Factory building roof large-diameter pipeline air opening alignment and integral sliding installation method

Abstract

The invention relates to a factory building roof large-diameter pipeline'air opening alignment 'and'integral sliding' installation method, and belongs to the technical field of building assembly. A winch is arranged on the roof of a plant, pipelines are spliced and welded on the ground, hoisting machinery is used for hoisting the pipelines to two pipeline supports on the edge of the plant, then the hoisted pipelines are connected with the hoisted pipelines in an air opening-to-opening mode, and then the pipelines are dragged by the winch to slide to preset positions along the supports. And repeatedly hoisting, aligning, welding and sliding the pipeline section by section until the whole pipeline slides in place. The technical problems that in the high-altitude installation process of a large-diameter pipeline which is limited by the space of an old plant and cannot be covered by hoisting machinery, the opening alignment difficulty is large, the operation risk is high, and the construction period is long are successfully solved.

Description

Technical Field

[0001] This invention patent relates to the field of building engineering, and in particular to a method for aerial alignment and overall sliding installation of large-diameter pipes on factory roofs. Background Technology

[0002] With social development and economic progress, an increasing number of old factories are facing the need for renovation and upgrading. Most of these factories were built in the 20th century, and their structures and facilities can no longer meet the demands of modern industrial production. Renovation can optimize production processes and improve efficiency. Specifically, it can involve replanning the spatial layout to improve space utilization; updating equipment and technology to improve production efficiency and quality; and adding production lines to increase output value. Therefore, the renovation of old factories has become an indispensable part of modern industrial development.

[0003] Taking the ultra-low emission retrofit of steelmaking projects as an example, the main method is to transform the traditional OG method primary dust removal into a new dry method primary dust removal, and to adopt a coal-cooled pre-installation process to reduce pollutant emissions. Because steelmaking workshops are compactly laid out and the diameter of the dust removal pipes is very large, many ultra-low emission pipes in steelmaking projects are installed on the roof of the steel plant building, which also brings great difficulty to the installation of the dust removal pipes.

[0004] The conventional installation approach is to assemble the dust collection pipes on the ground and then use cranes to hoist them to the roof. However, this method can only be used when the dust collection pipes and the factory building are being constructed simultaneously. For existing factory buildings, the dust collection pipes are too far from the roof to be directly hoisted into place.

[0005] A second, conventional installation approach involves assembling the dust collection pipes inside the factory building and then installing a mast on the roof for hoisting. However, this method is difficult to implement, involves unconventional hoisting techniques, requires the removal of corresponding roof tiles and purlins, has a long construction period, and disrupts normal production within the factory. Another approach is to install temporary support frames and sliding tracks on the roof, hoisting the pipes section by section onto the tracks for assembly and welding. However, this method increases the amount of pipe alignment and welding work on the roof, requires frequent use of lifting machinery, is costly, and poses significant safety risks. Summary of the Invention

[0006] To address the aforementioned technical challenges, this invention proposes an "aerial alignment" and "integrated sliding" installation method. This method involves hoisting prefabricated pipes to the roof and then sequentially connecting and sliding them to their installation positions, achieving efficient and safe installation of large-diameter pipes. This approach avoids large-scale high-altitude operations and roof modifications, does not interfere with normal production operations within the factory, significantly shortens the construction period, and reduces construction risks. It is particularly suitable for installing large-diameter pipes on the roofs of existing factory buildings.

[0007] The present invention adopts the following technical solution:

[0008] A method for aerial alignment and integral sliding installation of large-diameter pipes on factory roofs includes the following steps:

[0009] Step 1: Install a traction winch at the end of the roof dust removal duct, extend the traction winch wire rope along the roof to the starting point of the duct installation, and connect it to the first section of the duct.

[0010] Step 2: Weld two blocks to the upper surface of the upper crossbeam of the existing pipe support on the roof of the steel structure factory building. The two blocks are symmetrically arranged at both ends of the upper crossbeam to limit the lateral displacement of the pipe during the sliding process.

[0011] Step 3: Assemble and weld the dust removal pipes on the ground, and complete the pipe reinforcement. After the welds have cooled, conduct non-destructive testing to confirm that the quality is up to standard.

[0012] Step 4: Position the lifting machinery on the ground on one side of the factory building to hoist the pipe between the two blocks on the two old pipe supports at the edge of the factory building, so that the pipe axis is basically aligned with the installation axis;

[0013] Step 5: Next, hoist the dust removal pipe and connect it to the dust removal pipe on the old pipe support in the air. Use the high-altitude connection method to adjust the concentricity and gap of the two pipe sections to meet the docking requirements and ensure docking accuracy.

[0014] Step 6: Adjust the pipe level and connection accuracy, complete the welding and fixing, and then use a traction winch to slide the dust removal pipe along the old pipe support to the predetermined position;

[0015] After each section is slid, the next section of pipe is hoisted and welded together, and the operation is repeated until the entire pipe is accurately in place.

[0016] Step 7: Repeat steps 5 and 6, hoisting, aligning, welding, and sliding the pipeline section by section until the entire pipeline is slid into place.

[0017] Step 8: Remove the block to complete the final fixing of the pipeline and the closure of the system.

[0018] In a preferred embodiment, the traction winch is connected as a whole by I-beams and roof purlins of the factory building, serving as the base of the traction winch to enhance its stability during traction and prevent the traction winch from shifting.

[0019] In a preferred embodiment, the pipe reinforcing ribs should be arranged according to the design drawings and installed on the upper part of the pipe on the non-slip surface to ensure structural strength. The pipe reinforcing ribs on the slip surface should be installed after they have slid into place.

[0020] In a preferred embodiment, when the dust removal pipe is horizontally connected, when the hoisted dust removal pipe is connected to the dust removal pipe on the old pipe support in the air, the pipe opening gap and concentricity are corrected by adjusting screws and positioning clamps to ensure that the connection accuracy meets the specifications.

[0021] In a preferred embodiment, when the dust removal pipes are connected at an inclined angle, when the hoisted dust removal pipes are connected to the dust removal pipes on the old pipe supports in the air, the pipe openings and concentricity are corrected using a docking clamp.

[0022] The docking fixture includes a movable frame with casters at the bottom. A fixed plate is mounted on the movable frame, and multiple hydraulic claws are mounted on the outer side of the fixed plate. A spherical seat is located in the center of the fixed plate, and side pressure plates mounted on the fixed plate are located on both sides of the spherical seat. The side pressure plates constrain the spherical seat to the center of the fixed plate and allow the spherical seat to rotate freely between the two side pressure plates. A sliding rod is slidably inserted inside the spherical seat. A fixed plate is mounted on one end of the sliding rod, and multiple hydraulic claws are mounted on the fixed plate. A connecting plate is mounted on the other end of the sliding rod, and multiple hydraulic telescopic arms are mounted on the connecting plate. Traction wheels are mounted on the hydraulic telescopic arms.

[0023] In a preferred embodiment, before docking, at least two sets of fixing straps are installed on the outside of the dust removal pipe on the old pipe support. Multiple guide wheel seats are evenly distributed on the fixing straps, and the two ends of the fixing straps are respectively fixed to the top two ends of the old pipe support.

[0024] During the docking, the mobile frame is pre-installed inside the dust removal pipe of the old pipe support. The position of the mobile frame is adjusted to the bottom end of the dust removal pipe. The hydraulic claw on the fixed plate is then fixed inside the dust removal pipe of the old pipe support.

[0025] The lifting machinery hoists the dust removal pipe to the outside of the fixed plate two extending from the center of the spherical seat in a free state. The hydraulic claw two extends outward to fix the inside of the hoisted dust removal pipe. Then the lifting machinery steadily moves the dust removal pipe and the internal fixed plate two together toward the old pipe support at the edge of the roof until one end of the hoisted dust removal pipe sits on the old pipe support. The lifting machinery is used to adjust the posture of the hoisted dust removal pipe so that the tilt angle of the hoisted dust removal pipe is 1-5° greater than the tilt angle of the dust removal pipe on the old pipe support.

[0026] The hydraulic telescopic boom extends outward to abut the traction wheel against the inner wall of the dust removal pipe on the old pipe support, completing the concentricity correction. Then the traction wheel pulls the hoisted dust removal pipe to the end for fitting.

[0027] After welding assembly, hydraulic jaw one and hydraulic jaw two are retracted, the traction wheel adjusts the moving frame to the bottom position of the dust removal pipe, hydraulic jaw one extends outward again to fix the dust removal pipe, and the traction winch slides the dust removal pipe along the old pipe support to the predetermined position.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] This invention patent relates to a method for installing large-diameter pipes on factory roofs using "aerial alignment" and "integral sliding," belonging to the field of building assembly technology. By installing a winch on the factory roof, the pipes are assembled and welded on the ground. A crane is then used to hoist the pipes onto two pipe supports at the edge of the factory. The hoisted pipes are then aligned with the already hoisted pipes in the air. The winch then pulls the pipes along the supports to a predetermined position. This process of hoisting, aligning, welding, and sliding the pipes is repeated segment by segment until the entire pipe is in place. This invention patent successfully solves the technical challenges of difficult alignment, high operational risks, and long construction periods during the high-altitude installation of large-diameter pipes in old factory buildings where space is limited and cranes cannot reach. It significantly improves assembly accuracy and construction safety, increases construction efficiency, and reduces reliance on lifting equipment and overall construction costs. It is suitable for the rapid and efficient installation of large pipes in various industrial plants. It is particularly suitable for the expansion or renovation of existing factories, effectively avoiding interference with existing production lines. By optimizing the construction process, traditional high-altitude operations are transformed into ground assembly and low-altitude docking. Combined with modular prefabrication technology, it enables segmented prefabrication of pipelines, ground assembly, and overall sliding positioning, ensuring installation accuracy and controlling weld quality throughout the process, effectively guaranteeing construction quality and safety. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the aerial connection and overall sliding elevation of the pipeline of the present invention. Figure 1 .

[0031] Figure 2 This is a schematic diagram of the aerial connection and overall sliding plane of the pipeline according to the present invention.

[0032] Figure 3 This is a schematic diagram of the block and reinforcing rib of the present invention.

[0033] Figure 4 This is a schematic diagram of the aerial connection and overall sliding elevation of the pipeline of the present invention. Figure 2 .

[0034] Figure 5 This is a working diagram of the docking clamp of the present invention inside a pipeline.

[0035] Figure 6 This is a side view of the docking clamp of the present invention. Detailed Implementation

[0036] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0037] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0038] like Figures 1 to 3 As shown, a method for aerial alignment and integral sliding installation of large-diameter pipes on a factory roof includes the following steps:

[0039] Step 1: Install a traction winch 1 at the end of the roof dust removal pipe, extend the steel wire rope of the traction winch 1 along the roof to the starting point of the pipe installation, and connect it to the first section of the pipe.

[0040] Step 2: Weld two blocks 7 onto the upper surface of the upper crossbeam of the existing pipe support 2 on the roof of the steel structure factory building. The two blocks 7 are symmetrically arranged at both ends of the upper crossbeam to limit the lateral displacement of the pipe during the sliding process. Roller sets can be installed on the top of the upper crossbeam according to site requirements to facilitate pipe pulling. The roller sets can be removed after the pipe is installed.

[0041] Step 3: Assemble and weld the dust removal pipes on the ground, and complete the pipe reinforcement ribs 6. After the welds have cooled, conduct non-destructive testing to confirm that the quality is up to standard.

[0042] Step 4: Position the crane 8 on the ground on one side of the factory building and hoist the pipe between the two blocks 7 on the two old pipe supports 2 at the edge of the factory building, so that the pipe axis is basically aligned with the installation axis.

[0043] Step 5: Next, hoist the dust removal pipe 5-2 and connect it to the dust removal pipe 5-1 on the old pipe support in the air. Use the high-altitude connection method to adjust the concentricity and gap of the two pipe sections to meet the docking requirements and ensure docking accuracy.

[0044] Step 6: Adjust the pipe level and connection accuracy, complete the welding and fixing, and then use a traction winch to slide the dust removal pipe along the old pipe support to the predetermined position;

[0045] After each section is slid, the next section of pipe is hoisted and welded together, and the operation is repeated until the entire pipe is accurately in place.

[0046] Step 7: Repeat steps 5 and 6, hoisting, aligning, welding, and sliding the pipeline section by section until the entire pipeline is slid into place;

[0047] Step 8: Remove block 7 to complete the final fixing of the pipeline and the closure of the system.

[0048] The traction winch 1 is connected as a whole by I-beams and roof purlins of the factory building, which serve as the base of the traction winch 1 to enhance its stability during the traction process and prevent the traction winch from shifting.

[0049] The aforementioned pipe reinforcing ribs 6 should be arranged according to the design drawings and installed on the upper part of the pipe on the non-slip surface to ensure structural strength. The pipe reinforcing ribs on the slip surface should be installed after they have slid into place.

[0050] When the dust removal pipes are horizontally connected, when the hoisted dust removal pipe 5-2 is connected to the dust removal pipe 5-1 on the old pipe support in the air, the pipe opening gap and concentricity are corrected by adjusting screws and positioning clamps to ensure that the connection accuracy meets the specifications.

[0051] like Figures 4 to 6 As shown, when the dust removal pipes are connected at an inclined angle, when the hoisted dust removal pipe 5-2 is connected to the dust removal pipe 5-1 on the old pipe support in the air, the pipe openings and concentricity are corrected by the docking clamp.

[0052] The docking fixture includes a movable frame 2, with movable wheels 2-1 at its bottom. A fixed plate 2-2 is mounted on the movable frame 2. Multiple hydraulic jaws 2-3 are mounted on the outer side of the fixed plate 2-2. A spherical seat 2-4 is positioned in the center of the fixed plate 2-2. Side pressure plates 2-5, mounted on the fixed plate 2-2, are positioned on both sides of the spherical seat 2-4. The side pressure plates 2-5 constrain the spherical seat 2-4 to the center of the fixed plate 2-2. The spherical seat 2-4 is axially slidably inserted with a sliding rod 2-6. One end of the sliding rod 2-6 is equipped with a fixed plate 2-11. Multiple hydraulic claws 2-7 are installed on the fixed plate 2-11. The other end of the sliding rod 2-6 is equipped with a connecting plate 2-8. Multiple hydraulic telescopic arms 2-9 are provided on the connecting plate 2-8. Traction wheels 2-10 are provided on the hydraulic telescopic arms 2-9. At least one of the traction wheels 2-10 is equipped with a servo drive motor.

[0053] Before docking, at least two sets of fixing straps 4 are installed on the outside of the dust removal pipe 5-1 on the old pipe support 3, and distributed as far as possible at both ends of the dust removal pipe. Multiple guide wheel seats 4-1 are evenly distributed on the fixing straps 4. Multiple guide wheel seats and wheels on them are used to ensure that the pipe does not tilt or deviate during docking. The two ends of the fixing straps 4 are fixed to the two ends of the upper crossbeam of the old pipe support.

[0054] During docking, the movable frame 2 is pre-installed in the dust removal pipe 5-1 of the old pipe support, and the position of the movable frame 2 is adjusted to the bottom end of the dust removal pipe. The hydraulic claw 2-3 on the fixed plate 2-2 is fixed in the dust removal pipe on the old pipe support 3.

[0055] The lifting machinery hoists the dust removal pipe to the outside of the fixed plate 2 extending from the center of the spherical seat 2-4 in a free state. The hydraulic claw 2-7 extends outward to fix the inside of the hoisted dust removal pipe 5-1. Then the lifting machinery steadily moves the dust removal pipe and the internal fixed plate 2-11 towards the old pipe support 3 at the edge of the roof until one end of the hoisted dust removal pipe sits on the old pipe support 3. The lifting machinery is used to adjust the posture of the hoisted dust removal pipe until the tilt angle of the hoisted dust removal pipe 5-2 is 1-5° greater than the tilt angle of the dust removal pipe 5-1 on the old pipe support 3.

[0056] The hydraulic telescopic boom 2-9 extends outward to abut the traction wheel 2-10 against the inner wall of the dust removal pipe 5-1 on the old pipe support 3 to complete the concentricity correction. Then the traction wheel 2-10 pulls the hoisted dust removal pipe 5-1 until the end is attached.

[0057] After welding assembly, hydraulic claw 1 2-3 and hydraulic claw 2 2-7 are retracted, traction wheel 2-10 adjusts the moving frame 2 to the bottom position of the dust removal pipe, hydraulic claw 1 2-3 extends outward again to fix the dust removal pipe, and traction winch 1 slides the dust removal pipe along the old pipe support 3 to the predetermined position.

[0058] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. The substitutions may be replacements of some structures, devices, or method steps, or they may be complete technical solutions. Equivalent substitutions or modifications made to the technical solutions and inventive concepts of the present invention should all be covered within the scope of protection of the present invention.

Claims

1. A method for factory roof large diameter pipe aerial butt and integral sliding installation, characterized in that, The method comprises the following steps: Step one: a traction hoist is arranged at the end of the roof dust removal pipeline, the steel wire rope of the traction hoist is extended along the roof to the pipeline installation starting point and connected with the first pipeline; Step two: two stop blocks are welded on the upper surface of the upper beam of the old pipeline support on the steel structure roof, the two stop blocks are symmetrically arranged at the two ends of the upper beam and used for limiting the lateral deviation of the pipeline during sliding; Step three: the dust removal pipeline is assembled and welded on the ground, the pipeline reinforcing rib is improved, and after the welding seam is cooled, nondestructive testing is performed to confirm that the quality is qualified; Step four: the pipeline is hoisted to the space between the two stop blocks on the two old pipeline supports at the edge of the factory building by the ground-based hoisting machinery, so that the pipeline axis is basically aligned with the installation axis; Step five: then the hoisted dust removal pipeline is connected with the dust removal pipeline on the old pipeline support in the air, the concentricity and gap of the two pipelines are adjusted to meet the butt joint requirements by using the high-altitude butt joint method, and the butt joint accuracy is ensured; Step six: the pipeline levelness and butt joint accuracy are adjusted, welding and fixing are completed, and then the dust removal pipeline is slid along the old pipeline support to the predetermined position by the traction hoist; Every time a section is slid, the hoisting and butt joint welding of the next section of the pipeline are performed, and the cycle operation is performed until the whole pipeline is accurately positioned; Step seven: steps five and six are repeated, and the pipeline is hoisted, butt jointed, welded and slid section by section until the whole pipeline is slid and positioned. Step eight: the stop blocks are removed, and the final fixing and system sealing of the pipeline are completed.

2. The method according to claim 1, wherein, The traction hoist is connected with the I-shaped steel and the roof purlin to form a whole, and is used as the base of the traction hoist to enhance the stability during traction and prevent the traction hoist from moving.

3. The method of claim 1, wherein, The pipeline reinforcing rib should be arranged according to the design drawing, and is installed on the upper part of the pipeline on the non-sliding surface to ensure the structural strength, and the reinforcing rib of the pipeline on the sliding surface is supplemented after being slid to the position.

4. The method of claim 1, wherein, When the dust removal pipeline is horizontally butt jointed, the gap and concentricity between the pipe openings are corrected by using the adjusting screw and the positioning fixture when the hoisted dust removal pipeline is connected with the dust removal pipeline on the old pipeline support in the air, so that the butt joint accuracy meets the specification requirements.

5. The method of aligning and installing large diameter roof pipes in the air according to claim 1, characterized in that, When the dust removal pipeline is butt jointed at an inclination angle, the pipe opening and the concentricity are corrected by using the butt joint fixture when the hoisted dust removal pipeline is connected with the dust removal pipeline on the old pipeline support in the air; The butt joint fixture comprises a moving frame, a plurality of hydraulic clamping jaws one are arranged on the outer side of a fixing disc one, a spherical seat is arranged in the middle of the fixing disc one, a side pressing disc is arranged on the fixing disc one on the two sides of the spherical seat, the side pressing disc is used for constraining the spherical seat in the middle of the fixing disc one, the spherical seat can rotate freely between the two side pressing discs, a sliding rod is slidably inserted into the spherical seat, a fixing disc two is arranged at one end of the sliding rod, a plurality of hydraulic clamping jaws two are arranged on the fixing disc two, a connecting disc is arranged at the other end of the sliding rod, a plurality of hydraulic telescopic arms are arranged on the connecting disc, and a traction wheel is arranged on the hydraulic telescopic arm.

6. A method of factory roof large diameter pipe aerial butt and monolithic slip installation according to claim 1, characterized in that, Before butt joint, at least two groups of fixing belts are arranged outside the dust pipe on the old pipe support, a plurality of guide wheel group seats are uniformly distributed on the fixing belts, and two ends of the fixing belts are fixed at top end positions of the old pipe support; During butt joint, the movable frame is arranged in the dust pipe of the old pipe support in advance, the position of the movable frame is adjusted to the bottom end port position of the dust pipe, and the hydraulic claw one on the fixing disc one is fixed in the dust pipe on the old pipe support; The hoisting machinery hoists the dust pipe to the outside of the fixing disc two extending outside the center of the spherical seat in the free state, the hydraulic claw two extends outward to fix the inside of the hoisted dust pipe, then the hoisting machinery stably approaches the dust pipe and the fixing disc two in the dust pipe to the old pipe support close to the roof edge position, until one end of the hoisted dust pipe is arranged on the old pipe support, the posture of the hoisted dust pipe is adjusted by the hoisting machinery, and the inclination angle of the hoisted dust pipe is greater than that of the dust pipe on the old pipe support by 1-5°; The hydraulic telescopic arm extends outward to abut the traction wheel on the inner wall of the dust pipe on the old pipe support, the concentricity correction is completed, then the traction wheel pulls the hoisted dust pipe to the port abutment; After the welding group is arranged, the hydraulic claw one and the hydraulic claw two are recovered, the traction wheel adjusts the movable frame to the bottom end position of the dust pipe, the hydraulic claw one is extended outward to fix the dust pipe again, and the traction winch slides the dust pipe along the old pipe support to the predetermined position.

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