Installation method of integral outlet collector of large hydrogenation reactor

Abstract

The technical problem to be solved by the invention is to provide the mounting method for the integral outlet collector of the large hydrogenation reactor, which is small in mounting risk, more convenient to mount and lower in mounting cost. The installation method of the integral outlet collector of the large hydrogenation reactor comprises the steps that at least two radial limiting plates are arranged on the outer side of a collector installation boss, and the radial limiting plates are fixedly installed on the inner wall of a lower-section cylinder of the hydrogenation reactor in the circumferential direction of the lower-section cylinder of the hydrogenation reactor at intervals; a mounting cavity matched with the outer diameter of the collector is defined by the radial limiting plates; a collector is installed in the installation cavity, and an axial limiting plate is installed on the radial limiting plate; vertically hoisting the hydrogenation reactor and then vertically mounting the hydrogenation reactor; the radial limiting plate and the axial limiting plate are dismantled, and the collector is hoisted away from the collector mounting boss; a fixing stud is welded on the collector mounting boss; and the collector is put down, and installation of the collector is completed.

Description

Technical Field

[0001] The invention relates to the technical field of hydrogenation reactor installation, in particular to an installation method for an integral outlet collector of a large hydrogenation reactor. Background Art

[0002] With the development of large-scale and high-parameterized pressure vessels in the petrochemical industry, the structural dimensions of the hydrogenation reactor, the core equipment in the high-temperature and high-pressure hydrogenation unit, are getting larger and larger, and the internal parts of the equipment are also getting larger and larger. Among them, the reactor outlet collector is an internal part that plays a vital role in chemical production. Its main function is to collect reactor products and residual substances, support the lower catalyst, prevent catalyst powder from being taken out with the reaction products, and facilitate the export of reaction products. For large hydrogenation reactors, the integral outlet collector has a large structural size (outer diameter Φ3~Φ5m) and a heavy tonnage (8~10 tons). Usually, a full circle of bosses are welded on the lower head of the reactor for the support of the collector, which is fixed to the reactor outlet through nuts and fixed studs welded on the lower head boss. Due to the large size of the collector, it cannot be put in from the manhole of the hydrogenation reactor later. Therefore, during the manufacturing process of the reactor, the collector needs to be installed and fixed inside the reactor in advance. Since large hydrogenation reactors are usually assembled in horizontal sections and then installed upright, the integral outlet collector is usually installed in the following two ways:

[0003] The first method is to install the collector directly on the collector mounting boss of the lower head of the lower cylinder through nuts and fixing studs welded on the lower head boss when the hydrogenation reactor is in a horizontal state. This installation method, (1) because the hydrogenation reactor is horizontal, it is not convenient to accurately assemble and position, and the alignment of dozens of fixing studs and collectors is difficult and the assembly cycle is long. (2) For large hydrogenation reactors, the collector generally weighs 8 to 10 tons. The vibration during the subsequent transportation of the hydrogenation reactor can easily cause deformation and falling of the fixing studs, as well as damage to the ceramic fiber gaskets on the surface of the collector and the head collector mounting boss. It is necessary to re-purchase the fixing studs and ceramic fiber gaskets according to the damage after the reactor is hoisted to the vertical position in the later stage. The collector is disassembled from the head collector mounting boss, hoisted away, the fixing studs that need to be replaced are polished and removed, reassembled and welded, and finally the ceramic fiber gasket and collector are hoisted to the head collector mounting boss, which increases manufacturing costs.

[0004] The second one, see Figure 1, the collector 4 is temporarily fixed on the surface of the cylinder near the collector mounting boss by using the tooling 41; after the hydrogenation reactor is hoisted to the upright position in the later stage, the lifting coordination is performed to remove the tooling connection plate between the collector and the cylinder, and the collector is turned over so that its bowl is facing downward; the fixing studs are welded on the head collector mounting boss; finally, the collector is hoisted and shifted to be fixed on the head collector mounting boss. This installation method avoids damage to the fixing studs and ceramic fiber gaskets, but (1) since the inner wall of the cylinder is an arc, the contact surface between the collector and the cylinder is small, and most of the collector end face is suspended. In order to ensure that the collector is firmly fixed, a large amount of tooling is required; the tooling needs to be welded to the collector and the cladding layer inside the cylinder. There are many welding parts of the temporary accessories on the equipment, and the subsequent removal workload is large, and the risk of damaging the collector and the cylinder is high. (2) Since the collector is fixed on the inner wall of the cylinder, the collector needs to be turned over after removing the connection plate, which makes hoisting difficult and has a high safety risk. (3) The residues in the tooling removal area need to be removed by grinding. This location is on the inner wall of the cylinder, and scaffolding needs to be re-erected for grinding operations. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a method for installing an integral outlet collector of a large hydrogenation reactor with low installation risk, more convenient installation and lower installation cost, so as to improve the installation efficiency of the collector.

[0006] The technical solution adopted by the present invention to solve the technical problem is: a method for installing an integral outlet collector of a large hydrogenation reactor, comprising the following steps:

[0007] Assembling the lower cylinder of the hydrogenation reactor;

[0008] After the lower cylinder of the hydrogenation reactor is assembled, at least two radial stop plates are arranged on the outer side of the collector mounting boss, and the radial stop plates are fixedly installed on the inner wall of the lower cylinder of the hydrogenation reactor at intervals along the circumferential direction of the lower cylinder of the hydrogenation reactor, and the radial stop plates enclose a mounting cavity adapted to the outer diameter of the collector;

[0009] When the lower cylinder of the hydrogenation reactor is in a horizontal state, the collector is installed in the installation cavity, and an axial limit plate is installed on the radial limit plate to abut against the surface of the bottom side of the collector away from the lower cylinder of the hydrogenation reactor, so as to temporarily fix the collector on the collector installation boss;

[0010] The remaining cylinders of the hydrogenation reactor are assembled together with the lower cylinder of the hydrogenation reactor in a horizontal manner to form a hydrogenation reactor;

[0011] The hydrogenation reactor is hoisted upright and then installed vertically;

[0012] After the hydrogenation reactor is installed, the radial limit plate and the axial limit plate are removed and the collector is lifted off the collector mounting boss;

[0013] Welding fixing studs on the collector mounting boss;

[0014] The collector is lowered and fixed to the collector mounting boss by the fixing studs, thereby completing the installation of the collector.

[0015] Further, the inner diameter of the installation cavity is larger than the outer diameter of the collector, and the axial limit plate is composed of a vertical portion and a horizontal portion connected to one end of the vertical portion to form an L-structure;

[0016] When installing the axial limit plate, the horizontal portion of the axial limit plate abuts and cooperates with the outer side surface of the collector to further limit the radial direction of the collector through the horizontal portion, and the vertical portion of the axial limit plate abuts and cooperates with the bottom side surface of the collector away from the lower section of the hydrogenation reactor to axially limit the collector through the vertical portion.

[0017] Furthermore, the radial limiting plate is installed and fixed on the inner wall of the lower cylinder of the hydrogenation reactor by welding.

[0018] Furthermore, the inner diameter of the installation cavity is D, the outer diameter of the collector is d, and d+10mm≥D≥d+5mm.

[0019] Furthermore, the axial limiting plate and the radial limiting plate are connected by bolts;

[0020] When removing the radial limit plate and the axial limit plate and lifting the collector off the collector mounting boss, first remove the axial limit plate, then lift the collector off the collector mounting boss, and finally remove the radial limit plate.

[0021] Furthermore, the method further comprises the step of performing flaw detection on the welding connection between the lower cylinder of the hydrogenation reactor and the radial limiting plate after the radial limiting plate is removed.

[0022] Furthermore, the step of installing the collector in the installation cavity comprises the following steps:

[0023] A suspension rod is provided, and a lifting point is determined on the suspension rod, wherein the lifting point is located between two ends of the suspension rod, one end of the suspension rod is a fixed end of the collector, and a distance from the lifting point to the fixed end of the collector is greater than an installation depth of the collector on the lower cylinder of the hydrogenation reactor;

[0024] The collector is mounted and fixed on the fixed end of the collector, and a counterweight is arranged on the other end of the boom to ensure that both ends of the boom remain balanced when the boom is lifted horizontally from the lifting point;

[0025] The lifting rod is lifted horizontally through the lifting point by using a lifting device, and then the lifting rod is moved horizontally to install the collector into the installation cavity.

[0026] The beneficial effects of the present invention are:

[0027] 1. Before the hydrogenation reactor is installed, the collector 4 is temporarily fixed on the collector mounting boss 11 by using the radial stopper plate 2 and the axial stopper plate 5 fixed on the inner wall of the hydrogenation reactor, without the need to perform the centering assembly between dozens of fixing studs and the through holes on the collector. The operation is simple, the assembly time is short, the occupancy time of the lifting equipment is reduced, and it is beneficial to the on-site production organization;

[0028] 2. The axial limit plate is fixed by the radial limit plate 2 fixed on the inner wall of the lower cylinder 1 of the hydrogenation reactor. The axial limit plate and the radial limit plate 2 form a snap-fit ​​structure to fix the collector. The axial limit plate is not connected to the collector, and the tooling is easy to disassemble. There are fewer welding parts of the tooling on the equipment, and the amount of tooling removed is less, which can better avoid damage to the equipment surface, reduce tooling costs, and save installation time;

[0029] 3. After the equipment is installed vertically, the collector is lifted vertically to avoid overturning, making the lifting safer;

[0030] 4. The tooling that needs to be polished off is left on the outside of the collector mounting boss on the head of the lower cylinder of the hydrogenation reactor. No scaffolding is required, and the location is more convenient for operators to operate, making the operation safer;

[0031] 5. Effectively avoid the damage of the fixing studs, save the cost of repurchasing materials and cycle costs, save installation costs, and better ensure the installation quality of the collector. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a schematic diagram of an existing collector installation;

[0033] Figure 2 It is a schematic diagram of the radial limit plate arrangement structure of the present invention;

[0034] Figure 3 It is a schematic diagram of temporary installation and fixation of the collector of the present invention;

[0035] Figure 4 is a structural schematic diagram of a radial limit plate;

[0036] Figure 5 yes Figure 3 A magnified image of point A;

[0037] Figure 6 This is the schematic diagram of the final installation of the collector;

[0038] Figure 7 is a schematic diagram of a collector installed in the lower cylinder of a hydrogenation reactor;

[0039] As shown in the figure: the lower cylinder 1 of the hydrogenation reactor, the radial limit plate 2, the installation cavity 3, the collector 4, the axial limit plate 5, the hydrogenation reactor 6, the fixing studs 7, the suspension rod 8, the counterweight 9, the collector installation boss 11, the tooling 41, the vertical part 51, and the horizontal part 52. DETAILED DESCRIPTION

[0040] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0041] like Figures 2 to 6 As shown, the method for installing the integrated outlet collector of a large hydrogenation reactor of the present invention comprises the following steps:

[0042] Step 1, assembling the lower head and the like to form the lower cylinder 1 of the hydrogenation reactor, that is, assembling the lower cylinder 1 of the hydrogenation reactor;

[0043] Step 2: After the lower cylinder 1 of the hydrogenation reactor is assembled, at least two radial limit plates 2 are arranged on the outer side of the collector mounting boss 11 provided on the inner wall of the head of the lower cylinder 1 of the hydrogenation reactor (on the side close to the upper end of the lower cylinder 1 of the hydrogenation reactor), and the radial limit plates 2 are installed and fixed on the inner wall of the lower cylinder 1 of the hydrogenation reactor at intervals along the circumferential direction of the lower cylinder 1 of the hydrogenation reactor, and the radial limit plates 2 enclose a mounting cavity 3 adapted to the outer diameter of the collector 4;

[0044] Step 3: When the lower cylinder 1 of the hydrogenation reactor is in a horizontal state, the collector 4 is installed in the installation cavity 3, and an axial limit plate 5 is installed on the radial limit plate 2 to abut against the surface of the bottom side of the collector 4 away from the lower cylinder 1 of the hydrogenation reactor, so as to temporarily fix the collector 4 on the collector installation boss 11, thereby completing the temporary installation and fixation of the collector 4;

[0045] Step 4: assemble the remaining cylinders of the hydrogenation reactor horizontally with the lower cylinder 1 of the hydrogenation reactor to form a hydrogenation reactor 6;

[0046] Step 5, hoisting the hydrogenation reactor 6 upright and installing it vertically;

[0047] Step 6: After the hydrogenation reactor 6 is installed, the radial limit plate 2 and the axial limit plate 5 are removed and the collector 4 is lifted off the collector mounting boss 11;

[0048] Step 7, welding the fixing stud 7 on the collector mounting boss 11;

[0049] Step eight, lower the collector 4, pass the fixing studs 7 through the corresponding screw holes of the collector 4, install nuts, and fix the collector 4 to the collector mounting boss 11 through the fixing studs 7, thereby completing the installation of the collector 4.

[0050] In the present invention, step 1 and step 2 are generally also performed in a horizontal state.

[0051] The specific number of radial limiting plates 2 is set as required to ensure that the collector can be stably supported. In the embodiment of the present invention, the number of radial limiting plates 2 is 8. The radial limiting plates 2 are generally evenly arranged along the circumferential direction of the lower barrel 1 of the hydrogenation reactor.

[0052] The radial stop plate 2 and the axial stop plate 5 can be made of various materials. The hydrogenation reactor is generally made of stainless steel. If the radial stop plate 2 is not made of stainless steel, such as Q345R, in order to avoid material contamination, a stainless steel pad can be set between the radial stop plate 2 and the inner wall of the hydrogenation reactor, or a stainless steel isolation layer of not less than 6 mm can be pre-welded on the connection surface between the radial stop plate 2 and the inner wall of the hydrogenation reactor, and a stainless steel pad can be set between the radial stop plate 2 and the collector 4, and between the axial stop plate 5 and the collector 4.

[0053] Before the installation of the hydrogenation reactor is completed, that is, during the process of converting the horizontal assembly of the hydrogenation reactor into a vertical installation, the collector installation method of the present invention uses a radial limit plate 2 and an axial limit plate 5 fixed on the inner wall of the hydrogenation reactor to temporarily fix the collector 4 on the collector installation boss 11, and the limit plate is not connected to the collector. In this way, there is no need to install the fixing studs of the collector in the early stage, which can avoid deformation and falling off of the studs, and there is no need to perform centering assembly between dozens of studs and the through holes on the collector. The collector installation operation is simple and the assembly time is short, which reduces the occupancy time of the lifting equipment and is beneficial to on-site production organization. In the later stage, that is, after the vertical installation of the hydrogenation reactor is completed, the amount of tooling to be removed is small and there is no need to flip the collector, which saves installation time and makes lifting safer.

[0054] The collector 4 can be delivered into the lower cylinder of the hydrogenation reactor by a trolley, but the trolley needs to enter the lower cylinder of the hydrogenation reactor, which is easy to cause damage to the lower cylinder of the hydrogenation reactor. To this end, in the embodiment of the present invention, the collector 4 is installed in the lower cylinder of the hydrogenation reactor in the following manner:

[0055] A suspension rod 8 is provided, and a lifting point is determined on the suspension rod 8, wherein the lifting point is located between two ends of the suspension rod 8, one end of the suspension rod 8 is a fixed end of the collector, and a distance from the lifting point to the fixed end of the collector is greater than an installation depth of the collector 4 on the lower cylinder 1 of the hydrogenation reactor;

[0056] The collector 4 is mounted and fixed on the fixed end of the collector, and a counterweight 9 is arranged at the other end of the suspension rod 8 to ensure that both ends of the suspension rod 8 remain balanced when the suspension rod 8 is lifted horizontally from the lifting point;

[0057] The lifting rod 8 is lifted horizontally through the lifting point by using a lifting device, such as a crane, and then the lifting rod 8 is moved horizontally to deliver the collector 4 into the installation cavity 3 for installation.

[0058] The collector 4 can be fixed on the suspension rod 8 by bolt connection, welding or the like.

[0059] Specifically, the inner diameter of the installation cavity 3 may be greater than or equal to the outer diameter of the collector 4. For the convenience of installation, the inner diameter of the installation cavity 3 is preferably greater than the outer diameter of the collector 4, and the larger the inner diameter of the installation cavity 3, the easier it is to install the collector 4. If the inner diameter of the installation cavity 3 is too large, it is convenient to install the collector 4, but it is not convenient to fix the collector 4. In the present invention, assuming that the inner diameter of the installation cavity 3 is D and the outer diameter of the collector 4 is d, it is better to consider d+10mm≥D≥d+5mm.

[0060] The axial limit plate 5 can be in various shapes, such as Figure 4 As shown, in the present invention, in order to better temporarily fix the collector 4, preferably, the axial limit plate 5 is composed of a vertical portion 51 and a horizontal portion 52 connected to one end of the vertical portion 51 to form an L structure; when installing the axial limit plate 5, the horizontal portion 52 of the axial limit plate 5 abuts and cooperates with the outer side surface of the collector 4, so as to further limit the radial direction of the collector 4 through the horizontal portion 52, and the vertical portion 51 of the axial limit plate 5 abuts and cooperates with the surface of the bottom side of the collector 4 away from the lower section cylinder 1 of the hydrogenation reactor, so as to axially limit the collector 4 through the vertical portion 51. The above method is convenient for installing the collector in the installation cavity 3 and can better temporarily fix the collector 4.

[0061] The radial limit plate 2 and the lower barrel 1 of the hydrogenation reactor can be connected by bolts, welding, etc. In the present invention, the radial limit plate 2 is installed and fixed on the inner wall of the lower barrel 1 of the hydrogenation reactor by welding. After the radial limit plate 2 is welded, the weld can be inspected to detect whether there are welding quality problems such as false welding and cracks in the weld. The radial limit plate 2 can be set to various shapes as needed. In the present invention, in order to facilitate the welding connection between the radial limit plate 2 and the lower barrel 1 of the hydrogenation reactor, the radial limit plate 2 adopts a triangle.

[0062] Conventional fixed connection methods such as welding and bolt connection can be used between the axial limit plate 5 and the radial limit plate 2. If the axial limit plate 5 and the radial limit plate 2 are connected by welding, when removing the limit plate, in order to save time, the radial limit plate 2 is generally removed from the lower cylinder 1 of the hydrogenation reactor, so that the axial limit plate 5 can be removed together, but due to the existence of the collector 4, there is a problem that it is not convenient to remove the radial limit plate 2. In order to facilitate the removal of the radial limit plate 2, in the present invention, preferably, the axial limit plate 5 is connected to the radial limit plate 2 by bolts, that is, bolt connection is adopted; in this way, when removing the radial limit plate 2 and the axial limit plate 5 and lifting the collector 4 from the collector mounting boss 11, it is convenient to remove the axial limit plate 5 first, so that the collector 4 can be lifted off the collector mounting boss first, and then the radial limit plate 2 is finally removed, and the removal of the radial limit plate 2 is more convenient, which is conducive to improving the installation efficiency. In addition, especially when d+10mm≥D≥d+5mm, the radial limit plate 2 is finally removed. During the process of lifting the collector 4, the radial limit plate 2 can also be used to limit the collector 4 to a certain extent to avoid excessive shaking and displacement of the collector 4 during lifting, which may lead to difficulties in subsequent alignment and assembly with the fixing studs 7, and is also beneficial to improving the installation efficiency of the collector.

[0063] When the radial stop plate 2 is installed and fixed on the inner wall of the lower cylinder 1 of the hydrogenation reactor by welding, the method further includes the step of performing flaw detection on the welded connection between the lower cylinder 1 of the hydrogenation reactor and the radial stop plate 2 after the radial stop plate 2 is removed, so as to detect whether the lower cylinder 1 of the hydrogenation reactor is damaged during the installation and removal of the radial stop plate 2. The flaw detection can be performed by 100% PT flaw detection.

Claims

1. A method for installing an integral outlet collector of a large hydrogenation reactor, characterized in that: The following steps are involved: Assembling the lower barrel (1) of the hydrogenation reactor; After the lower barrel (1) of the hydrogenation reactor is assembled, at least two radial stop plates (2) are arranged on the outer side of the collector mounting boss (11), and the radial stop plates (2) are installed and fixed on the inner wall of the lower barrel (1) of the hydrogenation reactor at intervals along the circumferential direction of the lower barrel (1) of the hydrogenation reactor, and the radial stop plates (2) enclose a mounting cavity (3) adapted to the outer diameter of the collector (4); When the lower barrel (1) of the hydrogenation reactor is in a horizontal state, the collector (4) is installed in the installation cavity (3), and an axial stop plate (5) is installed on the radial stop plate (2) to abut against the surface of the collector (4) on one side away from the bottom of the lower barrel (1) of the hydrogenation reactor, so as to temporarily fix the collector (4) on the collector installation boss (11); The remaining cylinders of the hydrogenation reactor are assembled together with the lower cylinder (1) of the hydrogenation reactor in a horizontal manner to form a hydrogenation reactor (6); The hydrogenation reactor (6) is hoisted upright and then installed vertically; After the hydrogenation reactor (6) is installed, the radial limiting plate (2) and the axial limiting plate (5) are removed and the collector (4) is lifted off the collector mounting boss (11); Welding a fixing stud (7) onto the collector mounting boss (11); The collector (4) is lowered and fixed to the collector mounting boss (11) by means of the fixing studs (7), thereby completing the installation of the collector (4).

2. The method for installing an integrated outlet collector of a large hydrogenation reactor according to claim 1, characterized in that: The inner diameter of the installation cavity (3) is greater than the outer diameter of the collector (4); the axial limiting plate (5) is composed of a vertical portion (51) and a horizontal portion (52) connected to one end of the vertical portion (51) to form an L-structure; When installing the axial limit plate (5), the horizontal portion (52) of the axial limit plate (5) abuts against the outer side surface of the collector (4) to further limit the radial direction of the collector (4) through the horizontal portion (52), and the vertical portion (51) of the axial limit plate (5) abuts against the bottom side surface of the collector (4) away from the lower section cylinder (1) of the hydrogenation reactor to axially limit the collector (4) through the vertical portion (51).

3. The method for installing an integral outlet collector of a large hydrogenation reactor according to claim 1, characterized in that: The radial limiting plate (2) is installed and fixed on the inner wall of the lower cylinder (1) of the hydrogenation reactor by welding.

4. The method for installing an integrated outlet collector of a large hydrogenation reactor according to claim 1, characterized in that: The inner diameter of the installation cavity (3) is D, the outer diameter of the collector (4) is d, and d+10mm≥D≥d+5mm.

5. The method for installing an integral outlet collector of a large hydrogenation reactor according to claim 1 or 4, characterized in that: The axial limiting plate (5) and the radial limiting plate (2) are connected via bolts; When removing the radial limit plate (2) and the axial limit plate (5) and lifting the collector (4) off the collector mounting boss (11), first remove the axial limit plate (5), then lift the collector (4) off the collector mounting boss, and finally remove the radial limit plate (2).

6. The method for installing an integrated outlet collector of a large hydrogenation reactor according to claim 3, characterized in that: The method further comprises the step of performing flaw detection on the welded joint between the lower cylinder (1) of the hydrogenation reactor and the radial limit plate (2) after the radial limit plate (2) is removed.

7. The method for installing an integrated outlet collector of a large hydrogenation reactor according to claim 1, characterized in that: The step of installing the collector (4) in the installation cavity (3) comprises the following steps: A suspension rod (8) is provided, and a lifting point is determined on the suspension rod (8), wherein the lifting point is located between two ends of the suspension rod (8), one end of the suspension rod (8) is a fixed end of the collector, and the distance from the lifting point to the fixed end of the collector is greater than the installation depth of the collector (4) on the lower cylinder (1) of the hydrogenation reactor; The collector (4) is mounted and fixed on the fixed end of the collector, and a counterweight (9) is arranged at the other end of the suspension rod (8) to ensure that both ends of the suspension rod (8) remain balanced when the suspension rod (8) is lifted horizontally from the lifting point; The lifting rod (8) is lifted horizontally through the lifting point using a lifting device, and then the lifting rod (8) is moved horizontally to install the collector (4) in the installation cavity (3).

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