Waste heat boiler shell plate and thermal insulation material integrated manufacturing construction process

Abstract

The invention relates to the field of large waste heat recovery boiler technical equipment, and discloses a waste heat boiler shell plate and thermal insulation material integrated manufacturing construction technology which comprises the steps that part plates are blanked; the assembly of the shell comprises the following steps: a, processing the column body; b, processing the honeycomb connection beam; c, processing the access door; d, assembling, welding and galvanizing the column; e, assembling and welding a column frame; f, assembling and welding the shell plate; and g, other parts are installed. And meanwhile, the influence of construction on the environment is reduced, a large number of high-altitude operation and scaffold measures are reduced, the project progress is accelerated, the heat efficiency of the boiler is greatly improved by applying the shell plate and Morgan super cotton integrated manufacturing technology, and economic benefits and social benefits are achieved.

Description

Technical Field

[0001] The invention relates to the field of large-scale waste heat recovery boiler technology and equipment, and in particular to an integrated manufacturing and construction process for a waste heat boiler shell plate and thermal insulation materials. Background Art

[0002] In the past, high-temperature resistant adhesives were generally used to firmly adhere the insulation cotton to the surface of the furnace shell, and then hooks or clips were used to fix the insulation cotton to ensure that it would not loosen. This required one-time pasting on site, otherwise it would affect the thermal insulation effect. This construction method has very high requirements for construction workers and the construction progress is relatively slow. On-site insulation cotton is generally laid from the bottom of the furnace to the top of the furnace, which will generate a lot of high-altitude operations and scaffolding measures. Fees, greatly affecting the progress of on-site construction.

[0003] In the document CN202011288231, a premixed water-cooled combustion corner tube steam boiler is disclosed, including a burner including a premixer, a gradual expansion distributor and a water-cooled combustion head; the boiler body includes a drum, a frame structure composed of four-corner downcomers and a header, a front wall water-cooled wall connected to the burner, a convection tube screen, left and right membrane water-cooled walls, insulation materials and a shell; the condenser is arranged at the rear of the boiler body. In this structure, the thermal insulation materials are fixed in advance, and the engineering progress is relatively slow.

[0004] Therefore, a new technical solution is needed to solve the above technical problems. Summary of the invention

[0005] In order to solve the above problems, the present invention discloses an integrated manufacturing and construction process for waste heat boiler shell plates and thermal insulation materials, which reduces the difficulty of on-site construction, shortens the on-site construction period, and reduces the impact of construction on the environment. It does not require a large amount of high-altitude operations and scaffolding measures, improves the project progress, and the use of integrated manufacturing technology for shell plates and Morgan super cotton greatly improves the thermal efficiency of the boiler and realizes economic and social benefits.

[0006] The technical solution of the present invention is: an integrated manufacturing and construction process for waste heat boiler shell plates and thermal insulation materials, comprising the following steps: a. Processing of column body Step 1: Since the column body is composed of multiple sections of welded steel with different thicknesses, first complete the assembly welding of each section of steel, and finally complete the splicing of each section of steel; Step 2: After each section of steel is corrected and qualified, before splicing, attention should be paid to leaving the remainder on the steel at both ends; Step 3: Finally, complete the splicing of each section of the steel body; b. Processing of honeycomb connecting beams Step 1: The honeycomb beam body is BT steel, which is processed by first assembling BH and then dividing it according to the dividing line, and the front web is cut with a margin; Through the above technical solution, the margin cutting is, for example, the cutting seam length is 1050mm. If there is a concern about deformation after welding, only 500mm is cut at both ends, and 50mm is reserved in the middle. After the welding is completed and the structure is stable, the 50mm is cut, which is conducive to controlling deformation. Step 2: After segmentation, separate the two BT steels and perform staggered assembly, cut the remaining material, and form a honeycomb beam, where H=H f -h+3; Step 3: Butt joint of honeycomb beam webs; c. Processing of inspection doors Step 1: Drill holes in the support angle steel and weld it to the shell plate; Step 2: Two sets of bent plates are welded into frames and pre-assembled with door panels; Step 3: Assemble and weld the hinges, handles and door panels, and the connecting shaft and ring plate; Step 4: All components flow into the subsequent rust removal and painting process; Step 5: Complete the assembly of the components and determine the position of the hinge on the shell plate by matching the door plate with the angle steel; Step 6: Rotate the shaft to complete the opening and closing test, and finally close the inspection door as a whole; Step 7: Position and install the insulation cotton, lining, gasket and nut in sequence and repair the paint. After that, the inspection door will not be opened and closed in the factory; d. Column welding and galvanizing Step 1: Positioning, installing, and welding column base plates and shear keys; Step 2: Using the lower end surface of the column base plate as a reference, position and install and weld each level of stiffening plates and connecting plates from bottom to top, and position them through the holes; Step 3: The column body, honeycomb connecting beam and column top plate are sent to an external contractor for galvanizing; e. Column frame welding After the two sections of the column body are joined, the honeycomb connecting beam and transverse reinforcing channel steel between the two column bodies are welded based on the lower end surface of the column bottom plate to form a column frame; f. Shell plate welding Step 1: After the shell plate is corrected and qualified, the three-roll mill is used to weld the liner to the shell plate based on the center line in the length direction; Step 2: Using the lower end surface of the column base plate as a reference, position weld the shell plate to the column frame; Step 3: Turn over the column frame as a whole, and complete the welding between the shell plate and the reinforced channel steel, the column body and the liner in sequence; g. Installation of other components Step 1: After the frame is corrected and qualified, turn over the column frame as a whole, determine the total length of the component, cut the excess at both ends of the component and open the groove; Step 2: Install and weld the column top plate and the lifting lugs; Step 3: On the column body, except for the two ends connected to the beam body, the holes are marked and drilled, and the holes on the shell plate are marked and drilled; Step 4: Assemble and weld the pipe bracket and the corresponding end plate, complete the internal primer of the bracket assembly without considering the film thickness and the filling of the insulation cotton in the middle, and weld the whole assembly to the shell plate, and the nuts of the bracket assembly are positioned and welded with the bolts in the middle; Step 5: After passing the correction, locate and install the door frame and insulation nails on the shell plate in sequence; Step 6: Mark and drill holes at the two ends of the column body that connect to the beam body; Step 7: After passing the inspection, the frame, lining and access door will be sent to the back road for rust removal and painting; Step 8: After passing the inspection, use insulation nails with quick clamps and welding nails with nuts and gaskets to spread the insulation cotton on the 6mm shell plate.

[0007] Preferably, in step 2 of the processing of the column body, only +4mm of the body splicing shrinkage allowance is left for the intermediate steel, and in step 3, the flatness of the flange plate where the intermediate steel body and the shell plate are fitted is ≤1mm. If the length of a single column body in step 3 exceeds the size limit of the galvanizing pool, one splicing seam is retained for splicing after galvanizing.

[0008] Preferably, in step 1 of processing the honeycomb connecting beam, H is the cross-sectional height of the BH steel, and H f is the height of the honeycomb beam section, and h is half the height of the hexagonal hole.

[0009] Preferably, the short sides cut in step 2 of processing the honeycomb connecting beam correspond to the short sides, forming a hollowed-out partial-stroke honeycomb shape.

[0010] Preferably, in step 1 of column assembly welding and galvanizing, the verticality between the column base plate and the column body is ≤1 mm, and in step 3, epoxy paint is applied to the secondary welding, on-site welding and concrete contact surfaces to avoid adhesion of the zinc layer.

[0011] Preferably, in step 1 of installing other components, the center distance of the column body steel is checked to ensure that the center distance and the straightness of the shell plate including the gasket are 0 to +2 mm, and the straightness of the free edge is ≤2 mm; at the same time, the length, width and diagonal dimensions of the shell plate including the gasket are checked to ensure that the length and width dimensions are 0 to -2 mm, and the diagonal dimension is ±3 mm.

[0012] Preferably, in step 2 of installing other components, the verticality between the end surface of the top plate and the body is ≤1 mm.

[0013] Preferably, in step 4 of installing other components, the middle section is welded, the internal primer is painted and filled with thermal insulation cotton, the nuts are tack welded with the bolts in the middle section, and the middle section is welded and filled with thermal insulation cotton.

[0014] Preferably, in step 5 of installing other components, the verticality between the insulation nails and the shell plate is ≤1.5mm, and the positioning accuracy of the holes in step 6 is ±1mm.

[0015] The benefits of the present invention are as follows: 1. The present invention realizes integrated manufacturing by fixing Morgan super cotton to 6mm shell plates through insulation nails with quick clamps and welding nails with nuts or gaskets, which greatly improves the modular manufacturing capability of boiler shell and ensures that the whole is not loose.

[0016] 2. The present invention leaves a margin for cutting the web before assembly, so that deformation can be prevented during subsequent welding, thereby having the effect of controlling deformation.

[0017] 3. The present invention reduces the difficulty of on-site construction, shortens the on-site construction period, and reduces the impact of construction on the environment, reduces a large number of high-altitude operations and scaffolding measures, improves project progress, and the use of shell plate and Morgan super cotton integrated manufacturing technology greatly improves the thermal efficiency of the boiler to achieve economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is an overall schematic diagram of the present invention; Figure 2 For the present invention Figure 1 Schematic diagram of the reverse side; Figure 3 It is a schematic diagram of the section of laying the thermal insulation cotton of the present invention; Figure 4 It is a schematic diagram of step 2 in blanking of a part plate of the present invention; Figure 5 is a schematic diagram of processing step 1 of the column body of the present invention; Figure 6 It is a schematic diagram of processing step 1 of the column honeycomb connecting beam of the present invention; Figure 7 It is a schematic diagram of processing step 2 of the column honeycomb connecting beam of the present invention; Figure 8 It is a schematic diagram of processing step 4 of the column honeycomb connecting beam of the present invention; Fig. 9 A schematic diagram of processing step 1 of the access door of the present invention; Fig.10 A schematic diagram of processing step 2 of the access door of the present invention; Fig.11 A schematic diagram of processing step 7 of the access door of the present invention; Fig.12 For the present invention Fig.11 A schematic diagram of an enlarged view of part A; Fig.13 This is a schematic diagram of the column frame welding of the present invention; Figure 14-15 It is a schematic diagram of step 4 of installing other components of the present invention.

[0019] Among them: 1. lining plate, 101. bending line, 2. steel section, 3. honeycomb beam, 301. dividing line, 4. connecting beam, 6. supporting angle steel, 7. bending plate, 8. door panel, 9. hinge, 10. handle, 11. coupling, 12. ring plate, 13. rotating shaft, 14. hinge b, 15. column body, 16. middle welding and filling with insulation cotton, 17. inspection door, 18. nut, 19. insulation cotton, 20. shell plate, 21. insulation nails, 22. gasket, 23. lining, 24. stiffening plate, 25. connecting plate, 26. pad, 27. lifting ear, 28. reinforced channel steel. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0021] like Figure 1-3 As shown, the integrated manufacturing and construction process of waste heat boiler shell plate and insulation materials includes the following steps: When the extra-long and extra-wide parts are laid out, they are spliced ​​in sections. The shell plate 20 is spliced ​​first and then welded to the frame as a whole. The workload of welding and pyrotechnic correction is huge, and sufficient welding shrinkage needs to be reserved as required; Figure 4 As shown, part of the lining 23 plate 1 is bent in multiple passes, and the plate thickness must be considered when lofting the bending line 101 to meet the requirement of close fitting of the lining 23 plate 1 on the sheet body; a. Processing of column body like Figure 5 As shown, step 1: since the column body is composed of multiple sections of welded steel 2 of unequal thickness, first complete the welding of each section of steel 2 separately, and finally complete the splicing of each section of steel 2. During the splicing process, in order to ensure that the length of a single column body is ≤15.5m, one splicing seam is reserved for galvanizing before splicing; Step 2: After each section of steel 2 is qualified, before splicing, attention should be paid to retaining the allowance at both ends of the steel 2, and only +4mm of the main body splicing shrinkage allowance should be left in the middle steel. In step 3, the flatness of the flange plate where the middle steel body and the shell plate 20 are attached is ≤1mm; Step 3: Finally, complete the splicing of each section of steel 2. If the length of a single column exceeds the size limit of the galvanizing pool, consider leaving one splicing seam for splicing after galvanizing; b. Processing of honeycomb connecting beam 4 like Figure 6 As shown, step 1: the main body of the honeycomb beam 3 is BT steel, which is processed by first assembling BH and then dividing it according to the dividing line 301, and the front web is cut with a margin; like Figure 7As shown, step 2: After segmentation, separate the two BT steels and perform staggered assembly, cut the remaining material, and form a honeycomb beam, where H=H f -h+3, H is the section height of BH steel, H f is the height of the honeycomb beam cross section, h is half the height of the hexagonal hole, and the short sides completed by cutting correspond to the short sides, forming a hollowed-out partial-stroke honeycomb shape; Step 3: butt joint of the webs of the honeycomb beam 3; like Figure 8 As shown, step 4: the holes on the flange plate of the honeycomb beam 3 are drilled together with the corresponding light sheet body when they are to be packaged; c. Processing of inspection door 17 like Fig. 9 As shown, step 1: drilling holes in the support angle steel 6 and welding them to the shell plate 20; like Fig.10 As shown, step 2: two groups of bent plates 7 are respectively welded into frames and pre-assembled with the door panels; Step 3: The hinge 9, the handle 10 and the door panel 8 are welded together, and the connecting shaft 11 and the ring plate 12 are welded together; Step 4: All components are uniformly sent to the back-end for rust removal and painting. When the components are rust removed and painted, the holes for the pin shafts are plugged with wooden plugs; Step 5: Complete the assembly of the components and determine the position of the hinge 9 on the shell plate 20 by matching the door plate 8 with the angle steel; Step 6: Rotate the shaft 13 to complete the opening and closing test, and finally close the inspection door 17 as a whole; like Figure 11-12 As shown, step 7: sequentially locate and install the insulation cotton 19, lining 23, gasket 22 and nut 18 and repair the paint. After that, the inspection door 17 will not be opened and closed in the factory. The insulation cotton 19 is Morgan super cotton; d. Column welding and galvanizing Step 1: Position, install and weld the column base plate and shear key. The verticality between the column base plate and the column body should be ≤1mm. In step 3, the secondary welding, on-site welding and the concrete contact surface should be painted with epoxy paint to avoid the adhesion of the zinc layer. Step 2: Using the lower end surface of the column bottom plate as a reference, position and install and weld the stiffening plates 24 and connecting plates 25 of each level from bottom to top, and position them through the holes; Step 3: The column body, honeycomb connecting beam and column top plate are sent to an external contractor for galvanizing; e. Column frame welding, such as Fig.13 As shown, After the two sections of column bodies 15 are joined, the honeycomb connecting beam and the transverse reinforcing channel steel 28 between the two column bodies are welded based on the lower end surface of the column bottom plate to form a column frame; f. Shell plate 20 welding Step 1: After the shell plate 20 is corrected and qualified, a three-roll mill is used to weld the liner 26 to the shell plate 20 based on the center line in the length direction; Step 2: Using the lower end surface of the column bottom plate as a reference, position weld the shell plate 20 to the column frame; Step 3: The column frame is turned over as a whole, and the shell plate 20 and the reinforcing channel steel 28, the column body 15 and the liner 26 are welded in sequence. During the welding process, a welding method with a small current, a fast speed and a center-retracting welding method is adopted; g. Installation of other components Step 1: After the frame is corrected and qualified, the column frame is turned over as a whole, the total length of the component is determined, the excess at both ends of the component is cut and the groove is opened, and the center distance of the column body steel is checked to ensure that the center distance and the straightness of the shell plate 20 including the gasket 26 are 0~+2mm, and the straightness of the free edge is ≤2mm; at the same time, the length, width and diagonal dimensions of the shell plate including the gasket 26 are checked to ensure that the length and width dimensions are 0~-2mm, and the diagonal dimension is ±3mm; Step 2: Install and weld the column top plate and the lifting lug 27, and the verticality between the top plate end surface and the body is ≤1mm; Step 3: On the column body, except for the two ends connected to the beam body, the holes are marked and drilled, and the holes on the shell plate 20 are marked and drilled; like Figure 14-15 As shown, step 4: assemble and weld the pipe support and the corresponding end plate, complete the internal primer of the support assembly in the middle pass without considering the film thickness and the filling of the insulation cotton 19 and weld the whole to the shell plate 20, the nut 18 of the support assembly is positioned welded with the bolt in the middle pass, welded in the middle pass, the internal primer is applied and the insulation cotton 19 is filled, the nut is positioned welded with the bolt in the middle pass, welded in the middle pass and the insulation cotton 19 is filled; Step 5: After the correction is qualified, the door frame and the insulation nails 21 are positioned and installed on the shell plate 20 in sequence. The verticality of the insulation nails 21 and the shell plate is ≤1.5mm, and the positioning accuracy of the holes in step 6 is ±1mm; Step 6: Mark and drill holes at the two ends of the column body that connect to the beam body; Step 7: After passing the inspection, the frame, lining 23 and access door 17 are transferred to the back road for rust removal and painting; Step 8: After passing the inspection, use the insulation nails 21 with quick clamps and the welding nails with nuts 18 and gaskets 22 to spread the insulation cotton 19 on the 6mm shell plate 20.

[0022] It should be understood by those skilled in the art that the embodiments of the present invention described above and shown in the accompanying drawings are only examples and do not limit the present invention, and the purpose of the present invention has been fully and effectively achieved. The functional and structural principles of the present invention have been demonstrated and explained in the embodiments, and the embodiments of the present invention may be deformed or modified in any way without departing from the principles.

Claims

1. Integrated manufacturing and construction process of waste heat boiler shell plate and thermal insulation materials, characterized in that: The following steps are involved: Step 1: Cutting the parts sheet; Step 1: When lofting, the extra-long and extra-wide parts plates are spliced ​​in sections. After the shell plates are completed, they are spliced ​​first and then welded to the frame as a whole. The workload of welding and pyrotechnic correction is huge, and sufficient welding shrinkage needs to be reserved as required; Step 2: Due to multiple bends in some lining plates, the influence of plate thickness on the bending line must be considered during lofting to meet the requirement of close fitting of the lining plate on the sheet; a. Processing of column body Step 1: Since the column body is composed of multiple sections of welded steel with different thicknesses, first complete the assembly welding of each section of steel, and finally complete the splicing of each section of steel; Step 2: After each section of steel is corrected and qualified, before splicing, attention should be paid to leaving the remainder on the steel at both ends; Step 3: Finally, complete the splicing of each section of the steel body; Step 4: During the splicing process, to ensure that the length of a single column is ≤15.5m, retain one splicing seam and wait for galvanizing before splicing; b. Processing of honeycomb connecting beams Step 1: The honeycomb beam body is BT steel, which is processed by first assembling BH and then dividing it according to the dividing line, and the front web is cut with a margin; Step 2: After segmentation, separate the two BT steels and perform staggered assembly, cut the remaining material, and form a honeycomb beam, where H=H f -h+3; Step 3: Butt joint of honeycomb beam webs; Step 4: The holes on the flange plate of the honeycomb beam are drilled together with the corresponding light sheet body when they are packaged; c. Processing of inspection doors Step 1: Drill holes in the support angle steel and weld it to the shell plate; Step 2: Two sets of bent plates are welded into frames and pre-assembled with door panels; Step 3: Weld the hinge a, handle and door panel, and weld the connecting shaft and ring plate b; Step 4: All components flow into the subsequent rust removal and painting process; Step 5: Complete the assembly of the components and determine the position of the hinge on the shell plate by matching the door plate with the angle steel; Step 6: Rotate the shaft to complete the opening and closing test, and finally close the inspection door as a whole; Step 7: Position and install the insulation cotton, lining, gasket and nut in sequence and repair the paint. After that, the inspection door will not be opened and closed in the factory; d. Column welding and galvanizing Step 1: Position, install and weld the column base plate and shear keys; Step 2: Using the lower end surface of the column base plate as a reference, position and install and weld each level of stiffening plates and connecting plates from bottom to top, and position them through the holes; Step 3: The column body, honeycomb connecting beam and column top plate are sent to an external contractor for galvanizing; e. Column frame welding After the two sections of the column body are joined, the honeycomb connecting beam and transverse reinforcing channel steel between the two column bodies are welded based on the lower end surface of the column bottom plate to form a column frame; f. Shell plate welding Step 1: After the shell plate is corrected and qualified, the three-roll mill is used to weld the liner to the shell plate based on the center line in the length direction; Step 2: Using the lower end surface of the column base plate as a reference, position weld the shell plate to the column frame; Step 3: Turn over the column frame as a whole, and complete the welding between the shell plate and the reinforced channel steel, the column body and the liner in sequence; Step 4: During the welding process, a low current, fast speed, and center-to-center de-welding method are used; g. Installation of other components Step 1: After the frame is corrected and qualified, turn over the column frame as a whole, determine the total length of the component, cut the excess at both ends of the component and open the groove; Step 2: Install and weld the column top plate and the lifting lugs; Step 3: On the column body, except for the two ends connected to the beam body, the holes are marked and drilled, and the holes on the shell plate are marked and drilled; Step 4: Assemble and weld the pipe bracket and the corresponding end plate, complete the internal primer of the bracket assembly without considering the film thickness and the filling of the insulation cotton in the middle, and weld the whole assembly to the shell plate, and the nuts of the bracket assembly are positioned and welded with the bolts in the middle; Step 5: After passing the correction, locate and install the door frame and insulation nails on the shell plate in sequence; Step 6: Mark and drill holes at the two ends of the column body that connect to the beam body; Step 7: After passing the inspection, the frame, lining and access door will be sent to the back road for rust removal and painting; Step 8: After passing the inspection, use insulation nails with quick clamps and welding nails with nuts and gaskets to spread the insulation cotton on the 6mm shell plate.

2. The integrated manufacturing construction process for waste heat boiler shell plate and thermal insulation material according to claim 1 is characterized in that: In step 2 of the processing of the column body, only +4mm of shrinkage allowance is left for the intermediate steel body. In step 3, the flatness of the flange plate where the intermediate steel body and the shell plate are fitted is ≤1mm. If the length of the single column body in step 3 exceeds the size limit of the galvanizing pool, one splicing seam is retained for splicing after galvanizing.

3. The integrated manufacturing construction process for waste heat boiler shell plate and thermal insulation material according to claim 1 is characterized in that: In step 4 of the processing of the inspection door, when the components are rust-removed and painted, the hole for the pin shaft is blocked with a wooden plug.

4. The integrated manufacturing construction process for waste heat boiler shell plate and thermal insulation material according to claim 1 is characterized in that: In the step 1 of processing the honeycomb connecting beam, H is the cross-sectional height of the BH steel, and H f is the height of the honeycomb beam section, and h is half the height of the hexagonal hole.

5. The integrated manufacturing construction process for waste heat boiler shell plate and thermal insulation material according to claim 1 is characterized in that: The short sides cut in step 2 of processing the honeycomb connecting beam correspond to the short sides, forming a hollowed-out partial-stroke honeycomb shape.

6. The integrated manufacturing and construction process for waste heat boiler shell plate and thermal insulation material according to claim 1 is characterized in that: In step 1 of the column assembly welding and galvanizing, the verticality between the column base plate and the column body is ≤1mm, and in step 3, the secondary welding, on-site welding and the concrete contact surface are painted with epoxy paint to prevent the zinc layer from adhering.

7. The integrated manufacturing and construction process for waste heat boiler shell plate and thermal insulation material according to claim 1 is characterized in that: In step 1 of the installation of the other components, the center distance of the column body steel is checked to ensure that the center distance and the straightness of the shell plate including the gasket are 0 to +2 mm, and the straightness of the free edge is ≤2 mm; at the same time, the length, width and diagonal dimensions of the shell plate including the gasket are checked to ensure that the length and width dimensions are 0 to -2 mm, and the diagonal dimension is ±3 mm.

8. The integrated manufacturing and construction process for waste heat boiler shell plate and thermal insulation material according to claim 1 is characterized in that: In step 2 of installing the other components, the verticality between the end surface of the top plate and the body is ≤1mm.

9. The integrated manufacturing and construction process for waste heat boiler shell plate and thermal insulation material according to claim 1 is characterized in that: The step 4 of the installation of the other components is to weld in the middle, apply internal primer and fill with insulation cotton, weld the nuts and bolts in the middle, weld in the middle and fill with insulation cotton.

10. The integrated manufacturing construction process for waste heat boiler shell plate and thermal insulation material according to claim 1 is characterized in that: In step 5 of installing the other components, the verticality between the insulation nails and the shell plate is ≤1.5mm, and the positioning accuracy of the holes in step 6 is ±1mm.

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