Modularized installation machine and installation method for furnace tube of radiation section of ethylene cracking furnace

Abstract

The ethylene cracking furnace radiation section furnace tube modular installation machine comprises a ground conveying system and a winch lifting system, the ground conveying system comprises a rail, a conveying trolley and a tail sliding trolley, a detachable seamless steel pipe is erected on the tail sliding trolley, and the winch lifting system comprises a winch, a guide pulley block and a fixed pulley block. According to the machine, each radiation section furnace tube module is integrally hoisted into a radiation chamber of the ethylene cracking furnace from the furnace bottom of the ethylene cracking furnace through a winch hoisting system, and the in-place and sequential welding assembly of each radiation section furnace tube module are completed. The mechanical structure is simple, the manufacturing cost is low, modular installation of the radiation section furnace tube can be achieved, the construction quality of the ethylene cracking furnace can be guaranteed, the construction period is shortened, and the safety risk is low. The method is easy and convenient to operate, saves time and labor, can improve the construction efficiency, reduces the safety risk, remarkably improves the engineering quality, provides convenience for installation and replacement of the radiation section furnace tube of the ethylene cracking furnace, and has good comprehensive benefits.

Description

Technical Field

[0001] The invention relates to the field of equipment installation of petrochemical and other devices, and in particular to a modular installation machine and an installation method for a radiation section furnace tube of an ethylene cracking furnace. Background Art

[0002] With the vigorous development of domestic and foreign oil refining and chemical industries, more and more ethylene plants, as the leading projects of the chemical industry, are being built. As the heart of the ethylene plant, the ethylene cracking furnace has a long construction period, great construction difficulty and high construction cost. Therefore, the construction of the ethylene cracking furnace has always been the top priority of all construction units.

[0003] There are three common methods for installing and replacing ethylene cracking furnaces: the first is to install the radiation section furnace tubes as a single tube inside the furnace; the second is to install the radiation section furnace tubes as a single piece outside the furnace; the third is to install the radiation section furnace tubes as a system according to TLE (quench heat exchanger). The construction processes of the first two installation methods require the erection of a full-house scaffolding inside the furnace, which has a large welding workload inside the furnace, high safety risks, and difficult to effectively guarantee the quality. In addition, the construction period is long and the construction cost is high, which can no longer meet the requirements for the installation and replacement of the radiation section furnace tubes at this stage. The process of installing the radiation section furnace tubes as a system according to TLE increases the manufacturing depth and reduces the workload of on-site installation, but it requires the removal of a TLE and other auxiliary structures, and requires a large crane to cooperate with the construction, which has high requirements for the site and the installation and replacement costs are relatively high. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a modular installation machine and an installation method for the radiation section furnace tube of an ethylene cracking furnace in view of the deficiencies in the prior art, which can realize the modular installation of the radiation section furnace tube of the ethylene cracking furnace, is beneficial to ensuring the construction quality of the ethylene cracking furnace, shortening the construction period, reducing safety risks, significantly improving the project quality, providing convenience for the installation and replacement of the radiation section furnace tube of the ethylene cracking furnace, and having good comprehensive benefits.

[0005] The technical solution adopted by the present invention to solve the above technical problems is as follows: A modular installation machine for the radiant section furnace tubes of an ethylene cracking furnace, which includes a ground transportation system and a winch lifting system. The ground transportation system includes rails, a transportation trolley, and a tailing trolley. The rails are laid and extended to the furnace bottom ground of the ethylene cracking furnace. The transportation trolley and the tailing trolley are movably installed on the rails. A detachable seamless steel pipe is erected on the tailing trolley. The winch lifting system includes a winch, a guiding pulley group, and a fixed pulley group. The hauling rope of the winch is wound around the guiding pulley group and the fixed pulley group. The guiding pulley group is arranged on the frame cross beam of the ethylene cracking furnace. A set of the fixed pulley group is arranged on the lower head of each TLE above the ethylene cracking furnace. A pulley hook is installed at the end of the hauling rope of the winch. Before installation, the radiant section furnace tubes to be installed are prefabricated into several radiant section furnace tube modules according to the TLE system. When installing each radiant section furnace tube module, first fix the radiant section furnace tube module to be installed on a temporary packaging rack, then place the front end of the temporary packaging rack on the transportation trolley, and at the same time insert the seamless steel pipe on the tailing trolley into the round hole at the rear end of the temporary packaging rack. Then push the transportation trolley and the tailing trolley to the furnace bottom of the ethylene cracking furnace. After that, hook the pulley hook to the front end of the temporary packaging rack, and gradually lift the front end of the temporary packaging rack through the winch lifting system, so that the top of the radiant section furnace tube module is gradually lifted into the radiant chamber of the ethylene cracking furnace. During the lifting process, the transportation trolley and the tailing trolley automatically move forward as the radiant section furnace tube module rises, and the rear end of the temporary packaging rack rotates on the tailing trolley until it automatically detaches from the tailing trolley. Then the temporary packaging rack can be removed and the welding and assembly of the radiant section furnace tube module can be started.

[0006] The installation machine of the present invention hoists each radiant section furnace tube module from the furnace bottom of the ethylene cracking furnace into the radiant chamber of the ethylene cracking furnace as a whole through the winch lifting system, and completes the positioning and sequential welding and assembly of each radiant section furnace tube module. This installation machine has a simple structure, low manufacturing cost, can realize the modular installation of the radiant section furnace tubes of the ethylene cracking furnace, is beneficial to ensuring the construction quality of the ethylene cracking furnace, shortening the construction period, and has a low safety risk.

[0007] Preferably, the tailing trolley includes a first vehicle body, first wheels, a first lifting lug, and two vertical rods. The first wheels are installed at the bottom of the first vehicle body. The first lifting lug is fixed at the top of the first vehicle body. The two vertical rods are fixed at the top of the first vehicle body at intervals front and rear. The top of each vertical rod is provided with a U-shaped groove with an upper opening. The U-shaped grooves on the two vertical rods are used for detachably horizontally installing the seamless steel pipe.

[0008] Preferably, a support rib plate, a reinforcing angle steel, and an angle steel diagonal brace are welded between the side surface of each vertical rod and the first vehicle body.

[0009] Preferably, the first vehicle body is made of H-shaped steel support beams. The first wheels are mounted on the first wheel fixing channel steels, and the first wheel fixing channel steels are welded to the bottom of the first vehicle body.

[0010] Preferably, the transport trolley includes a second vehicle body, second wheels, second lifting lugs and a pallet steel plate. The second wheels are mounted on the bottom of the second vehicle body. The second lifting lugs are fixed to the top of the second vehicle body. A plurality of reinforcing channel steels are welded to the top of the second vehicle body, and the pallet steel plate is welded to the top of the plurality of reinforcing channel steels.

[0011] Preferably, the second vehicle body is made of H-shaped steel support beams. The second wheels are mounted on the second wheel fixing channel steels, and the second wheel fixing channel steels are welded to the bottom of the second vehicle body.

[0012] The above-mentioned tail-sliding trolley and transport trolley are simple and reliable in structure, low in manufacturing cost, and good in use effect.

[0013] A method for modular installation of the radiant section furnace tubes of an ethylene cracking furnace implemented by using the above installation machinery includes the following steps:

[0014] S1. Modular prefabrication

[0015] Prefabricate the radiant section furnace tubes to be installed into a number of radiant section furnace tube modules according to the TLE system;

[0016] S2. Modular installation of the radiant section furnace tube modules

[0017] Fix the radiant section furnace tube modules to be installed on a temporary packaging rack, then place the front end of the temporary packaging rack on the transport trolley. At the same time, insert the seamless steel pipe on the tail-sliding trolley into the round hole at the rear end of the temporary packaging rack. Then push the transport trolley and the tail-sliding trolley to the bottom of the ethylene cracking furnace. After that, hook the pulley hook to the front end of the temporary packaging rack, and gradually lift the front end of the temporary packaging rack through the hoist system, so that the top of the radiant section furnace tube modules is gradually lifted into the radiant chamber of the ethylene cracking furnace. During the lifting process, the transport trolley and the tail-sliding trolley move forward automatically as the radiant section furnace tube modules rise, and the rear end of the temporary packaging rack rotates on the tail-sliding trolley until it automatically detaches from the tail-sliding trolley. Then the temporary packaging rack can be removed and the welding and assembly of the radiant section furnace tube modules can be started; repeat the above operations until the modular installation of all the radiant section furnace tube modules is completed.

[0018] Preferably, for the replacement of the furnace tubes in the radiation section of the ethylene cracking furnace, before performing step S2, it further includes the steps of removing some end wall panels and synchronously removing the furnace top sealing cover plate, the furnace bottom sealing cover plate, and the corresponding old furnace tubes in the radiation section. That is, for each group of old furnace tubes in the radiation section removed from the outside to the inside, the corresponding furnace top sealing cover plate and furnace bottom sealing cover plate are then removed, and when removing some end wall panels, the load-bearing columns are avoided; after removing the furnace bottom sealing cover plate, columns extending to the ground are added on both sides of the position where the furnace bottom sealing cover plate is located. Removing the furnace bottom sealing cover plate provides a transportation passage for the removal of the old furnace tubes in the radiation section and the installation of new furnace tubes. The function of the columns is to reinforce and support the bottom part of the furnace. The removal of each group of old furnace tubes in the radiation section and the corresponding furnace top sealing cover plate is basically synchronous, aiming to use the furnace top cover plate as a hard isolation for cross-construction inside and outside the furnace.

[0019] Compared with the prior art, the present invention has the following advantages: The installation machine of the present invention hoists each furnace tube module in the radiation section from the furnace bottom of the ethylene cracking furnace into the radiation chamber of the ethylene cracking furnace as a whole through a winch lifting system, and completes the positioning and sequential welding and assembly of each furnace tube module in the radiation section. This installation machine has a simple structure and low manufacturing cost, can realize the modular installation of the furnace tubes in the radiation section of the ethylene cracking furnace, is beneficial to ensuring the construction quality of the ethylene cracking furnace, shortening the construction period, and having a low safety risk. The method of the present invention is simple to operate, time-saving and labor-saving, can improve the construction efficiency, reduce the safety risk, significantly improve the project quality, provide convenience for the installation and replacement of the furnace tubes in the radiation section of the ethylene cracking furnace, and has good comprehensive benefits. Brief Description of the Drawings

[0020] Figure 1 Schematic diagram of the effect after the installation of the winch lifting system in Embodiment 1;

[0021] Figure 2 Front view of the tailing trolley in Embodiment 1;

[0022] Figure 3 Side view of the tailing trolley in Embodiment 1;

[0023] Figure 4 Front view of the transport trolley in Embodiment 1;

[0024] Figure 5 Side view of the transport trolley in Embodiment 1;

[0025] Figure 6 Appearance schematic diagram of a single furnace tube module to be installed in Embodiment 2;

[0026] Figure 7 Schematic diagram of the state when some pipe sections of the furnace tubes in the radiation section enter the furnace bottom of the ethylene cracking furnace in Embodiment 2;

[0027] The specific reference numerals in the drawings are as follows:

[0028] 1 - Rail, 2 - Transport trolley, 21 - Second body, 22 - Second wheel, 23 - Second lifting lug, 24 - Tray steel plate, 25 - Reinforcing channel steel, 26 - Second wheel fixing channel steel, 3 - Tail - skid trolley, 31 - First body, 32 - First wheel, 33 - First lifting lug, 34 - Vertical pole, 35 - Support rib plate, 36 - Reinforcing angle steel, 37 - Angle steel brace, 38 - U - shaped groove, 39 - Seamless steel pipe, 30 - First wheel fixing channel steel, 4 - Winch, 41 - Running rope, 42 - Pulley hook head, 5 - Guide pulley set, 6 - Fixed pulley set, 71 - Furnace bottom ground, 72 - Frame cross beam, 73 - TLE, 74 - Furnace top sealing cover plate, 75 - Furnace bottom sealing cover plate, 76 - Column, 8 - Radiant section furnace tube module, 81 - Temporary packaging rack. Specific implementation mode

[0029] The present invention will be further described in detail below in conjunction with the embodiments with the attached drawings.

[0030] The mechanical device for modular installation of the radiant section furnace tubes of the ethylene cracking furnace in Embodiment 1, as Figures 1 - 5 shown, includes a ground transportation system and a winch lifting system. The ground transportation system includes a rail 1, a transport trolley 2, and a tail - skid trolley 3. In this embodiment, the rail 1 is made of channel steel and is laid and extended to the furnace bottom ground 71 of the ethylene cracking furnace. The transport trolley 2 and the tail - skid trolley 3 are movably installed on the rail 1. A detachable seamless steel pipe 39 is erected on the tail - skid trolley 3. The winch lifting system includes a winch 4, a guide pulley set 5, and a fixed pulley set 6. In this embodiment, the model of the winch 4 is a 5 - ton winch. The running rope 41 of the winch 4 is wound around the guide pulley set 5 and the fixed pulley set 6. The guide pulley set 5 is arranged on the frame cross beam 72 of the ethylene cracking furnace. A set of fixed pulley sets 6 is arranged on the lower sealing head of each TLE 73 above the ethylene cracking furnace. The end of the running rope 41 of the winch 4 is installed with a pulley hook head 42.

[0031] In Embodiment 1, the tail - skid trolley 3 includes a first body 31, a first wheel 32, a first lifting lug 33, and two vertical poles 34. The first wheel 32 is installed at the bottom of the first body 31. The first lifting lug 33 is fixed at the top of the first body 31. The two vertical poles 34 are fixed at the top of the first body 31 at intervals front and back. A support rib plate 35, a reinforcing angle steel 36, and an angle steel brace 37 are welded between the side of each vertical pole 34 and the first body 31. The top of each vertical pole 34 is provided with a U - shaped groove 38 with an upper opening. The U - shaped grooves 38 on the two vertical poles 34 are used for detachably horizontally installing the seamless steel pipe 39. The first body 31 is made of H - shaped steel support beams. The first wheel 32 is installed on the first wheel fixing channel steel 30, and the first wheel fixing channel steel 30 is welded to the bottom of the first body 31.

[0032] In Embodiment 1, the transport trolley 2 includes a second vehicle body 21, second wheels 22, second lifting lugs 23 and a tray steel plate 24. The second wheels 22 are installed at the bottom of the second vehicle body 21, the second lifting lugs 23 are fixed at the top of the second vehicle body 21, a plurality of reinforcing channel steels 25 are welded to the top of the second vehicle body 21, and the tray steel plate 24 is welded to the top of the plurality of reinforcing channel steels 25. The second vehicle body 21 is made of an H-shaped steel support beam. The second wheels 22 are installed on a second wheel fixing channel steel 26, and the second wheel fixing channel steel 26 is welded to the bottom of the second vehicle body 21.

[0033] Embodiment 2: For the replacement of the radiant section furnace tubes of an ethylene cracking furnace, the installation machinery of Embodiment 1 is used for modular installation of the radiant section furnace tubes of the ethylene cracking furnace, including the following steps:

[0034] S1. Modular prefabrication

[0035] Prefabricate the radiant section furnace tubes to be installed into a plurality of radiant section furnace tube modules 8 according to the TLE system, as Figure 6 shown;

[0036] S2. Demolition of some end wall panels, furnace top sealing cover plates 74, furnace bottom sealing cover plates 75 and old radiant section furnace tubes

[0037] Steps of demolishing some end wall panels and synchronously demolishing the furnace top sealing cover plates 74, furnace bottom sealing cover plates 75 and the corresponding old radiant section furnace tubes, that is, for each group of old radiant section furnace tubes demolished from outside to inside, then demolish the corresponding furnace top sealing cover plates 74 and furnace bottom sealing cover plates 75, and avoid the load-bearing columns when demolishing some end wall panels; after demolishing the furnace bottom sealing cover plate 75, add columns 76 extending to the ground on both sides of the position where the furnace bottom sealing cover plate 75 is located;

[0038] S3. Modular installation of the radiant section furnace tube modules 8

[0039] Fix the radiant section furnace tube modules 8 to be installed on a temporary packaging rack 81, then use a 25-ton crane outside the furnace bottom of the ethylene cracking furnace to lift the temporary packaging rack 81 and the radiant section furnace tube modules 8 onto two trolleys, place the front end of the temporary packaging rack 81 on the transport trolley 2, and at the same time insert the seamless steel pipe 39 on the tailing trolley 3 into the round hole at the rear end of the temporary packaging rack 81, and then push the transport trolley 2 and the tailing trolley 3 to the furnace bottom of the ethylene cracking furnace (see Figure 7) The traveling distance of the transport trolley 2 and the tailing trolley 3 is approximately 20 meters. Then, the pulley hook 42 is hooked to the front end of the temporary packaging rack 81, and the front end of the temporary packaging rack 81 is gradually lifted through the winch lifting system, so that the top of the radiant section furnace tube module 8 is gradually lifted into the radiant chamber of the ethylene cracking furnace. During the lifting process, the transport trolley 2 and the tailing trolley 3 move forward automatically as the radiant section furnace tube module 8 rises, while the rear end of the temporary packaging rack 81 rotates on the tailing trolley 3 until it automatically detaches from the tailing trolley 3. Then, the temporary packaging rack 81 can be removed and the welding and assembly of the radiant section furnace tube module 8 can be started; repeat the above operations until the modular installation of all the radiant section furnace tube modules 8 is completed.

Claims

1. A modular installation machine for the radiant section furnace tubes of an ethylene cracking furnace, characterized in that, It includes a ground transportation system and a hoist lifting system. The ground transportation system includes tracks, a transportation trolley, and a tailing trolley. The tracks are laid and extended to the bottom ground of the ethylene cracking furnace. The transportation trolley and the tailing trolley are movably installed on the tracks. A detachable seamless steel pipe is erected on the tailing trolley. The hoist lifting system includes a hoist, a guiding pulley set, and a fixed pulley set. The hoisting rope of the hoist is wound around the guiding pulley set and the fixed pulley set. The guiding pulley set is arranged on the frame cross beam of the ethylene cracking furnace. A set of the fixed pulley sets is arranged on the lower head of each TLE above the ethylene cracking furnace. A pulley hook is installed at the end of the hoisting rope of the hoist. Before installation, the radiation section furnace tubes to be installed are prefabricated into several radiation section furnace tube modules according to the TLE system. When installing each radiation section furnace tube module, first fix the radiation section furnace tube module to be installed on a temporary packaging rack, then place the front end of the temporary packaging rack on the transportation trolley, and at the same time insert the seamless steel pipe on the tailing trolley into the round hole at the rear end of the temporary packaging rack. Then push the transportation trolley and the tailing trolley to the bottom of the ethylene cracking furnace. After that, hook the pulley hook on the front end of the temporary packaging rack, and gradually lift the front end of the temporary packaging rack through the hoist lifting system, so that the top of the radiation section furnace tube module is gradually lifted into the radiation chamber of the ethylene cracking furnace. During the lifting process, the transportation trolley and the tailing trolley automatically move forward as the radiation section furnace tube module rises, and the rear end of the temporary packaging rack rotates on the tailing trolley until it automatically detaches from the tailing trolley. Then the temporary packaging rack can be removed and the welding and assembly of the radiation section furnace tube module can be started.

2. The mechanical device for modular installation of furnace tubes in the radiation section of an ethylene cracking furnace according to claim 1, characterized in that, The tailing trolley includes a first body, first wheels, a first lifting lug, and two vertical rods. The first wheels are installed at the bottom of the first body. The first lifting lug is fixed at the top of the first body. The two vertical rods are fixed at the top of the first body at intervals front and rear. The top of each vertical rod is provided with a U-shaped groove with an upper opening. The U-shaped grooves on the two vertical rods are used for detachably horizontally installing the seamless steel pipe.

3. A mechanical device for modular installation of furnace tubes in the radiant section of an ethylene cracking furnace according to claim 2, characterized in that, Supporting rib plates, reinforcing angle steels, and angle steel diagonal braces are welded between the side of each vertical rod and the first body.

4. A mechanical device for modular installation of furnace tubes in the radiation section of an ethylene cracking furnace according to claim 2, characterized in that, The first body is made of an H-shaped steel support beam. The first wheels are installed on a first wheel fixing channel steel, and the first wheel fixing channel steel is welded to the bottom of the first body.

5. A mechanical device for modular installation of furnace tubes in the radiation section of an ethylene cracking furnace according to claim 1, characterized in that, The transportation trolley includes a second body, second wheels, a second lifting lug, and a tray steel plate. The second wheels are installed at the bottom of the second body. The second lifting lug is fixed at the top of the second body. Several reinforcing channel steels are welded to the top of the second body. The tray steel plate is welded to the top of the several reinforcing channel steels.

6. The modular installation machine for the radiant section furnace tubes of an ethylene cracking furnace according to claim 1, characterized in that, The second body is made of an H-shaped steel support beam. The second wheels are installed on a second wheel fixing channel steel, and the second wheel fixing channel steel is welded to the bottom of the second body.

7. A modular installation method for the radiant section furnace tubes of an ethylene cracking furnace implemented by using the installation machinery according to any one of claims 1-6, characterized in that, It includes the following steps: S1. Modular prefabrication Prefabricate the radiant section furnace tubes to be installed into several radiant section furnace tube modules according to the TLE system; S2. Modular installation of the radiant section furnace tube modules Fix the radiant section furnace tube modules to be installed on the temporary packaging rack, then place the front end of the temporary packaging rack on the transport trolley. At the same time, insert the seamless steel pipe on the trailing trolley into the round hole at the rear end of the temporary packaging rack. Then push the transport trolley and the trailing trolley to the furnace bottom of the ethylene cracking furnace. After that, hook the pulley hook to the front end of the temporary packaging rack, and gradually lift the front end of the temporary packaging rack through the hoist system, so that the top of the radiant section furnace tube module is gradually lifted into the radiant chamber of the ethylene cracking furnace. During the lifting process, the transport trolley and the trailing trolley automatically move forward as the radiant section furnace tube module rises, while the rear end of the temporary packaging rack rotates on the trailing trolley until it automatically detaches from the trailing trolley. Then the temporary packaging rack can be removed and the welding and assembly of the radiant section furnace tube modules can be started; repeat the above operations until the modular installation of all radiant section furnace tube modules is completed.

8. The modular installation method of the furnace tubes in the radiant section of the ethylene cracking furnace according to claim 7, characterized in that For the replacement of the radiant section furnace tubes of the ethylene cracking furnace, before performing step S2, it also includes the steps of removing some end wall panels and synchronously removing the furnace top seal cover plate, the furnace bottom seal cover plate and the corresponding old radiant section furnace tubes, that is, remove a group of old radiant section furnace tubes from the outside to the inside, and then remove the corresponding furnace top seal cover plate and furnace bottom seal cover plate, and avoid the load-bearing columns when removing some end wall panels; after removing the furnace bottom seal cover plate, add columns extending to the ground on both sides of the position where the furnace bottom seal cover plate is located.

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