Blast furnace hot blast valve rapid replacement device and method

Abstract

The invention relates to a device and a method for quickly replacing a blast furnace hot blast valve. The device comprises an auxiliary beam support, a separated hydraulic jack and a stress application connecting rod, the number of the auxiliary beam supports is eight, four auxiliary beam supports are welded to the outer walls of the adjacent sides of the two pipelines in the circumferential direction, the four auxiliary beam supports on the outer walls of the two pipelines correspond to one another, and every two auxiliary beam supports form a group. The stress application connecting rods are respectively arranged between the corresponding groups of auxiliary beam supports; the separated hydraulic jacks are correspondingly arranged on one sides of the stress application connecting rods, and the output ends of the separated hydraulic jacks are connected with one ends of the stress application connecting rods. The system is high in response speed, the replacement efficiency can be effectively improved, the regular repair time completion rate is reduced, the production process performance is ensured, the daily maintenance cost is reduced, the operation safety is improved, effective reference and solutions are provided for replacement, first-aid repair and hidden danger treatment of valves of the same type, and popularization and guidance values are achieved.

Description

Technical Field

[0001] This invention relates to the technical field of mechanical equipment supporting blast furnace air supply systems, and in particular to a quick replacement device and method for blast furnace hot blast valves. Background Technology

[0002] In recent years, my country's blast furnace ironmaking technology has been developing rapidly, and the technology and equipment have been continuously upgraded and transformed. With the increase in blast furnace volume, the specifications and volume of various supporting equipment, components, valves and other facilities have also increased accordingly, and the difficulty of maintenance, repair and spare parts replacement has also increased.

[0003] The main equipment in the ironmaking process includes: the blast furnace body, furnace top charging equipment, tapping equipment, slag treatment, air supply facilities, and environmental dust removal systems. The air supply facilities mainly include: hot blast stoves, blowers, and various valves, which are further subdivided into combustion valves, shut-off valves, and hot blast valves. Among these, hot blast valves, due to their frequent operation, large size (internal diameter approximately 1700mm), and long-term exposure to high temperatures (approximately 1200℃), have a relatively high failure rate and replacement frequency. Furthermore, due to the special nature of the process, the pipes contain a large amount of grouting material and refractory bricks, making replacement more difficult than replacing other types of valves.

[0004] Therefore, there is an urgent need to design a quick replacement device for hot air valves to solve a series of problems such as difficulty in replacing hot air valves and other large valves in hot air furnaces, low operating efficiency, and overdue scheduled maintenance. Summary of the Invention

[0005] To address the aforementioned problems, the present invention aims to provide a rapid replacement device and method for blast furnace hot blast valves. This device and method offer a fast response time, effectively improving operational efficiency, reducing scheduled maintenance completion rates, ensuring production process performance, reducing daily maintenance costs, and enhancing operational safety. It also provides effective reference and solutions for the replacement, emergency repair, and handling of potential hazards of similar valves, and has widespread application and guiding value.

[0006] The technical solution adopted in this invention is as follows: The present invention proposes a quick replacement device for a blast furnace hot blast valve, comprising auxiliary beam supports, detachable hydraulic jacks, and force-applying connecting rods; eight auxiliary beam supports are provided, with four auxiliary beam supports welded circumferentially on the outer wall of each of two adjacent pipes, and the four auxiliary beam supports on the outer wall of each pipe corresponding to each other, forming a group of two; the force-applying connecting rods are respectively arranged between the corresponding groups of auxiliary beam supports; the detachable hydraulic jacks are respectively arranged on one side of the force-applying connecting rods, and their output ends are connected to one end of the force-applying connecting rods.

[0007] Furthermore, the auxiliary beam support consists of a positioning plate and triangular plates fixed side by side to the outside of the positioning plate; the bottoms of the positioning plate and the triangular plates are welded and fixed perpendicularly to the outer wall of the pipe.

[0008] Furthermore, the set square is a right triangle.

[0009] Furthermore, the initial position of the auxiliary beam support is selected based on the horizontal direction of the circular cross-section of the hot air valve pipe. Two mutually perpendicular diameters are drawn inside the pipe circle. Tangents to the circle are drawn through the endpoints of each diameter. The four tangents intersect to form a square. The four corners of this square are the basic stress areas, ensuring that the stress is evenly distributed at the four points.

[0010] Furthermore, the auxiliary beam supports are located at the four corners of a square formed by connecting four tangents; and the outer diameter of the hot air valve is not greater than the distance between the two beam supports above the pipe.

[0011] A method for quick replacement of a blast furnace hot blast valve, the method comprising the following steps: S1. First, weld the auxiliary beam supports onto the surfaces of the pipes on both sides of the hot air valve to be replaced as required, with 4 pieces on the left pipe and 4 pieces on the right pipe, and the auxiliary beam supports on the left and right sides are arranged accordingly. S2. Arrange four separate hydraulic jacks inside the four auxiliary beam supports on one side of the hot air valve, ensuring that the output direction of the jacks is consistent. At the same time, place four force-applying rods between the jacks and the four auxiliary beam supports on the other side. During the process, ensure that the center lines of the jacks and the force-applying rods are consistent in the horizontal direction. Operate the four jacks to apply force simultaneously. As the stroke of the jacks increases, the auxiliary beam supports on the left and right sides of the hot air valve, the force-applying rods in the middle, and the jack body maintain a certain pressure balance. The position is then fixed. S3 and four jacks apply force simultaneously. As the stroke of the jacks continues to increase, the auxiliary beams on both sides expand outwards, which in turn drives the pipes on both sides of the hot air valve to move in the opposite direction of the hot air valve. When the distance between the two ends of the pipes is greater than the thickness of the hot air valve body, the hot air valve no longer bears the clamping force of the pipes on both sides and has enough space to move freely. S4. At this time, operate the overhead crane above the hot air valve to complete the quick lifting of the hot air valve. S5. Under the condition that the original hot air valve is hoisted out and the working conditions remain unchanged, use an overhead crane to hoist the new spare hot air valve into the original hot air valve position and align it with the pipes on both sides. Simultaneously depressurize the four jacks and remove the jacks and the force-reducing rod. S6. Tighten or weld the flange bolts of the hot air valve to complete the quick replacement of the hot air valve.

[0012] Compared with the prior art, the present invention has the following beneficial effects: 1. Improve the replacement efficiency of blast furnace hot blast valves, reduce the completion rate of scheduled maintenance, and reduce maintenance costs; 2. Create advanced operating methods, improve operating skills, enhance the convenience of inspection and maintenance, and create the best economic benefits; 3. Effectively reduces resource waste and maintenance overtime, and can inspire the efficiency of large valve replacement in similar blast furnace production lines, which has popularization and guidance value. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of a quick replacement device for a blast furnace hot blast valve proposed in this invention. Figure 2 for Figure 1 A schematic diagram showing the relative positions of the hot air valve, pipes, and auxiliary beam supports; Figure 3 A schematic diagram of the structural points for supporting the beam; Figure 4 A schematic diagram of the auxiliary beam support structure; Figure 5 This is a schematic diagram illustrating the stress on the auxiliary beam support.

[0014] In the attached drawings, the following labels are used: 1-Auxiliary beam support; 11-Positioning plate; 12-Triangle plate; 2-Separable hydraulic jack; 3-Force-adding rod; 4-Pipeline; 5-Hot air valve. Detailed Implementation

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] It should be noted that in the description of this invention, the terms "upper", "lower", "top", "bottom", "one side", "the other side", "left", "right", 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 mean that the device or element must have a specific orientation, or be constructed and operated in a specific orientation.

[0017] See appendix Figures 1-4The present invention proposes a quick replacement device for a blast furnace hot blast valve, comprising an auxiliary beam support 1, a detachable hydraulic jack 2, and a force-adding rod 3. There are eight auxiliary beam supports 1 in total, with four auxiliary beam supports 1 welded circumferentially on the outer wall of each of two adjacent pipes 4, and the four auxiliary beam supports 1 on the outer wall of each pipe 4 corresponding to each other and forming a pair. The force-adding rod 3 is respectively positioned between corresponding pairs of auxiliary beam supports 1 on the two pipes 4. The detachable hydraulic jack 2 is a 50t or 100t detachable jack, which is respectively positioned on the left side of the force-adding rod 3, and the output end of the detachable hydraulic jack 2 is connected to the left end of the corresponding force-adding rod 3.

[0018] The auxiliary beam support 1 (commonly known as the corbel) is an additional support added during routine valve replacement operations. Its function is to distribute the force to the structure below, prevent stress concentration, and improve the stability of the valve replacement process.

[0019] In this embodiment, the auxiliary beam support 1 consists of a positioning plate 11 and three triangular plates 12 fixedly connected side-by-side to the outside of the positioning plate 11; the bottoms of the positioning plate 11 and the triangular plates 12 are welded and fixed perpendicularly to the outer wall of the pipe 4. The triangular plates 12 are right triangles, which effectively improve overall stability. Figure 4 As shown.

[0020] like Figure 3 As shown, the initial position of the auxiliary beam support 1 is selected based on the horizontal direction of the circular cross-section of the hot air valve pipe 4. Two mutually perpendicular diameters are drawn inside the circle of pipe 4, and tangents to the circle are drawn through the endpoints of each diameter. The four tangents intersect to form a square, and the four corners of this square form the basic stress area, ensuring that the stress is evenly distributed at four points. The points of the auxiliary beam support 1 are located at the four corner areas of the square formed by the four tangents; and the outer diameter of the hot air valve 5 is not greater than the distance between the two auxiliary beam supports 1 above the pipe.

[0021] The specific location of the auxiliary beam support 1 can be represented by four dispersed circular points. Each circular point is positioned away from the outer circle of the hot air valve 5. The two upper horizontal circular points are connected to the outer circle of the hot air valve 5 by an outer common tangent 1; the two lower circular points are connected to the outer circle of the hot air valve 5 by an outer common tangent 2; simultaneously, the two upper and lower circular points on the left are connected to the outer circle of the hot air valve 5 by an inner common tangent 1; and the two upper and lower circular points on the right are connected to the outer circle of the hot air valve 5 by an inner common tangent 2. This positioning relationship ensures that the outer diameter of the hot air valve 5 is no greater than the distance between the two auxiliary beam supports 1 above the pipe, facilitating hoisting.

[0022] A method for quick replacement of a blast furnace hot blast valve, the method comprising the following steps: S1. First, weld the auxiliary beam supports onto the surfaces of the pipes on both sides of the hot air valve to be replaced as required, with 4 pieces on the left pipe and 4 pieces on the right pipe, and the auxiliary beam supports on the left and right sides are arranged accordingly. S2. Arrange four separate hydraulic jacks inside the four auxiliary beam supports on one side of the hot air valve, ensuring that the output direction of the jacks is consistent. At the same time, place four force-applying rods between the jacks and the four auxiliary beam supports on the other side. During the process, ensure that the center lines of the jacks and the force-applying rods are consistent in the horizontal direction. Operate the four jacks to apply force simultaneously. As the stroke of the jacks increases, the auxiliary beam supports on the left and right sides of the hot air valve, the force-applying rods in the middle, and the jack body maintain a certain pressure balance. The position is then fixed. S3 and four jacks apply force simultaneously. As the stroke of the jacks continues to increase, the auxiliary beams on both sides expand outwards, which in turn drives the pipes on both sides of the hot air valve to move in the opposite direction of the hot air valve. When the distance between the two ends of the pipes is greater than the thickness of the hot air valve body, the hot air valve no longer bears the clamping force of the pipes on both sides and has enough space to move freely. S4. At this time, operate the overhead crane above the hot air valve to complete the quick lifting of the hot air valve. S5. Under the condition that the original hot air valve is hoisted out and the working conditions remain unchanged, use an overhead crane to hoist the new spare hot air valve into the original hot air valve position and align it with the pipes on both sides. Simultaneously depressurize the four jacks and remove the jacks and the force-reducing rod. S6. Tighten or weld the flange bolts of the hot air valve to complete the quick replacement of the hot air valve.

[0023] Due to the tight schedule for replacing the hot air valve, it was required to be replaced before the hot air furnace had completely cooled down to room temperature. The hot air valve and its connecting pipes were in a state of high-temperature thermal expansion, causing the pipes on both sides of the valve to be squeezed and tightly connected to the valve body, making normal replacement impossible. By adopting the solution of this invention, auxiliary beam supports are prefabricated and welded at appropriate positions. Jacks are used to effectively separate the pipes on both sides. Due to limitations in jack stroke and space, direct use is not possible; therefore, connecting rods are added to extend the jack stroke. Similarly, because the space and pipe surfaces are smooth and have no protrusions as stress points, additional auxiliary beam supports are fabricated to support the jacks and the connecting rods.

[0024] Once the positional relationship between the auxiliary beam support 1 and the pipe 4 is determined, the height at which the split hydraulic jack 2 applies a horizontal thrust to the auxiliary beam support 1 also needs to be determined. Specifically, when a horizontal thrust is applied from the left, the force on the auxiliary beam support 1 changes. Due to the thrust, the auxiliary beam support 1 tends to flip to the right around the bottom welded area. At this time, the clamping force between the pipes 4 and the hot air valve 5 is no longer uniformly distributed, but forms a couple relationship. Without applying sufficient thrust to cause actual displacement of the pipe, the thrust is mainly concentrated on the auxiliary beam support 1, and the stress is concentrated in the weld area between the auxiliary beam support 1 and the pipe 4, resulting in slight deformation over time. To limit the aggravation of deformation, the height of the horizontal thrust applied from the left needs to be further determined, such as... Figure 5 As shown: (1) When the horizontal thrust is F3 and the height of the action is h3 from the surface of the pipe 4, the torque is the largest, the weld joint bears a large stress, the danger is greater, and it is not conducive to reuse.

[0025] (2) When the horizontal thrust is F2 and the working height moves downward to a distance of h2 from the surface of pipe 4, the thrust and welding stress are relatively balanced, and the deformation is reduced, but it is not an ideal working area.

[0026] (3) When the horizontal thrust is F1, the height of action is less than h2, and it is infinitely close to the surface h1 of pipe 4, the torque is theoretically the smallest and the effort is the least, but it is inconvenient to operate due to space limitations and cannot be realized.

[0027] In summary, when the height of the support point is less than half of the moment, and the distance between the two auxiliary beam support points 1 above is not less than the diameter of the hot air valve 5, that is, it does not hinder the crane from hoisting the hot air valve 5 up and down, the required force is minimal and the operation is the most labor-saving.

[0028] Matters not covered in this invention are common knowledge.

[0029] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A quick-change device for blast furnace hot blast valves, characterized in that: The device includes auxiliary beam supports, detachable hydraulic jacks, and force-applying connecting rods. Eight auxiliary beam supports are provided, with four auxiliary beam supports welded circumferentially on the outer wall of each of the two adjacent pipes, and the four auxiliary beam supports on the outer walls of the two pipes correspond to each other, forming a pair. The force-applying connecting rods are respectively positioned between corresponding pairs of auxiliary beam supports. The detachable hydraulic jacks are respectively positioned on one side of the force-applying connecting rods, and their output ends are connected to one end of the force-applying connecting rod.

2. The quick replacement device for a blast furnace hot blast valve according to claim 1, characterized in that: The auxiliary beam support consists of a positioning plate and triangular plates fixed side by side to the outside of the positioning plate; the bottoms of the positioning plate and the triangular plates are welded and fixed perpendicularly to the outer wall of the pipe.

3. The quick replacement device for a blast furnace hot blast valve according to claim 2, characterized in that: The set square is a right triangle.

4. The quick replacement device for a blast furnace hot blast valve according to claim 1, characterized in that: The initial position of the auxiliary beam support is selected based on the horizontal direction of the circular cross-section of the hot air valve pipe. Two mutually perpendicular diameters are drawn inside the pipe circle. Tangents to the circle are drawn through the endpoints of each diameter. The four tangents intersect to form a square. The four corners of this square are the basic stress areas, ensuring that the stress is evenly distributed at the four points.

5. A quick-change device for a blast furnace hot blast valve according to claim 4, characterized in that: The auxiliary beam supports are located at the four corners of a square formed by connecting four tangents; and the outer diameter of the hot air valve is not greater than the distance between the two beam supports above the pipe.

6. A method for quickly replacing a blast furnace hot blast valve, implemented using the quick replacement device for a blast furnace hot blast valve as described in claim 5, characterized in that: The method includes the following steps: S1. First, weld the auxiliary beam supports onto the surfaces of the pipes on both sides of the hot air valve to be replaced as required, with 4 pieces on the left pipe and 4 pieces on the right pipe, and the auxiliary beam supports on the left and right sides are arranged accordingly. S2. Arrange four separate hydraulic jacks inside the four auxiliary beam supports on one side of the hot air valve, ensuring that the output direction of the jacks is consistent. At the same time, place four force-applying rods between the jacks and the four auxiliary beam supports on the other side. During the process, ensure that the center lines of the jacks and the force-applying rods are consistent in the horizontal direction. Operate the four jacks to apply force simultaneously. As the stroke of the jacks increases, the auxiliary beam supports on the left and right sides of the hot air valve, the force-applying rods in the middle, and the jack body maintain a certain pressure balance. The position is then fixed. S3 and four jacks apply force simultaneously. As the stroke of the jacks continues to increase, the auxiliary beams on both sides expand outwards, which in turn drives the pipes on both sides of the hot air valve to move in the opposite direction of the hot air valve. When the distance between the two ends of the pipes is greater than the thickness of the hot air valve body, the hot air valve no longer bears the clamping force of the pipes on both sides and has enough space to move freely. S4. At this time, operate the overhead crane above the hot air valve to complete the quick lifting of the hot air valve. S5. Under the condition that the original hot air valve is hoisted out and the working conditions remain unchanged, use an overhead crane to hoist the new spare hot air valve into the original hot air valve position and align it with the pipes on both sides. Simultaneously depressurize the four jacks and remove the jacks and the force-reducing rod. S6. Tighten or weld the flange bolts of the hot air valve to complete the quick replacement of the hot air valve.

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