In-plant integral manufacturing method for ultra-large container

Abstract

The invention discloses an in-plant integral manufacturing method for an ultra-large container, which comprises the following steps: segmented manufacturing, heat treatment, rust-proof treatment, closing general assembly, pressure resistance test and roll-on-ship, specifically, the ultra-large container is divided into multiple segments, the length of each segment is not more than 20 meters, and each segment is subjected to assembly welding and segmented heat treatment; performing sand blasting on the container subjected to each section of heat treatment, and painting the inside and the outside of the container; sequentially hoisting each section of the container to a multi-purpose saddle, controlling the coaxiality of each section of the container by using a laser tracker, and performing assembly welding on the closed circular seams to form an integral container; performing water pressure test on the whole container; and jacking the multi-purpose saddle of the container which is qualified in the pressure test to a certain height by adopting a jacking method, and rolling and loading the container on a ship through an SPMT module vehicle set. According to the method, the requirement for the capacity of in-plant manufacturing equipment is low, overall assembly of the ultra-large container in a plant is achieved, welding residual stress is effectively eliminated, the service life is prolonged, the manufacturing time is effectively saved, and the manufacturing cost is reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of container manufacturing, and in particular relates to an integrated manufacturing method for super-large containers in a factory. Background Art

[0002] With advancements in production processes and continuous improvements in technology within the chemical industry, the trend toward larger-scale production has become increasingly pronounced. This increasing size of chemical plants has driven the rapid development of large-scale chemical equipment manufacturing. Reactors and towers are key components of chemical production. Currently, some equipment in large chemical plants can exceed 100 meters in height and weigh over 1,500 tons.

[0003] In the existing technology, ultra-large container equipment is limited by site conditions and is usually manufactured in sections and welded on-site. Due to the poor on-site welding environment, welding quality is difficult to control and the manufacturing cycle is long. During transportation, the high cost of section transportation leads to low on-site assembly accuracy and prone to stress concentration. After assembly, multiple lifting and repeated anti-corrosion treatments are required, which is costly and time-consuming. Summary of the Invention

[0004] In order to at least partially solve the technical problems existing in the above-mentioned prior art, the present invention provides an in-plant integrated manufacturing method for super-large containers.

[0005] The in-plant integrated manufacturing method of the ultra-large container of the present invention comprises:

[0006] Segmented manufacturing: The ultra-large container is divided into multiple sections, each section not exceeding 20 meters in length, and each section is welded together;

[0007] Heat treatment: each section of the container after welding is heat treated in sections;

[0008] Anti-rust treatment: sandblast the container after each heat treatment and paint the inside and outside of the container;

[0009] Closing and assembly: After the paint is completely dry, each section of the container is hoisted onto the multi-purpose saddle in turn. At the same time, a laser tracker is used to control the coaxiality between each section of the container, and the circumferential seams between each two sections of the container are welded to form an integral container.

[0010] Pressure test: Perform a water pressure test on the integral container on the multi-purpose saddle. The test pressure is 1.25 times the design pressure, and the pressure holding time is ≥30 minutes;

[0011] Roll-on / roll-off loading: The container that has passed the pressure test is lifted by the jacking method, the multi-purpose saddle is lifted to a certain height, and the container is rolled onto the ship through the SPMT module train. The roll-on / roll-off slope is ≤5° and the center of gravity offset is ≤500mm.

[0012] Furthermore, in the above-mentioned overall manufacturing method within the ultra-large container factory, during the segmented manufacturing process, when the first and last segments are performing circumferential seam welding, the circumferential seams are welded using submerged arc horizontal welding or manual welding, and the circumferential seams are subjected to TOFD ultrasonic testing.

[0013] Furthermore, in the above-mentioned integrated manufacturing method within the super-large container factory, during the segmented manufacturing process, the shell is firstly welded, and then the internal and external components are welded.

[0014] Furthermore, in the above-mentioned overall manufacturing method of the super-large container in the factory, during the anti-rust treatment process, it is necessary to reserve the joint weld of each section.

[0015] Furthermore, in the above-mentioned integrated manufacturing method of the super-large container factory, during the closing and final assembly process, the coaxiality deviation between each section of the container is controlled to be ≤3 mm / m.

[0016] Furthermore, in the above-mentioned integrated manufacturing method in the super-large container factory, during the closing assembly process, the ovality of the container shell is corrected by support tooling before the annular seam group is welded, and the error is controlled to be ≤25mm.

[0017] Furthermore, in the above-mentioned integrated manufacturing method within the super-large container factory, during the closing assembly process, all-position welding is adopted for the circumferential seam group welding, and the interlayer temperature is strictly controlled at ≤230°C.

[0018] The in-plant integrated manufacturing method of the ultra-large container of the present invention has the following advantages and beneficial effects:

[0019] The present invention has low requirements on the manufacturing equipment capabilities in the factory, and realizes the overall assembly of super-large containers in the factory. By heat treating the welds after segmented manufacturing, the welding residual stress is effectively eliminated and the service life is increased. By rust-proofing each section, the manufacturing time is effectively saved and the manufacturing cost is reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the embodiments or the description of the prior art. Obviously, the drawings described below are only used to further understand the embodiments of the present invention and constitute part of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative work. In the drawings:

[0021] Figure 1 Schematic diagram of the process of the overall manufacturing method of the ultra-large container factory of the present invention;

[0022] Figure 2 This is a schematic diagram of the segmented structure of the super-large container in Example 1;

[0023] Figure 3 This is a schematic diagram of the structure of the super-large container after assembly in Example 1. DETAILED DESCRIPTION

[0024] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with specific embodiments of the present invention and corresponding drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0025] like Figure 1 As shown, the in-plant integrated manufacturing method of the ultra-large container of the present invention comprises:

[0026] Segmented manufacturing: The ultra-large container is divided into multiple sections, each section not exceeding 20 meters in length, and each section is welded together;

[0027] Heat treatment: each section of the container after welding is heat treated in sections;

[0028] Anti-rust treatment: sandblast the container after each heat treatment and paint the inside and outside of the container;

[0029] Closing and assembly: After the paint is completely dry, each section of the container is hoisted onto the multi-purpose saddle in turn. At the same time, a laser tracker is used to control the coaxiality between each section of the container, and the circumferential seams between each two sections of the container are welded to form an integral container.

[0030] Pressure test: Perform a water pressure test on the integral container on the multi-purpose saddle. The test pressure is 1.25 times the design pressure, and the pressure holding time is ≥30 minutes;

[0031] Roll-on / roll-off loading: The container that has passed the pressure test is lifted by the jacking method, the multi-purpose saddle is lifted to a certain height, and the container is rolled onto the ship through the SPMT module train. The roll-on / roll-off slope is ≤5° and the center of gravity offset is ≤500mm.

[0032] Furthermore, in the above-mentioned overall manufacturing method within the ultra-large container factory, during the segmented manufacturing process, when the first and last segments are performing circumferential seam welding, the circumferential seams are welded using submerged arc horizontal welding or manual welding, and the circumferential seams are subjected to TOFD ultrasonic testing.

[0033] Furthermore, in the above-mentioned integrated manufacturing method within the super-large container factory, during the segmented manufacturing process, the shell is firstly welded, and then the internal and external components are welded.

[0034] Furthermore, in the above-mentioned overall manufacturing method of the super-large container in the factory, during the anti-rust treatment process, it is necessary to reserve the joint weld of each section.

[0035] Furthermore, in the above-mentioned integrated manufacturing method of the super-large container factory, during the closing and final assembly process, the coaxiality deviation between each section of the container is controlled to be ≤3 mm / m.

[0036] Furthermore, in the above-mentioned integrated manufacturing method in the super-large container factory, during the closing assembly process, the ovality of the container shell is corrected by support tooling before the annular seam group is welded, and the error is controlled to be ≤25mm.

[0037] Furthermore, in the above-mentioned integrated manufacturing method within the super-large container factory, during the closing assembly process, all-position welding is adopted for the circumferential seam group welding, and the interlayer temperature is strictly controlled at ≤230°C.

[0038] Example 1

[0039] like Figures 2 to 3 As shown in the figure, the overall manufacturing process in the super large container factory with a height of 110m is as follows:

[0040] Segmented manufacturing: The ultra-large vessel is divided into 6 sections, each no longer than 20 meters. Each section of the shell is first welded together, and then the internal and external pre-welded parts such as the lifting lugs are welded together. The circumferential seams of the first and last sections are welded using submerged arc welding or manual welding to ensure weld quality. The circumferential seams are also inspected using TOFD ultrasonic testing.

[0041] Heat treatment: After welding, each section of the container is immediately heat treated in sections to eliminate welding residual stress;

[0042] Anti-rust treatment: sandblast each section of the heat-treated container, paint the inside and outside of the container, and reserve the joint welds;

[0043] Closing assembly: After the paint is completely dry, the six sections of the container are hoisted onto the multi-purpose saddle in sequence. At the same time, a laser tracker is used to control the coaxiality between each section of the container, and the coaxiality deviation is controlled to be ≤3mm / m. When assembling the circumferential seams, support tools are used to correct the ovality to a roundness error of ≤25mm. The circumferential seams between each two sections of the container are welded using all-position welding, and the interlayer temperature is strictly controlled at ≤230℃ to form an integrated container.

[0044] Pressure test: Perform a water pressure test on the integral container on the multi-purpose saddle. The test pressure is 1.25 times the design pressure, and the pressure holding time is ≥30 minutes;

[0045] Roll-on / roll-off loading: The container that has passed the pressure test is lifted by the jacking method, the multi-purpose saddle is lifted to a certain height, and the container is rolled onto the ship through the SPMT module train. The roll-on / roll-off slope is ≤5° and the center of gravity offset is ≤500mm.

[0046] In summary, compared with the prior art, the method for overall in-factory manufacturing of ultra-large containers of the present invention has the following advantages and beneficial effects: the present invention has low requirements on the in-factory manufacturing equipment capabilities, realizes the overall assembly of ultra-large containers in the factory, and effectively eliminates welding residual stress and improves service life by heat treating the welds after segmented manufacturing. By performing rust-proof treatment on each segment, manufacturing time is effectively saved and manufacturing costs are reduced.

[0047] It should be noted that, in this document, unless otherwise expressly specified or limited, the term "connected" or its synonyms should be interpreted broadly. For example, "connected" can mean a fixed or removable connection; a mechanical or electrical connection; a direct connection or an indirect connection through an intermediate medium; or the internal communication between two elements or the interaction between two elements. A person of ordinary skill in the art will understand the specific meanings of these terms in the present invention based on the specific circumstances. Furthermore, expressions such as "first" and "second" are used solely to distinguish one entity or operation from another and do not necessarily require or imply any actual relationship or order between these entities or operations. Furthermore, the terms "comprise," "include," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a process, method, article, or apparatus comprising a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus. Furthermore, the terms "front," "rear," "left," "right," "upper," and "lower" herein are used with reference to the positions shown in the accompanying drawings.

[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A method for manufacturing an ultra-large container in an integrated manner in a factory, characterized in that: The in-plant integrated manufacturing method of the ultra-large container comprises: Segmented manufacturing: The ultra-large container is divided into multiple sections, each section not exceeding 20 meters in length, and each section is welded together; Heat treatment: each section of the container after welding is heat treated in sections; Anti-rust treatment: sandblast the container after each heat treatment and paint the inside and outside of the container; Closing and assembly: After the paint is completely dry, each section of the container is hoisted onto the multi-purpose saddle in turn. At the same time, a laser tracker is used to control the coaxiality between each section of the container, and the circumferential seams between each two sections of the container are welded to form an integral container. Pressure test: Perform a water pressure test on the integral container on the multi-purpose saddle. The test pressure is 1.25 times the design pressure, and the pressure holding time is ≥30 minutes; Roll-on / roll-off loading: The container that has passed the pressure test is lifted by the jacking method, the multi-purpose saddle is lifted to a certain height, and the container is rolled onto the ship through the SPMT module train. The roll-on / roll-off slope is ≤5° and the center of gravity offset is ≤500mm.

2. The method for manufacturing an ultra-large container in a factory as claimed in claim 1, characterized in that: During the segmented manufacturing process, when the first and last segments are performing circumferential seam welding, submerged arc horizontal welding or manual welding is used for the circumferential seam, and TOFD ultrasonic testing is performed on the circumferential seam.

3. The method for manufacturing an ultra-large container in a factory as claimed in claim 1, characterized in that: During the segmented manufacturing process, the shell is welded first, followed by the internal and external components.

4. The method for manufacturing an ultra-large container in a factory as claimed in claim 1, characterized in that: During the anti-rust treatment process, it is necessary to reserve space for each joint weld.

5. The method for manufacturing an ultra-large container in a factory as claimed in claim 1, characterized in that: During the closing and assembly process, the coaxiality deviation between each section of the container is controlled to be ≤3mm / m.

6. The method for manufacturing an ultra-large container in a factory as claimed in claim 1, characterized in that: During the closing assembly process, the container shell is corrected for ovality through supporting tooling before the annular seam group is welded, and the error is controlled to ≤25mm.

7. The method for manufacturing an ultra-large container in a factory as claimed in claim 1, characterized in that: During the joint assembly process, all-position welding is used for the circumferential seam group welding, and the interlayer temperature is strictly controlled at ≤230℃.

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