Modular construction method suitable for coil heat exchangers for boilers of various models

Abstract

The invention discloses a modular construction method suitable for coil heat exchangers for boilers of various models. The modular construction method comprises the following steps that a packaging frame of the coil heat exchanger is designed and manufactured, modular manufacturing of the coil heat exchanger is conducted, a combined hoisting tool is installed, and modular installation of the coil heat exchanger is conducted. The modular construction method is suitable for integral manufacturing, transportation and turnover hoisting of coil heat exchangers for boilers of various models, effectively solves the problem that a large coil heat exchanger is inconvenient to turn over and hoist, assemble a suspender at high altitude, weld a header at high altitude and test pressure, optimizes the construction process, saves the cost, and effectively improves the construction safety.

Description

[Technical field]

[0001] The invention relates to the manufacturing and installation technology of waste heat boilers such as thermal power and garbage incineration, and in particular to a modular construction method for coil heat exchangers suitable for various types of boilers. [Background technology]

[0002] In the horizontal section of waste heat boilers in large power plants and waste incineration plants, there are a large number of coil heat exchangers, such as Figure 1 As shown, the existing coil heat exchanger consists of an upper suspension beam 1', an elastic hanger 2', two headers 3' and a lower coil heat exchanger 4' (tube bundle), the header 3' on one side is provided with an inlet 30', and the header 3' on the other side is provided with an outlet 31'; each coil heat exchanger has about 20 elastic hangers 2', and has about 60 small-diameter pressure pipe welding joints with the header 3', and each elastic hanger 2' is provided with a basket bolt 20'.

[0003] In the traditional construction process, the lower coil heat exchanger 4' (tube bundle) is first manufactured and hoisted into the boiler, and then the suspension beam 1' and the elastic hanger 2' are bolted and assembled, and the lower coil heat exchanger 4' and the header 3' are welded and assembled. There are many problems with this process: (1) The coil heat exchanger is built horizontally and installed vertically, and needs to be turned over before installation. In the traditional construction method, the lower coil heat exchanger lacks a fulcrum, which makes it difficult to fix the lock. In addition, since the coil heat exchanger is composed of small-diameter steel pipes, it is very easy to cause pipeline damage; (2) The lower coil heat exchanger is hoisted first, and the elastic hanger and the welding header are assembled at high altitude. The construction is difficult, requires large-scale hoisting resources, and is costly; (3) After the lower coil heat exchanger 4' and the header 3' are welded at high altitude, a water pressure test is required.

[0004] The traditional construction method of coil heat exchanger requires high-altitude assembly of hangers, welding of headers and water pressure testing of coil heat exchangers, which results in great construction difficulty and high cost. There is an urgent need to improve the existing construction process. [Summary of the invention]

[0005] In view of the problem that the existing coil heat exchangers require high-altitude assembly of hangers, welding of headers and water pressure tests, which cause great construction difficulty and high costs, the present invention provides a modular construction method suitable for coil heat exchangers for various models of boilers. By making combined tooling, the welding quality and production efficiency are improved, the cost is effectively saved, thereby improving the lifting efficiency and achieving the purpose of reducing costs and increasing efficiency.

[0006] The technical solution adopted by the present invention to solve its technical problem is:

[0007] A modular construction method for coil heat exchangers for boilers of various models, the modular construction method comprising the following steps:

[0008] Step S1, designing and manufacturing a packaging frame for the coil heat exchanger, wherein the packaging frame is suitable for manufacturing, transporting and hoisting various types of heat exchangers and can be recycled;

[0009] Step S2, modular production of the coil heat exchanger, the coil heat exchanger is directly produced in the tire frame produced in step S1;

[0010] Step S3, installing the combined hoisting tool, installing the combined hoisting tool on the upper part of the coil heat exchanger, after which the modular production of the coil heat exchanger is completed, and the same combined hoisting tool can be used for hoisting coil heat exchangers of different models;

[0011] The combined lifting tool comprises an upper lifting lug, a lifting frame, a lower lifting lug, a connecting plate and a combined self-locking latch assembly, wherein the upper lifting lug, the lifting frame and the lower lifting lug are fixed by welding, and the lower lifting lug is distributed according to the layout characteristics of the upper suspension beam of the coil heat exchanger;

[0012] The connecting plate is detachably connected to the lower lifting ear through a combined self-locking latch assembly, and different numbers of connecting plates are connected according to the layout quantity and spacing characteristics of the upper suspension beams of the coil heat exchanger to achieve the connection between the overall lifting device and coil heat exchangers of different models, thereby turning over and lifting the coil heat exchanger;

[0013] Step S4, modular installation of the coil heat exchanger, during which the coil heat exchanger hoisting stress points are all on the temporary packaging frame.

[0014] Furthermore, the step S1 also includes:

[0015] Step S1.1, during the design, the maximum load-bearing weight and the maximum dimensions of the packaging frame should be determined after comprehensive consideration based on all types of coil heat exchangers;

[0016] Step S1.2, according to the composition of the coil heat exchanger, determine the number and spacing of the suspension support beams, as well as the spacing of the tube bundles, and determine the length of the support beams and the bolt hole spacing of the heat exchanger packaging frame;

[0017] Step S1.3, and determining the position of the lifting lugs in the heat exchanger packaging frame according to the weight and center of gravity of the packaging frame.

[0018] Furthermore, the step S2 also includes welding the elastic suspension rods and the headers, leaving only one pipeline inlet and outlet, and completing the hydraulic pressure test as a whole before leaving the factory; specifically, the following steps are included:

[0019] Step S2.1, in the packaging frame, horizontally weld and integrate the pipes and header parts of the coil heat exchanger, wherein sleepers are required to be fixed between the coils to ensure the spacing between the upper and lower pipes. After the coil heat exchanger is erected, the sleepers need to be taken out;

[0020] Step S2.2, installation of the suspension beam, fixing the suspension beam corresponding to the tube bundle to the supporting beam of the packaging frame corresponding to the coil heat exchanger with bolts;

[0021] Step S2.3, installation of elastic suspension rods, connecting all single-row suspension rods to the header and the suspension beam from bottom to top, and tightening the elastic suspension rods with basket bolts;

[0022] Step S2.4, water pressure test. The coil heat exchanger after overall assembly has only one outlet and one inlet, and the water pressure test is started.

[0023] Furthermore, the step S3 also includes:

[0024] The combined self-locking bolt assembly comprises a connecting bolt, a retaining ring, a limiting bolt and a self-locking ring. The retaining ring is welded at one end of the connecting bolt to form a limiting structure. The other end of the connecting bolt has a hole and is used to connect the limiting bolt and the retaining ring to form a detachable self-locking structure.

[0025] The self-locking ring is inserted into the upper part of the fiber pin and can be flipped. When installing the self-locking ring, the self-locking ring needs to be flipped downward to pass through the connecting pin to achieve the self-locking function. When removing the structure corresponding to the self-locking ring, the self-locking ring needs to be flipped upward to release the self-locking relationship with the connecting pin, so that the combined self-locking pin assembly can be gradually removed as a whole.

[0026] Furthermore, in step S4, the entire coil heat exchanger is hoisted into the boiler using a primary crane and hung on the upper part of the boiler steel structure; during installation, two cranes are used to turn over the horizontal coil heat exchanger and erect it; specifically, the following steps are included:

[0027] Step S4.1, two cranes simultaneously lift the coil heat exchanger about 800 mm off the ground;

[0028] Step S4.2: The tail crane does not move, the main crane slowly rises and approaches the tail crane, and the equipment starts to reverse until the heat exchanger module stands upright and is placed on the ground;

[0029] Step S4.3, the tail crane is unhooked and the lock of the tail crane is removed;

[0030] Step S4.4, using a guy rope to fix the packaging frame to the ground to prevent the coil heat exchanger from being affected by wind and tilting;

[0031] Step S4.5, after removing the detachable part on the upper part of the packaging frame, the main crane lifts the coil heat exchanger out of the packaging frame;

[0032] Step S4.6, lift the coil heat exchanger to the module height and place it inside the module boiler, and place the suspension beam on the upper part of the coil heat exchanger above the steel structure.

[0033] Furthermore, the step S4 also includes: during installation, using a wheel-changing group to increase the stress points of the hoisting, reducing the deformation of the coil heat exchanger during the hoisting process, thereby reducing the strength requirements for the packaging frame and reducing the amount of material used.

[0034] The beneficial effects of the present invention are:

[0035] The modular construction method provided by the present invention, firstly, reduces the assembly work on the construction site, makes the production of the coil heat exchanger more flexible, and can be produced simultaneously at different locations, thereby speeding up the construction progress through modular installation; secondly, it reduces a large number of high-altitude operations, such as the assembly of elastic hangers, the welding of tube bundles and headers, and high-altitude water pressure tests; and the combined boiler coil heat exchanger lifting tooling is reusable. Under normal circumstances, a boiler has 10 to 30 heat exchangers. By designing universal tooling, the tooling utilization rate is improved, and the labor input is reduced, a large amount of material costs can be saved, the lifting efficiency is improved, and the lifting safety is improved.

Brief Description of the Drawings

[0036] Figure 1 It is a three-dimensional structural schematic diagram of a coil heat exchanger in the prior art;

[0037] Figure 2 is a schematic diagram of the three-dimensional structure of the packaging frame in step S1 of the present invention;

[0038] Figure 3 is a schematic diagram of the main structure of the packaging frame in step S1 of the present invention;

[0039] Figure 4 It is a schematic diagram of the three-dimensional structure in which the elastic suspension rod is omitted after the coil heat exchanger and the packaging frame are assembled in step S2 of the present invention;

[0040] Figure 5 is a schematic diagram of the main structure after the coil heat exchanger and the packaging frame are assembled in step S2 of the present invention;

[0041] Figure 6 It is a schematic diagram of the three-dimensional structure of the lifting tool in step S3 of the present invention;

[0042] Figure 7 is an enlarged schematic diagram of the three-dimensional structure of the lower lifting ear in step S3 of the present invention;

[0043] Figure 8is an enlarged schematic diagram of the main structure of the connecting pin in step S3 of the present invention;

[0044] Fig. 9 It is an enlarged schematic diagram of the main structure of the retaining ring in step S3 of the present invention;

[0045] Fig.10 yes Fig. 9 A schematic diagram of the side view structure of the retaining ring;

[0046] Fig.11 is an enlarged schematic diagram of the side view structure of the limit latch in step S3 of the present invention;

[0047] Fig.12 is an enlarged schematic diagram of the assembly of the combined self-locking latch assembly in step S3 of the present invention;

[0048] Fig.13 It is a front view schematic diagram of the horizontal placement of the modularized production and installation tooling in step S3 of the present invention;

[0049] Fig.14 is a schematic diagram of modular hoisting in step S4 of the present invention;

[0050] Figure 1 5 is a schematic diagram of the hoisting process in step S4 of the present invention;

[0051] Figure 1 6 is a schematic diagram of the hoisting and placing into the boiler for fixing in step S4 of the present invention. [Specific implementation method]

[0052] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0053] A modular construction method for coil heat exchangers for boilers of various models, the modular construction method comprising the following steps:

[0054] Step S1, such as Figure 2 and Figure 3 As shown in the figure, a packaging frame a of a coil heat exchanger is designed and manufactured. The packaging frame is suitable for manufacturing, transporting and hoisting various types of heat exchangers and can be recycled. Figure 2 and Figure 3 In the figure, it is the packaging frame corresponding to one type of coil heat exchanger. Different types of coil heat exchangers have different numbers of coil heat exchangers (tube bundles) and different hanging beams. Figure 3In the figure, the virtual frame part on the upper part of the packaging frame a is a detachable part.

[0055] Step S1.1, when designing, the maximum load-bearing weight and maximum dimensions of the packaging frame should be determined after comprehensive consideration of all types of coil heat exchangers;

[0056] Step S1.2, according to the composition of the coil heat exchanger, determine the number and spacing of the suspension support beams, as well as the spacing of the coil heat exchangers (tube bundle tubes), and at the same time determine the length and bolt hole spacing of the support beams a1 and a2 of the heat exchanger packaging frame a;

[0057] Step S1.3, and determining the positions of the main lifting lug a3 and the spare lifting lug a4 in the packaging frame of the heat exchanger according to the weight and the center of gravity of the packaging frame.

[0058] Step S2, such as Figures 2 to 5 As shown, the coil heat exchanger is manufactured in a modular manner. The coil heat exchanger is directly manufactured in the tire frame manufactured in step S1; the elastic suspension rods and headers are all welded, leaving only one pipeline inlet and outlet, and the whole is subjected to a water pressure test before leaving the factory. Compared with the existing technology, the manufacturing integrity is high, which is conducive to improving the quality of the heat exchanger leaving the factory and reducing the work of assembling the elastic suspension rods, welding, and testing at high altitude on the construction site; the specific steps include:

[0059] Step S2.1, such as Figure 5 As shown, in the packaging frame a, the pipes and the header b1 of the coil heat exchanger are horizontally welded and integrated, wherein the coils need to be fixed with sleepers b2 to ensure the spacing between the upper and lower pipes. After the coil heat exchanger is erected, the sleepers need to be taken out;

[0060] Step S2.2, installation of the suspension beam, fixing the suspension beam b4 corresponding to the tube bundle b3 (coil heat exchanger) to the support beam a1 and support beam a2 of the packaging frame a corresponding to the coil heat exchanger using bolts;

[0061] Step S2.3, installation of elastic suspension rods b5, connecting all single-row suspension rods from bottom to top to header b1 and suspension beam b4, and tightening elastic suspension rods b5 using turnbuckle bolts b6;

[0062] Step S2.4, water pressure test. The overall assembled coil heat exchanger has only one outlet and one inlet. Compared with the traditional construction process, the water pressure test can be started.

[0063] Step S3, such as Figure 6 to Figure 1 As shown in Figure 3, the combined lifting tool is installed on the upper part of the coil heat exchanger. After installation, the modular production of the coil heat exchanger is completed, and the same combined lifting tool can be used for the lifting of coil heat exchangers of different models;

[0064] In this embodiment, if Figure 6 to Figure 1 As shown in FIG. 3 , the combined lifting tool comprises an upper lifting ear 1, a lifting frame 2, a lower lifting ear 3, a connecting plate 4 and a combined self-locking pin assembly 5. The upper lifting ear 1, the lifting frame 2 and the lower lifting ear 3 are fixed by welding, and the lower lifting ear 3 is distributed according to the layout characteristics of the upper suspension beam of the coil heat exchanger; the connecting plate 4 is detachably connected to the lower lifting ear 3 through the combined self-locking pin assembly 5, and different numbers of connecting plates 4 are connected according to the layout quantity and spacing characteristics of the upper suspension beam of the coil heat exchanger, so as to realize the connection between the overall lifting device and different types of coil heat exchangers, thereby turning over and lifting the coil heat exchanger.

[0065] The combined self-locking bolt assembly 5 comprises a connecting bolt 5.1, a retaining ring 5.2, a limiting bolt 5.3 and a self-locking ring 5.4. The retaining ring 5.2 is welded to one end of the connecting bolt 5.1 to form a limiting structure. The other end of the connecting bolt 5.1 has a hole and is used to connect the limiting bolt 5.3 and the retaining ring 5.2 to form a detachable self-locking structure. The self-locking ring 5.4 penetrates the upper part of the fiber bolt 5.3 and can be flexibly flipped. When installing the self-locking ring 5.4, the self-locking ring 5.4 needs to be flipped downward to pass through the connecting bolt 5.1, so as to realize the self-locking function. When removing the structure corresponding to the self-locking ring 5.4, the self-locking ring 5.4 needs to be flipped upward to release the self-locking relationship with the connecting bolt 5.1, so that the combined self-locking bolt assembly 5 can be gradually dismantled as a whole.

[0066] Step S4, such as Figures 14 to 16 As shown, the coil heat exchanger is installed in a modular manner. The entire coil heat exchanger is hoisted into the boiler using a single crane and hung on the upper part of the boiler steel structure. During installation, the horizontal coil heat exchanger is turned over and erected using two cranes with locks, hanging beams and pulleys. The specific steps include:

[0067] Step S4.1, such as Fig.14 and Figure 1 As shown in 5, two cranes simultaneously lift the hooks and lift the coil heat exchanger about 800mm off the ground;

[0068] Step S4.2, such as Figure 1 As shown in FIG. 5 , the tail crane 6 does not move, the main crane 7 slowly rises and approaches the tail crane, and the equipment starts to reverse until the heat exchanger module is erected and placed on the ground;

[0069] Step S4.3, the tail crane is unhooked and the lock of the tail crane is removed;

[0070] Step S4.4, using a guy rope to fix the packaging frame to the ground to prevent the coil heat exchanger from being affected by wind and tilting;

[0071] Step S4.5, after removing the detachable part on the upper part of the packaging frame, the main crane lifts the coil heat exchanger out of the packaging frame;

[0072] Step S4.6, lift the coil heat exchanger to the module height and place it inside the module boiler, and place the suspension beam on the upper part of the coil heat exchanger above the steel structure.

[0073] During installation, the coil heat exchanger's lifting stress points are all on the temporary packaging frame, which causes less damage to the coil heat exchanger. During installation, the wheel changer is used to increase the lifting stress points, reduce the deformation of the coil heat exchanger during the lifting process, thereby reducing the strength requirements for the packaging frame and reducing the amount of materials used.

[0074] In this embodiment, the construction method can effectively reduce the assembly work on the construction site, make the production of the coil heat exchanger more flexible, and can be produced simultaneously at different locations, speeding up the construction progress through modular installation; it can also reduce a large amount of high-altitude operations, such as the assembly of elastic hangers, welding of tube bundles and headers, high-altitude water pressure testing, etc.; moreover, the corresponding coil heat exchanger lifting tooling can be reused. Under normal circumstances, a boiler has 10 to 30 heat exchangers. By designing universal tooling, a large amount of material costs can be saved and the safety of lifting can be effectively improved.

[0075] The above-described embodiments are only preferred embodiments of the present invention and are not intended to limit the scope of implementation of the present invention. All equivalent changes made based on the shape, structure and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A modular construction method for coil heat exchangers for various types of boilers, characterized in that: The modular construction method comprises the following steps: Step S1, designing and manufacturing a packaging frame for the coil heat exchanger, wherein the packaging frame is suitable for manufacturing, transporting and hoisting various types of heat exchangers and can be recycled; Step S2, modular production of the coil heat exchanger, the coil heat exchanger is directly produced in the tire frame produced in step S1; Step S3, installing the combined hoisting tool, installing the combined hoisting tool on the upper part of the coil heat exchanger, after which the modular production of the coil heat exchanger is completed, and the same combined hoisting tool can be used for hoisting coil heat exchangers of different models; The combined lifting tool comprises an upper lifting lug (1), a lifting frame (2), a lower lifting lug (3), a connecting plate (4) and a combined self-locking latch assembly (5); the upper lifting lug (1), the lifting frame (2) and the lower lifting lug (3) are connected and fixed by welding, and the lower lifting lug (3) is distributed according to the layout characteristics of the upper suspension beam of the coil heat exchanger; The connecting plate (4) is detachably connected to the lower lifting ear (3) via a combined self-locking latch assembly (5), and different numbers of connecting plates (4) are connected according to the layout number and spacing characteristics of the upper suspension beams of the coil heat exchanger to achieve connection between the overall lifting device and coil heat exchangers of different models, thereby performing the overturning lifting of the coil heat exchanger; Step S4, modular installation of the coil heat exchanger, during which the coil heat exchanger hoisting stress points are all on the temporary packaging frame.

2. A modular construction method for coil heat exchangers for boilers of various models according to claim 1, characterized in that: The step S1 also includes: Step S1.1, during the design, the maximum load-bearing weight and the maximum dimensions of the packaging frame should be determined after comprehensive consideration based on all types of coil heat exchangers; Step S1.2, according to the composition of the coil heat exchanger, determine the number and spacing of the suspension support beams, as well as the spacing of the tube bundles, and determine the length of the support beams and the bolt hole spacing of the heat exchanger packaging frame; Step S1.3, and determining the position of the lifting lugs in the heat exchanger packaging frame according to the weight and center of gravity of the packaging frame.

3. The modular construction method for coil heat exchangers for boilers of various models according to claim 1, characterized in that: The step S2 also includes welding the elastic suspension rod and the header, leaving only one pipeline inlet and outlet, and completing the water pressure test as a whole before leaving the factory; specifically, the following steps are included: Step S2.1, in the packaging frame, horizontally weld and integrate the pipes and header parts of the coil heat exchanger, wherein sleepers are required to be fixed between the coils to ensure the spacing between the upper and lower pipes. After the coil heat exchanger is erected, the sleepers need to be taken out; Step S2.2, installation of the suspension beam, fixing the suspension beam corresponding to the tube bundle to the supporting beam of the packaging frame corresponding to the coil heat exchanger with bolts; Step S2.3, installation of elastic suspension rods, connecting all single-row suspension rods to the header and the suspension beam from bottom to top, and tightening the elastic suspension rods with basket bolts; Step S2.4, water pressure test. The coil heat exchanger after overall assembly has only one outlet and one inlet, and the water pressure test is started.

4. The modular construction method for coil heat exchangers for boilers of various models according to claim 1, characterized in that: The step S3 also includes: The combined self-locking bolt assembly (5) comprises a connecting bolt (5.1), a retaining ring (5.2), a limiting bolt (5.3) and a self-locking ring (5.4); a retaining ring (5.2) is welded to one end of the connecting bolt (5.1) to form a limiting structure; and a hole is opened at the other end of the connecting bolt (5.1) and is used to connect the limiting bolt (5.3) and the retaining ring (5.2) to form a detachable self-locking structure. The self-locking ring (5.4) penetrates into the upper part of the fiber plug (5.3) and can flexible When installing the self-locking ring (5.4), the self-locking ring (5.4) needs to be turned downward to pass through the connecting pin (5.1), thereby realizing the self-locking function. When removing the structure corresponding to the self-locking ring (5.4), the self-locking ring (5.4) needs to be turned upward to release the self-locking relationship with the connecting pin (5.1), thereby gradually removing the combined self-locking pin assembly (5) as a whole.

5. The modular construction method for coil heat exchangers for boilers of various models according to claim 1, characterized in that: In step S4, the entire coil heat exchanger is hoisted into the boiler using a primary crane and hung on the upper part of the boiler steel structure; during installation, two cranes are used to turn over the horizontal coil heat exchanger and erect it; the specific steps include: Step S4.1, two cranes simultaneously lift the coil heat exchanger 800 mm off the ground; Step S4.2: The tail crane does not move, the main crane slowly rises and approaches the tail crane, and the equipment starts to reverse until the heat exchanger module stands upright and is placed on the ground; Step S4.3, the tail crane is unhooked and the lock of the tail crane is removed; Step S4.4, using a guy rope to fix the packaging frame to the ground to prevent the coil heat exchanger from being affected by wind and tilting; Step S4.5, after removing the detachable part on the upper part of the packaging frame, the main crane lifts the coil heat exchanger out of the packaging frame; Step S4.6, lift the coil heat exchanger to the module height and place it inside the module boiler, and place the suspension beam on the upper part of the coil heat exchanger above the steel structure.

6. A modular construction method for coil heat exchangers for boilers of various models according to claim 5, characterized in that: The step S4 also includes: during installation, using a wheel-changing assembly to increase the stress points of the hoisting, reducing the deformation of the coil heat exchanger during the hoisting process, thereby reducing the strength requirements for the packaging frame and reducing the amount of material used.

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