inlet diffuser after all the scaffolds are removed.

2. The hydrogenation reactor internals installation construction method as claimed in claim 1, characterized by: In step one, the circular basket comprises a circular pipe, the outer wall of which is welded with lifting lugs, the bottom of which is provided with a baffle, and the sidewall of which is provided with a hole and a ladder.

3. The hydrogenation reactor internal installation construction method according to claim 1 or 2, characterized by: In step two, the temporarily fixed box distribution plates near the hydrogenation reactor equipment are installed, and after all the box distribution plates near the equipment are installed, the gaps are adjusted, the flatness of two adjacent groups is adjusted and checked, and in the subsequent installation, the flatness of the previous group is compared after each group is installed.

4. The hydrogenation reactor internals installation construction method according to claim 3, characterized by: In step two, the quench ring bottom support system comprises a plurality of square members in the transverse direction and a plurality of square members in the longitudinal direction.

5. The hydrogenation reactor internal installation construction method according to claim 1 or 4, characterized by: In step five, when the scaffold is removed, a ladder is erected inside the hydrogenation reactor for personnel to go up and down.

6. The hydrogenation reactor internals installation construction method according to claim 5, characterized by: In step five, the ladder is divided into multiple sections, and the sections are connected by pins; the scaffold is removed from top to bottom, and the ladder extends downward as the scaffold is removed.

7. The hydrogenation reactor internals installation method according to claim 6, characterized by: In step five, when the scaffold is removed, compressed air is supplied to multiple points in the hydrogenation reactor equipment.

8. The hydrogenation reactor internal installation construction method according to claim 6 or 7, characterized by: In step five, the inlet diffuser is assembled on the ground and then lifted and installed in place by a monorail crane, and after the gap is adjusted and qualified, the hydrogenation reactor top cover is installed.

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