Overall lifting construction method for process pipeline of outer pipe gallery

Abstract

The invention discloses an overall lifting construction method for an outer pipe gallery process pipeline. Firstly, pipe gallery steel structure stand columns and beams of a top layer structure are installed; the secondary layer structure of the pipe gallery is integrally spliced and welded at the corresponding position of the ground; after the secondary layer structure is welded, arranging the process pipelines of the layer on the completed secondary layer structure according to the process installation drawing, and assembling and welding the process pipelines on the secondary layer structure; a beam of the top layer structure is used as a lifting point, an electric chain block is used as a lifting device to lift the secondary layer structure together with the process pipeline to a mounting position, and then the beam of the secondary layer structure is welded to the stand columns; and repeating the step 2 to the step 4, and completing simultaneous lifting and mounting of other sub-layer structures and process pipelines from top to bottom. The structure and the process pipeline can be prefabricated on the ground, the steel structure and the process pipeline are lifted to the installation position through the electric chain block lifting device at the same time, the hoisting machinery cost is reduced, the construction operation efficiency is improved, and safety risk factors are advantageously avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of pipe gallery process pipeline construction, and in particular to a method for integrally lifting and constructing process pipelines in an outer pipe gallery. Background Art

[0002] The installation project of process pipelines in the external pipeline corridors of petrochemical and coal chemical industries is highly comprehensive, complex, and technical, and is greatly affected by environmental factors. It is an installation project that consumes a large amount of manpower, machinery, and safety technical measures.

[0003] The traditional construction process is to spread out the work teams along the line or concentrate their efforts locally after the outer pipe gallery structure is fully or partially connected. In terms of pipe threading, after the process pipeline materials enter the construction site, one or more lifting work teams are divided into areas according to the length of the line to carry out pipe threading operations. The height of each floor of the outer pipe gallery structure is generally not high, and the structural span generally does not exceed 12m except for the crossing truss. The length of each carbon steel and alloy steel pipe is about 12m. Whether it is threading from the top floor or from the side of the structure, it is necessary to reverse the rope several times before it can be hoisted into place. During the rope hoisting operation, there will be personnel on the structural operation layer to cooperate with the mechanical operation, which is prone to safety hazards of bumping. In terms of assembly and welding, after the lifting operation team uses the lifting machinery to lift the raw materials of the pipeline to the structural position, the pipeline group also needs to use the manual hoist with the sliding group to place the raw materials of the pipeline to the precise installation position, and then weld them according to the characteristics of the pipeline parent material using the corresponding welding process. The expansion bend can be centrally prefabricated in the ground prefabrication yard and then centrally hoisted using lifting machinery.

[0004] The traditional external pipe gallery pipeline installation process has problems such as long construction period, frequent high-altitude operations and frequent use of lifting machinery. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a method for overall lifting construction of the process pipelines in an external pipe gallery, so as to at least achieve the purpose of shortening the construction period of the process pipeline installation project in the external pipe gallery and reducing the amount of high-altitude operations.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is: A method for integrally lifting process pipelines in an outer pipe gallery comprises the following steps: Step 1: Install the steel structure columns and top structure beams of the corridor first; Step 2: The secondary structure of the pipe gallery is assembled and welded as a whole at the corresponding position on the ground; Step 3: After the sub-layer structure is welded, the process pipelines of this layer are arranged on the completed sub-layer structure according to the process installation drawing, and the process pipelines on the sub-layer structure are assembled and welded; Step 4: Use the beams of the top structure as lifting points and the electric fall chain as a lifting device to lift the sub-structure together with the process pipeline to the installation position, and then weld the beams and columns of the sub-structure; Step 5: Repeat steps 2 to 4 to complete the simultaneous lifting and installation of the remaining sub-layer structures and process pipelines from top to bottom.

[0007] Furthermore, in step three, a pipeline prefabrication platform is set on the ground at the turning point or bend of the outer pipeline corridor, a winch is set at the other end of the pipeline corridor, a pulley block is set on the assembled sub-layer structure, and the straight sections of the process pipelines are centrally prefabricated at the pipeline prefabrication platform. The prefabricated pipelines are pulled toward the winch by the winch, and the pulling is stopped when the other end of the pipeline reaches the edge of the prefabrication platform, and then prefabrication welding is continued, and this sequence is repeated.

[0008] Furthermore, a plurality of pulley blocks are arranged on each beam of the assembled secondary structure.

[0009] Furthermore, the pipeline prefabrication platform is arranged between the columns, and the width of the pipeline prefabrication platform is the same as the width between the two columns.

[0010] Furthermore, in step 4, the center of the crossbeam of the top structure is used as the lifting point of the electric fall chain suspension, and the two sides of the crossbeam of the sub-structure are used as the force points for lifting the sub-structure and the process pipeline.

[0011] Furthermore, in step 4, the center of the longitudinal beam of the top structure is used as the lifting point of the electric fall chain suspension, and the two sides of the longitudinal beam of the sub-structure are used as the force points for lifting the sub-structure and the process pipeline.

[0012] Furthermore, the stress point is 500 mm away from the column.

[0013] Furthermore, in step 4, 5-7 sub-layer structures are lifted at a time.

[0014] By adopting the overall lifting construction method of the process pipeline of the outer pipe gallery provided by the present invention, the steel structure and the process pipeline are simultaneously lifted to the installation position by the electric chain hoisting device, and the cost of lifting machinery is reduced; the structure and the process pipeline can be prefabricated on the ground, and the construction efficiency is improved. Most of the construction work of this construction process is completed on the ground, and the safety risk factors are advantageously avoided, so that the cost investment of safety technical measures is reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the pulling of prefabricated pipelines; Figure 2 It is the plane of the upper EL894.100 component; Figure 3 It is the plane of the middle-level EL891.600 component; Figure 4 It is the plane of the lower EL889.600 component; Figure 5 and Figure 6 All are component facades; Figure 7 This is the EL894.100 electric chain-fall arrangement diagram; Figure 8 It is the stress point of EL891.600 wire rope; Fig. 9 It is a schematic elevation diagram of the force point.

[0016] In the figure, 1-pipe prefabrication platform, 2-pulley block, 3-winch, 4-process pipeline, 5-hanging point, 6-stress point. DETAILED DESCRIPTION

[0017] A typical embodiment of the present invention provides an overall lifting construction method for process pipelines in an outer pipe gallery, which mainly includes the following steps: Step 1: Install the steel structure columns of the pipe gallery and the main beams, secondary beams and other auxiliary components of the top structure; Step 2: The secondary structure of the pipe gallery is assembled and welded as a whole at the corresponding position of each span on the ground; Step 3: After the sub-layer structure is welded, the process pipeline 4 of this layer is arranged on the completed sub-layer structure according to the process installation drawing, and the process pipeline 4 on the sub-layer structure is assembled and welded; Step 4: Use the beams of the top structure of the steel structure as the lifting points 5, and use the electric fall chain as the lifting device to lift the sub-structure together with the process pipeline 4 to the installation position, and then weld the beams and columns of the sub-structure according to the steel structure installation and welding requirements; Step 5, repeat steps 2 to 4 to complete the simultaneous lifting and installation of the remaining sub-layer structures and the process pipeline 4 from top to bottom, thereby completing the goal of simultaneous installation of the steel structure and the process pipeline 4.

[0018] The overall lifting construction method for the process pipelines of the outer pipe gallery provided by the above implementation mode can realize a one-time overall lifting after multiple spans are installed simultaneously.

[0019] In the above implementation manner, the electric fall chain lifting device realizes synchronous lifting by linking multiple electric fall chains. This construction technology can realize the prefabrication and pipe threading of pipeline materials in one place when installing the process pipeline 4.

[0020] The outer pipe gallery is usually long along the whole field, with 90° or other angle bends at intervals. Based on this, a simple pipe prefabrication platform 1 (such as Figure 1As shown in the figure, the width of the pipeline prefabricated platform 1 is the same as the width between the steel structure columns. A winch 3 is set at the other end of the corridor, and a pulley block 2 is set on the assembled secondary structure.

[0021] Exemplarily, a plurality of pulley blocks 2 are arranged at intervals of about 6 m along the assembled secondary structure at the beam position.

[0022] All straight sections of the process pipeline 4 can be prefabricated at the pipeline prefabrication platform 1. The prefabricated pipeline is pulled toward the winch 3 by the winch 3. When the other end of the pipeline reaches the edge of the pipeline prefabrication platform 1, the pulling is stopped, and the prefabrication welding is continued. This sequence is repeated. After the installation of the process pipeline 4 and the bracket of the secondary structure is completed, the electric chain hoisting device is used to lift it as a whole to the installation position.

[0023] The technical solution claimed for protection of the present invention is further clearly and completely described below in conjunction with a relatively specific embodiment.

[0024] This embodiment takes the single span 109-110 axis of the external pipe process pipeline installation project of the Yanchang Oilfield Associated Gas Resource Recycling Project as an example, and the other ones that need to be lifted simultaneously are the same as the single span steps.

[0025] The steel structure between axis 109 and axis 110 includes upper EL894.100 components, middle EL891.600 components and lower EL889.600 components. The upper EL894.100 components are the top structure described in the present invention, and the middle EL891.600 components and lower EL889.600 components are the substructure described in the present invention. The plan and elevation drawings of the above components are shown in Figure 1. Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 shown.

[0026] Assemble and weld all the component columns and beams above the EL894.100 elevation. Assemble and weld all the beams of EL891.600 on the ground directly below the 109-110 axis. After the welding of the beams of this span is completed, start the prefabrication and installation of the pipes of this span. Figure 7 , Figure 8 , Fig. 9 As shown, the center of the beam with component number GL4-5 (HM390×300×16×16) at the elevation EL894.100 serves as the lifting point 5 of the electric fall chain suspension, and the two sides of the component number GL4-5 at the elevation EL891.600, 500mm away from the center of the column, serve as the force points 6 for lifting the structure and pipeline of this layer.

[0027] The calculation of the self-weight of the steel structure at the EL891.600 elevation is detailed in Table 1 below, and the comparison of the steel beams and supporting components is detailed in Table 2. The calculation of the self-weight of the pipelines and supports at the EL891.600 elevation is detailed in Table 3 below.

[0028] Table 1 Steel structure calculation table

[0029] Table 2 Comparison of steel beams and supporting components

[0030] Table 3 Process pipeline calculation table

[0031] Calculation of wire rope weight: The steel wire rope is made of two strands with one bend and the angle between it and the horizontal plane is γ.

[0032] According to 2Psinγ=Q, 2T =P, we can get T=Q / (4sinγ), Calculate ∠γ=arctan[(H1-H2) / (L / 2-L1)]=arctan[(891.6-883.1) / (7500 / 2-300)×1000]= 67.91 0 ; T=Q / 2(4sinγ)=(3720.35+6173.6) / 2(4×sin67.91)=1334.7kg; Because the allowable tension of the wire rope [Fg] = αFg / K, the total breaking tension Fg of the selected wire rope should be ≥ K[Fg] / α ≥ KT / α = 6×1334.7×9.8 / 0.85 = 92.33KN.

[0033] Where: K——safety factor, take K=6; α——conversion factor, α=0.85 for 6×19+1 wire rope; T——Force per strand of wire rope, kg; P——the sum of the forces on each two-strand wire rope, kg; Q——the sum of the weight of the steel structure and pipelines at the elevation of EL891.600, kg; γ——the angle between each wire rope and the horizontal plane; L——the length of component GL4-5 at elevation EL891.600, mm; L1——the distance between the center of the column and the force point of the component GL4-5 at the elevation of EL891.600, mm; H1——the distance between the elevation EL894.100 and the ground EL883.100, m; H2——The height from the center of the electric fall chain hook to the hook hanging wire rope (the hook length is 300mm), mm; According to the above calculation, the nominal tensile strength of the hoisting wire rope is 1850MPa, and the diameter of the wire rope is 14mm, which can meet the hoisting requirements. The length is 4m. Check the heavy equipment hoisting manual and according to the technical parameters of the 6×19+1 wire rope, the weight of the wire rope is 4×68.5 / 100=2.74kg.

[0034] Force calculation of hanging point 5: (1) Load calculation at hanging point 5 The deadweight of the electric fall chain is considered to be 60kg. The constant load at the EL891.600 elevation is the sum of the deadweight of the structure, the deadweight of the pipeline and the bracket, the deadweight of the electric fall chain, and the deadweight of the wire rope. The constant load of hanging point 5 is 3720.35+6173.7+2.74+60=9956.79kg.

[0035] (2) Load calculation at hanging point 5 The load partial factor for permanent combinations shall comply with the following provisions: (1) When the permanent load effect is unfavorable to the structure, the partial factor should be 1.2 for the combination to be controlled by the variable load effect, and 1.35 for the combination to be controlled by the permanent load effect; (2) When the variable load effect is favorable to the structure, the partial factor should not be greater than 1.0.

[0036] The partial factors of variable loads shall comply with the following provisions: (1) For standard values ​​greater than 4KN / m 2 The live load on the floor structure of an industrial building should be taken as 1.3; in other cases, it should be taken as 1.4.

[0037] For the verification of overturning, sliding or floating of the structure, the partial coefficient of the load shall comply with the requirements of the relevant building structure design specifications.

[0038] The load on the hanging point 5 is divided into a constant load and a live load. The constant load is a permanent load that cannot be changed on the load-bearing component, and the live load is also called a variable load. According to the live load of the industrial building, the live load is taken as the most unfavorable 9KN / m 2 .

[0039] The load calculation formula for hanging point 5 is: P=1.2P 恒 +1.4P 活 =1.2×9956.79×9.8+1.4×9=117104.45KN The optional electric fall chain has a length of 6m and a lifting capacity of 8T. The single load that can be carried is 8×1000×9.8=78400KN. The load of the EL891.600 elevation is shared by the two beams on the EL894.100. The load borne by the electric fall chain on each beam is 117104.45÷2=58552.23KN. Therefore, the 8T electric fall chain can meet the lifting capacity requirements.

[0040] Bending moment of bending member: (1) Maximum inherent bending moment of H-beam EL894.100 member number GL4-5 is a bending member, which is subjected to concentrated load. Its maximum bending moment calculation is f≥Mmax / (γ×W), Mmax≤f×γ×W; Where: f——Component strength, GL4-5 is made of Q235 material, so the value is 215N / mm 2 ; W——H-section modulus of steel; γ——section plastic development coefficient, I-section, value is 1.2; Mmax——bending moment, KN×m.

[0041] The specification of EL894.100 component number GL4-5 is HM390×300×10×16. According to the hot-rolled H-beam section characteristics table, the section modulus of GL4-5 in the strong axis direction is 2000cm 3 .

[0042] Mmax≤f×γ×W=215×1.2×2000=516000KN.

[0043] According to the bending moment diagram of EL894.100 component number GL4-5, the bending moment of the hanging point beam is M=PL / 8. Where: P——load, KN; L——length of EL894.100 component number GL4-5, m; Mmax——bending moment, KN×m.

[0044] M=PL / 8=58552.23×7.5 / 8=54892.72KN×m Through the above comparison, the bending moment borne by the hanging point beam is much smaller than the bending moment of its own structural characteristics, and can bear the weight of the EL891.600 elevation structure and pipelines.

[0045] Deflection calculation: (1) Maximum deflection of concentrated load The maximum deflection under a concentrated load in the mid-span is at the mid-span of the measurement, and its calculation formula is: Ymax=8PI^3 / (384EI)=1PI^3 / (48EI).

[0046] Where: Ymax is the maximum deflection in the span (mm); P is the sum of the standard values ​​of each concentrated load (KN); E is the elastic modulus of steel. For engineering structural steel, E=2100000N / mm^2; I is the interface sawtooth of steel, which can be found in the steel table (mm^4).

[0047] The specifications of EL894.100 component number GL4-5 are HM390×300×10×16. From Table 5, we know that I=38900cm 4 , Ymax=58552.23×7.5 3 / (48×2100×38900)=6.3mm.

[0048] (2) The deflection of a flexural member should satisfy the following requirement: ν≦[ν], where: ν is the member deflection calculated from the standard value of all loads or variable loads, determined by static calculation based on the load and support conditions; [ν] is the allowable deflection value of the member, determined according to the table of allowable deflection values ​​of flexural members.

[0049] The specifications of the EL894.100 component number GL4-5 are HM390×300×10×16. The suspension electric fall chain is similar to the light duty bridge crane, so [ν]=L / 800=7500 / 800=9.38mm. ν=Ymax=6.3≤[ν]=9.38mm. The deflection of this component also meets the lifting requirements.

[0050] stability: The structure of the EL894.100 elevation has been fully installed before it is used, and the beams used as suspension points will not become unstable. The EL891.600 elevation structure of axis 109 to axis 110 has a width of 7500mm and a span of 9000mm. The steel structure of this layer is originally designed to bear various forces of the process pipelines of this layer during operation, so it is also safe during the lifting process. However, the span of this layer is large. In order to ensure the stability of the structure of this layer during the lifting process, it is necessary to set a force point 6 in the span direction.

[0051] To ensure synchronization during the lifting process, the specifications of the electric fall chain and wire rope along the span direction should be consistent with those in the same width direction.

[0052] After the installation of the EL891.600 elevation layer is completed, the structure and pipelines of the EL889.600 elevation layer are installed from top to bottom, using the same construction technology as the upper layer.

[0053] According to the method provided in this embodiment, 5-7 spans can be installed simultaneously by using an electric chain hoist for overall lifting of the structure and process pipelines. There are many straight sections in the outer pipe gallery. This construction process can realize the centralized prefabrication and installation of pipelines, greatly improve the efficiency of lifting machinery, greatly improve the efficiency of welding, and thus greatly improve the construction efficiency, and reduce the cost of safety technical measures. The prefabrication depth can reach 70%, and each welder can prefabricate and install 30Din per day, which increases the construction efficiency by 30%.

Claims

1. A method for integrally lifting the process pipeline of an outer pipe gallery, characterized in that: The following steps are involved: Step 1: Install the steel structure columns and top structure beams of the corridor first; Step 2: The secondary structure of the pipe gallery is assembled and welded as a whole at the corresponding position on the ground; Step 3: After the sub-layer structure is welded, the process pipelines of this layer are arranged on the completed sub-layer structure according to the process installation drawing, and the process pipelines on the sub-layer structure are assembled and welded; Step 4: Use the beams of the top structure as lifting points and the electric fall chain as a lifting device to lift the sub-structure together with the process pipeline to the installation position, and then weld the beams and columns of the sub-structure; Step 5: Repeat steps 2 to 4 to complete the simultaneous lifting and installation of the remaining sub-layer structures and process pipelines from top to bottom.

2. The overall lifting construction method of the outer pipe gallery process pipeline according to claim 1 is characterized in that: In step three, a pipeline prefabrication platform is set on the ground at the turning point or bend of the outer pipeline corridor, a winch is set at the other end of the pipeline corridor, a pulley block is set on the assembled sub-layer structure, and the straight sections of the process pipeline are centrally prefabricated at the pipeline prefabrication platform. The prefabricated pipeline is pulled toward the winch by the winch. When the other end of the pipeline reaches the edge of the prefabrication platform, the pulling is stopped, and then prefabrication welding is continued, and this sequence is repeated.

3. The overall lifting construction method of the outer pipe gallery process pipeline according to claim 2 is characterized in that: A plurality of pulley blocks are arranged on each beam of the assembled secondary structure.

4. The overall lifting construction method for the outer pipe gallery process pipeline according to claim 2 or 3 is characterized in that: The pipeline prefabrication platform is arranged between the columns, and the width of the pipeline prefabrication platform is the same as the width between the two columns.

5. The overall lifting construction method of the outer pipe gallery process pipeline according to claim 4 is characterized in that: In step 4, the center of the crossbeam of the top structure is used as the lifting point of the electric fall chain suspension, and the two sides of the crossbeam of the sub-structure are used as the force points for lifting the sub-structure and the process pipeline.

6. The overall lifting construction method of the outer pipe gallery process pipeline according to claim 5 is characterized in that: In step 4, the center of the longitudinal beam of the top structure is used as the lifting point of the electric fall chain suspension, and the two sides of the longitudinal beam of the sub-structure are used as the force points for lifting the sub-structure and the process pipeline.

7. The overall lifting construction method for the process pipeline of the outer pipe gallery according to claim 5 or 6 is characterized in that: The force bearing point is 500mm away from the column.

8. The overall lifting construction method of the outer pipe gallery process pipeline according to claim 7 is characterized in that: In step 4, 5-7 sub-layer structures are upgraded at a time.

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