Vertical bucket elevator installation method in closed factory building

Abstract

The application discloses a vertical bucket elevator installation method in a closed factory building, which comprises the following steps: foundation re-measurement, lower section installation, machine shell installation, machine shell support installation, upper section installation, driving platform and metal fixing frame installation, transmission device installation, traction cable rope installation, hopper installation and trial running. The lower section, the upper section and the transmission device are installed by using a winch and a pulley block. After the machine shell installation and correction are completed, the driving platform and the metal fixing frame are made by using surrounding factory building structures. The application is suitable for vertical bucket elevator installation in different floors of a closed factory building, and can realize safe and efficient installation of the vertical bucket elevator in different floors of the closed factory building. Through reasonable arrangement of construction procedures, the application guarantees engineering construction quality, speeds up installation efficiency and guarantees one-time equipment installation acceptance.

Description

Technical Field

[0001] This invention relates to a method for installing large-scale chemical equipment, and more specifically, to a method for installing a vertical bucket elevator in a closed plant using a forward mounting method. Background Technology

[0002] In the chemical industry, material hoists are increasingly widely used due to their large conveying capacity, high lifting height, stable operation, and long service life.

[0003] Traditionally, material hoists are installed before the equipment building is topped out, primarily to facilitate the use of large hoisting machinery and improve efficiency. However, in the chemical industry today, due to various practical considerations, the equipment building is often topped out before the equipment is installed, making it impossible to install large equipment within the building using large hoisting machinery. Installing equipment in such confined spaces places higher demands on the installation methods. Summary of the Invention

[0004] The purpose of this invention is to provide a method for installing a vertical bucket elevator in a closed factory building, which achieves the goal of installing a vertical bucket elevator in different floors of a closed factory building by reasonably arranging the construction process.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A method for installing a vertical bucket elevator in a closed factory building using a forward mounting method includes the following steps: Step 1, basic re-measurement; before equipment installation, mark the longitudinal and transverse center lines of the lower section of the hoist. Step 2, lower section installation; use a front winch to slide and transport the equipment to the lifting position, then use another winch to hoist the lower section above the equipment foundation via a high pulley block; adjust the relative position of the lower section and the foundation bolts, and slowly lower the lower section to accurately install it on the equipment foundation; Step 3, casing installation; Based on the number of casings required for each floor of the factory, use a winch to hoist them from the pre-drilled holes for equipment installation to the floor level of each floor, and install them in sequence; Step 4: Install the casing brackets; After the casing of each floor of the factory building is installed, install the fixing brackets on the casing of that floor and fix the fixing brackets on the nearest floor structure. Step 5, Upper Section Installation: Use a winch to hoist the upper section to the top of the casing via a high pulley system. Insert asbestos rope between the connecting flanges of the top casing to ensure sealing and the levelness of the flange surfaces. Adjust the relative position of the upper section and the flange surfaces on the casing, lower the upper section, and precisely install it on top of the casing. Step 6: Installation of the drive platform and metal mounting frame; The drive platform and metal mounting frame are constructed using surrounding factory buildings and structures, and the hoist is reinforced at the same time. Step 7, Installation of the transmission device; Use a winch and pulley block to hoist the transmission device to the drive platform and connect it to the head wheel axle of the upper section; Before connection, first confirm that the backstop direction of the backstop on the transmission device is opposite to the rotation direction of the transmission drum, and then use a dial indicator to align the output shaft of the transmission device with the head wheel axle. Step 8: Installation of the traction wire rope belt; Press the hopper bolts into the wire rope belt. According to the site and hoisting conditions, install the wire rope belt into the hoisting chamber. Raise the lower adjusting screw to the highest position. Clamp one end of the wire rope belt with the wire rope belt clamp. Hoist the wire rope belt head to the top of the hoisting machine from the middle of the machine casing on the feed port side using a hoisting rope. Clamp the other end of the wire rope belt with the wire rope belt clamp in the same way. Hoist the wire rope belt head to the top of the hoisting machine from the discharge port side. Finally, seal both ends of the belt with glue. Step 9, Hopper Installation; During installation, a rubber pad should be placed on the back of the hopper. The hoppers should be installed one by one in sequence, starting from the lower part of the feed inlet side, and the bolts of each hopper should be fully tightened. Step 10: Test drive.

[0006] Furthermore, in step one, after the foundation re-measurement is completed, flat shims are placed at the anchor bolt holes using the grouting method. The elevation error of each group of shims is no more than 1mm, and the levelness error is no more than 0.1 / 1000.

[0007] Furthermore, in step two, after the lower section is in place, its reference surface needs to be leveled. The allowable tolerance for the parallelism between the reference surface and the horizontal plane is 1 / 1000mm, and the adjusting shims must be close to the anchor bolts.

[0008] Furthermore, in step three, during the installation of the housing, asbestos rope is inserted between the connecting flanges of the middle housing to ensure sealing and the levelness of the flange surfaces; after the housing is assembled, the center lines of the housings of each channel are on the same vertical plane, and their straightness deviation shall not exceed 2 / 1000, and the cumulative deviation shall not exceed 8mm.

[0009] Furthermore, in step four, a fixed support is installed on each floor of the factory building. The installation of the fixed support does not restrict the free extension and contraction of the hoist in the vertical direction.

[0010] Furthermore, in step five, after the upper section is installed, the center lines of the upper and lower drive shafts of the hoist are calibrated so that the two shafts are horizontal and in the same vertical plane. The allowable tolerance for the parallelism between the center line of the upper shaft and the horizontal plane is 0.3 / 1000mm, the error of the upper and lower shafts being in the same vertical plane is less than 4mm, and the error of the upper and lower roller end faces being in the same vertical plane is less than 5mm.

[0011] Furthermore, in step seven, the transmission device is recalibrated before installation. During adjustment, a dial indicator and feeler gauge are used to align the motor, hydraulic coupling, and reducer. The radial and axial runout of the hydraulic coupling, motor output shaft, and reducer input shaft should be ≤0.3mm.

[0012] Furthermore, in step eight, the horizontal edge of the wire rope belt joint must be perpendicular to the center line of the conveyor belt, and the perpendicularity error must not exceed 0.2% of the belt width. The misalignment at both ends of the wire rope belt joint must be less than 2mm.

[0013] Furthermore, in step ten, after all components of the hoist are installed as required, a no-load test run is first conducted. During the test run, the hoist is started, and the inspection door is opened during the hoist test run to carefully observe the operation of each part of the equipment. The operation time is not less than 2 hours.

[0014] Furthermore, in step ten, after the no-load test is completed and the equipment is confirmed to be completely normal, a load test can be conducted. During the test, the elevator is started under the designed conveying capacity and the material to be conveyed. First, observe the operation of the transmission device, the load of the motor, whether it reaches full load or overload, whether the electrical control equipment is working normally, whether the noise of the reducer is excessive, whether the operation of the upper and lower sections is normal, whether the wire rope belt slips on the drum, and whether the running speed meets the design requirements. Finally, observe whether the elevator reaches the designed conveying capacity when the material is fed evenly, whether the unloading is normal, and whether there is obvious material return or accumulation. When the elevator stops running, is there obvious reverse running? After there are no defects in the above-mentioned load test, it can be handed over to production.

[0015] This invention discloses a method for installing a vertical bucket elevator in an enclosed factory building using a forward mounting method. The method utilizes a winch and pulley system to install the lower section, upper section, and transmission device. After the casing is installed and aligned, a drive platform and metal mounting frame are constructed using surrounding factory structures. This invention is applicable to the installation of vertical bucket elevators on different floors of an enclosed factory building, enabling safe and efficient installation. By rationally arranging the construction sequence, it ensures project construction quality, accelerates installation efficiency, and guarantees successful equipment installation and acceptance on the first attempt. Attached Figure Description

[0016] Figure 1 This is the construction procedure of the installation method described in this invention; Figure 2 This is a structural schematic diagram of the vertical bucket elevator described in this invention. In the diagram, 1-Equipment foundation, 2-Lower section, 3-Casing, 4-Fixed bracket, 5-Upper section, 6-Drive platform, 7-Metal fixed frame, 8-Transmission device, 9-Wire rope belt, 10-Hopper. Detailed Implementation

[0017] With the equipment plant already topped out, vertical bucket elevators cannot be installed using large hoisting machinery, so the installation method must be optimized and improved.

[0018] Based on this, this embodiment provides a method for installing a vertical bucket elevator in a closed factory building, including the following steps one to ten.

[0019] I. Basic Retest Before installation, based on the location of the equipment on the drawings and the distance to the connected equipment, draw the longitudinal and transverse center lines of the lower section of the hoist. The error shall not exceed ±10mm.

[0020] After the re-measurement of equipment foundation 1 is completed, flat shims should be installed at the anchor bolt holes using the grouting method. The elevation error of each set of shims should not exceed 1mm, and the levelness error should not exceed 0.1 / 1000.

[0021] Second, installation in the lower section. The equipment is slidably transported to the lifting position using a front-mounted winch, and then another winch is used to slowly and safely hoist the lower section 2 to a position 5mm above the equipment foundation 1 via a high pulley system. The relative position of the lower section 2 and the foundation bolts is adjusted, and the lower section 2 is slowly lowered and precisely installed on the equipment foundation 1.

[0022] After the lower section 2 is in place, its reference surface needs to be leveled. The allowable tolerance for the parallelism between the reference surface and the horizontal plane is 1 / 1000mm, and the adjusting shims must be close to the anchor bolts.

[0023] 3. Installation of casing 3 Based on the required number of machine casings 3 for each floor of the factory, hoist them from the pre-drilled holes for equipment installation to the floor level of each floor using a winch, and arrange them in the installation sequence for installation.

[0024] During the installation of housing 3, a 3mm thick asbestos rope should be inserted between the connecting flanges of the middle housing 3 to ensure sealing and the levelness of the flange surfaces. A small amount of grease can be applied to the asbestos rope, and then it should be wrapped around the bolts between the housing flanges for easy positioning and to enhance the sealing effect.

[0025] During installation, the flange surfaces of each section of the housing 3 must be flat, and there must be no obvious misalignment during connection.

[0026] After the housing is assembled, the center line of the housing 3 of each channel should be on the same vertical plane, and the straightness deviation should not exceed 2 / 1000, and the cumulative deviation should not exceed 8mm.

[0027] IV. Housing bracket installation After the machine casing of each floor of the factory building is installed, a fixing bracket 4 must be installed on that floor's casing. The fixing bracket 4 should be reliably fixed to the nearest floor structure. It is advisable to install one fixing bracket 4 on each floor, and the installation of the fixing bracket 4 should not restrict the free extension and contraction of the hoist in the vertical direction.

[0028] 5. Installation of the upper section Using a winch, the upper section 5 is slowly and safely hoisted to a position 5mm above the top casing via a high pulley system. A 3mm thick asbestos rope is inserted between the connecting flanges of the top casing to ensure a seal and the levelness of the flange surfaces. The relative position of the upper section and the flange surfaces of the casing is adjusted, and the upper section 5 is slowly lowered and precisely installed above the top casing.

[0029] After the upper section 5 is installed, the center lines of the upper and lower drive shafts of the hoist must be calibrated to ensure that the two shafts are horizontal and in the same vertical plane. The allowable tolerance for the parallelism between the center line of the upper shaft and the horizontal plane is 0.3 / 1000mm, the error of the upper and lower shafts being in the same vertical plane must be less than 4mm, and the error of the upper and lower roller end faces being in the same vertical plane must be less than 5mm.

[0030] 6. Installation of drive platform and metal mounting frame After the hoist casing is installed and aligned, the drive platform 6 and metal fixing frame 7 should be constructed using the surrounding factory buildings and structures, and the hoist should be reinforced to further reduce vibration and make the operation more stable.

[0031] When installing the metal fixing frame 7, the bucket elevator will generate heat during normal operation, causing the casing temperature to rise. Therefore, it is strictly forbidden to weld the bucket elevator casing to the metal fixing frame 7. This is to prevent the elevator from bending or the fixing frame from cracking when the casing temperature rises, which could lead to a safety accident.

[0032] 7. Installation of transmission device The transmission device 8 is hoisted to the drive platform 6 using a winch and pulley block, and connected to the head wheel axle of the upper section 5. Before connecting the two parts, ensure that the backstop direction of the backstop on the transmission device 8 is opposite to the rotation direction of the drive drum. Then, use a dial indicator to align the output shaft of the transmission device with the head wheel axle. The coaxiality error between the output shaft of the transmission device 8 and the head wheel axle should be ≤0.05mm.

[0033] Since the transmission device 8 is usually shipped to the site as a whole, its original precision may be compromised during transportation, so it must be recalibrated before installation. During adjustment, a dial indicator and feeler gauge should be used to align the motor, hydraulic coupling, and reducer. The radial and axial runout of the hydraulic coupling, motor output shaft, and reducer input shaft should be ≤0.3mm.

[0034] 8. Installation of traction cable and tape First, confirm the specifications, model, and length of the wire rope conveyor belt 9 to be installed. Then, press the hopper bolts into the belt. Based on the site conditions and hoisting requirements, install the belt into the elevator cavity. Raise the lower adjusting screw to its highest position. Clamp one end of the wire rope conveyor belt 9 using a wire rope belt clamp. Hoist the head of the wire rope conveyor belt 9 to the top of the elevator using a hoisting rope from the middle of the housing on the feed port side. Repeat the same method for the other end of the wire rope conveyor belt 9. Clamp the other end of the wire rope conveyor belt 9 and hoist it to the top of the elevator from the discharge port side. Finally, seal both ends of the belt with adhesive. The horizontal edge of the wire rope conveyor belt joint must be perpendicular to the center line of the conveyor belt, with a perpendicularity error not exceeding 0.2% of the belt width. The misalignment between the two ends of the wire rope conveyor belt 9 joint must be less than 2mm.

[0035] Drill connection holes of the same size at both ends of the traction cable tape, ensuring that the center line of the connection hole is perpendicular to the center line of the tape and that the distance between the two sides of the tape and the edge of the connector is equal. Then place the tape pad between the two tapes and the two tape clamps on the outside of the tapes. Insert the high-strength bolts, then adjust the connector to be perpendicular to the center line of the tape and that the distance between both ends and the edge of the tape is equal. Finally, tighten the bolts.

[0036] After bolting the connection points at both ends of the wire rope tape 9, leave 100mm of wire rope at the tape end joint and cut off the excess wire rope. Then, install wire rope clamps at 20mm intervals at the wire rope end and tighten them one by one. Finally, clean the wire rope end and wire rope clamps with acetone or rosin and then use the special matching glue to bond the joint.

[0037] 9. Hopper Installation When installing hopper 10, a rubber pad must be placed on the back of hopper 10. Hoppers 10 should be installed one by one in sequence, starting from the lower part of the inlet side, and the bolts of each hopper should be fully tightened. It is strictly forbidden to install hopper 10 on the outlet side to prevent the conveyor belt from becoming unbalanced due to gravity and causing it to rotate, which could lead to personal injury.

[0038] When the hopper 10 is installed, the wire rope belt 9 moves along with the hopper 10. The position of the wire rope belt 9 can be moved by manually turning the hydraulic coupling. It is strictly forbidden to use a speed reducer to drive the wire rope belt 9 to move during the installation of the hopper 10.

[0039] 10. Test drive 1. No-load test run After all components of the hoist are installed as required, a no-load test run must be conducted first. During the test run, start the hoist, open the inspection door, and carefully observe the operation of each part of the equipment. If any problems are found, adjust them promptly. The test run time must not be less than 2 hours. After the no-load test run is completed and the equipment is confirmed to be completely normal, a load test run can be conducted.

[0040] During the no-load test run of the hoist, pay attention to whether the traction components such as the wire rope belt 9 and the bucket 10, as well as the backstop mechanism, are operating normally. Check for any abnormal noises or leaks in the motor and reducer. Then, after the equipment has been running for 2 hours, check whether the temperature rise of each bearing exceeds 40℃. Finally, check whether all fasteners on the equipment are loose. After stopping the no-load test run, focus on checking whether the fastening bolts on the bucket 10, the wire rope belt 9, and the wire rope belt joint are tightened properly.

[0041] 2. Load test After the equipment passes the no-load test run and undergoes necessary adjustments, a load test run begins. During the test run, the elevator is started under the designed conveying capacity and the material to be conveyed. First, observe the operation of the transmission device, the load on the motor (whether it reaches full load or overload), the normal operation of the electrical control equipment, whether the noise from the reducer is excessive, the normal operation of the upper and lower sections, whether the wire rope belt slips on the drums, and whether the running speed meets the design requirements. Finally, observe whether the elevator reaches the designed conveying capacity under uniform feeding conditions, whether the unloading is normal, and whether there is obvious material backflow or blockage. When the elevator stops, observe whether there is obvious reverse flow. After confirming that there are no defects in the above load test run, the equipment can be handed over to production.

Claims

1. A method for installing a vertical bucket elevator in a closed factory building using a forward mounting method, characterized in that, Includes the following steps: Step 1, basic re-measurement; before equipment installation, mark the longitudinal and transverse center lines of the lower section of the hoist. Step 2, lower section installation; use a front winch to slide and transport the equipment to the lifting position, then use another winch to hoist the lower section above the equipment foundation via a high pulley block; adjust the relative position of the lower section and the foundation bolts, and slowly lower the lower section to accurately install it on the equipment foundation; Step 3, casing installation; Based on the number of casings required for each floor of the factory, use a winch to hoist them from the pre-drilled holes for equipment installation to the floor level of each floor, and install them in sequence; Step 4: Install the casing brackets; After the casing of each floor of the factory building is installed, install the fixing brackets on the casing of that floor and fix the fixing brackets on the nearest floor structure. Step 5, Upper Section Installation: Use a winch to hoist the upper section to the top of the casing via a high pulley system. Insert asbestos rope between the connecting flanges of the top casing to ensure sealing and the levelness of the flange surfaces. Adjust the relative position of the upper section and the flange surfaces on the casing, lower the upper section, and precisely install it on top of the casing. Step 6: Installation of the drive platform and metal mounting frame; The drive platform and metal mounting frame are constructed using surrounding factory buildings and structures, and the hoist is reinforced at the same time. Step 7, Installation of the transmission device; Use a winch and pulley block to hoist the transmission device to the drive platform and connect it to the head wheel axle of the upper section; Before connection, first confirm that the backstop direction of the backstop on the transmission device is opposite to the rotation direction of the transmission drum, and then use a dial indicator to align the output shaft of the transmission device with the head wheel axle. Step 8: Installation of the traction wire rope belt; Press the hopper bolts into the wire rope belt. According to the site and hoisting conditions, install the wire rope belt into the hoisting chamber. Raise the lower adjusting screw to the highest position. Clamp one end of the wire rope belt with the wire rope belt clamp. Hoist the wire rope belt head to the top of the hoisting machine from the middle of the machine casing on the feed port side using a hoisting rope. Clamp the other end of the wire rope belt with the wire rope belt clamp in the same way. Hoist the wire rope belt head to the top of the hoisting machine from the discharge port side. Finally, seal both ends of the belt with glue. Step 9, Hopper Installation; During installation, a rubber pad should be placed on the back of the hopper. The hoppers should be installed one by one in sequence, starting from the lower part of the feed inlet side, and the bolts of each hopper should be fully tightened. Step 10: Test drive.

2. The installation method of the vertical bucket elevator in a closed factory building according to claim 1, characterized in that: In step one, after the foundation re-measurement is completed, flat shims are placed at the anchor bolt holes using the grouting method. The elevation error of each group of shims is no more than 1mm, and the levelness error is no more than 0.1 / 1000.

3. The installation method of the vertical bucket elevator in a closed factory building according to claim 2, characterized in that: In step two, after the lower section is in place, its reference surface needs to be leveled. The allowable tolerance for the parallelism between the reference surface and the horizontal plane is 1 / 1000mm, and the adjusting shims must be close to the anchor bolts.

4. The installation method of a vertical bucket elevator in a closed factory building according to claim 1, 2 or 3, characterized in that: In step three, during the installation of the housing, asbestos rope is inserted between the connecting flanges of the middle housing to ensure sealing and the levelness of the flange surfaces; after the housing is assembled, the center lines of the housing in each channel are on the same vertical plane, and their straightness deviation shall not exceed 2 / 1000, and the cumulative deviation shall not exceed 8mm.

5. The installation method of the vertical bucket elevator in a closed factory building according to claim 4, characterized in that: In step four, a fixed support is installed on each floor of the factory building. The installation of the fixed support does not restrict the free expansion and contraction of the hoist in the vertical direction.

6. The installation method of a vertical bucket elevator in a closed factory building according to claim 1 or 5, characterized in that: In step five, after the upper section is installed, the center lines of the upper and lower drive shafts of the hoist are calibrated so that the two shafts are horizontal and in the same vertical plane. The allowable tolerance for the parallelism between the center line of the upper shaft and the horizontal plane is 0.3 / 1000mm, the error of the upper and lower shafts being in the same vertical plane is less than 4mm, and the error of the upper and lower roller end faces being in the same vertical plane is less than 5mm.

7. The installation method of a vertical bucket elevator in a closed factory building according to claim 6, characterized in that: In step seven, the transmission device is recalibrated before installation. During adjustment, a dial indicator and feeler gauge are used to align the motor, hydraulic coupling, and reducer. The radial and axial runout of the hydraulic coupling, motor output shaft, and reducer input shaft should be ≤0.3mm.

8. The installation method of a vertical bucket elevator in a closed factory building according to claim 1 or 7, characterized in that: In step eight, the horizontal edge of the wire rope belt joint must be perpendicular to the center line of the conveyor belt, and the perpendicularity error must not exceed 0.2% of the belt width. The misalignment at both ends of the wire rope belt joint must be less than 2mm.

9. The installation method of a vertical bucket elevator in a closed factory building according to claim 8, characterized in that: In step ten, after all components of the hoist are installed as required, a no-load test run is first conducted. During the test run, the hoist is started, and the inspection door is opened during the hoist test run. The operation of each part of the equipment is carefully observed, and the operation time is not less than 2 hours.

10. The installation method of a vertical bucket elevator in a closed factory building according to claim 9, characterized in that: In step ten, after the no-load test is completed and the equipment is confirmed to be completely normal, a load test is conducted. During the test, the elevator is started under the designed conveying capacity and the material to be conveyed. First, observe the operation of the transmission device, the load of the motor, whether it reaches full load or overload, whether the electrical control equipment is working normally, whether the noise of the reducer is excessive, whether the operation of the upper and lower sections is normal, whether the wire rope belt slips on the drum, and whether the running speed meets the design requirements. Finally, observe whether the elevator reaches the designed conveying capacity when the material is fed evenly, whether the unloading is normal, and whether there is obvious material return or accumulation. When the elevator stops running, is there obvious reverse running? After there are no defects in the above load test, it is handed over to production.

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