Method for manufacturing and installing large oil tank in basement

Abstract

The invention discloses a method for manufacturing and installing a basement large oil tank, and relates to the technical field of basement equipment manufacturing and installing. In order to reliably solve the transportation and installation bottlenecks of the oversized finished oil tank under the premise of not depending on segmented splicing, the invention provides the following technical scheme: the method comprises the following steps: S1, synchronously forming and reserving a secondary hoisting hole for penetrating and hoisting in a structural construction stage of a basement top plate; s2, the discrete raw materials which are subjected to surface treatment and form the oil tank are hoisted to a basement through the secondary hoisting holes, the maximum boundary dimension of the discrete raw materials is smaller than that of the finished oil tank, and the discrete raw materials are matched with the secondary hoisting holes; s3, the discrete raw materials are transferred to a preset installation position through carrying equipment in the basement; and S4, at the mounting position, the discrete raw materials are spliced and welded into a complete oil tank on site through cooperation of hoisting equipment and carrying equipment. According to the method, systematic optimization is realized in the aspects of implementability, economy, construction period control and project quality.

Description

Technical Field

[0001] This invention relates to the field of basement equipment manufacturing and installation technology, specifically to a method for manufacturing and installing a large fuel tank in a basement. Background Technology

[0002] In industries such as metallurgy and non-ferrous metals, key processes such as hot-rolled and cold-rolled emulsion systems and oil film lubrication systems often require large oil storage tanks installed in basements. These tanks, designed to meet process capacity requirements, are typically large in size and complex in structure. The term "large" oil tank specifically refers to those whose final overall dimensions (length, width, height) exceed the limits of conventional road transport vehicles or the allowable dimensions of pre-reserved passageways in buildings (such as factory gates or basement access holes), making it impossible to transport them from the factory to the construction site as a single unit. These tanks typically have a large volume (e.g., tens to hundreds of cubic meters). In current manufacturing and installation practices, a mainstream method is to manufacture the entire tank in a specialized factory and then transport it to the project site for overall hoisting. For example, the emulsion oil tank disclosed in patent CN205423357U employs this type of integrated manufacturing method.

[0003] Specifically, to meet functional zoning requirements, such as oil suction and return zones, and structural strength requirements, a rigidly welded box-type structure is typically adopted. This integrated design means that its length, width, and height are fixed after manufacturing. When the required tank volume increases, its overall dimensions easily exceed road transport limits or the dimensions of pre-reserved passageways in the basement, creating physical transportation obstacles between manufacturing completion and on-site placement. With the increasing size of equipment, tank dimensions often far exceed the height and width limits of conventional road transport, or are limited by the dimensions of pre-reserved passageways in the basement, such as doorways and hoisting holes, making it impossible to transport the finished tank from the factory to the construction site, or resulting in extremely high transportation costs. To circumvent this problem, existing technologies have introduced alternative solutions such as segmented manufacturing of the tank and on-site assembly, but this introduces new problems such as limited on-site welding conditions, difficulty in quality control, and complex process connections.

[0004] Therefore, the technical problem to be solved by the present invention is: how to overcome the inherent transportation size limitations of finished oil tanks in the existing integrated manufacturing mode, while avoiding the quality and process complexity caused by segmented splicing. Summary of the Invention

[0005] This invention provides a method for manufacturing and installing large fuel tanks in basements, aiming to reliably solve the bottleneck of transportation and installation of ultra-large finished fuel tanks without relying on segmented splicing.

[0006] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: A method for manufacturing and installing a large fuel tank in a basement includes the following steps: S1. During the structural construction phase of the concrete roof slab, a secondary hoisting hole for through hoisting is simultaneously formed and reserved. S2. The surface-treated discrete raw materials used to form the oil tank are hoisted into the basement through the secondary hoisting hole. The maximum external dimensions of the discrete raw materials are smaller than the finished oil tank and are compatible with the secondary hoisting hole. S3. Use handling equipment inside the basement to transfer discrete raw materials to the preset installation location; S4. At the installation location, use lifting and handling equipment to assemble and weld the discrete raw materials into a complete oil tank on site.

[0007] Furthermore, the discrete raw materials include structural steel and steel plates, which undergo rust removal and anti-corrosion coating treatment at the manufacturing plant. The rust removal treatment achieves a cleanliness level of Sa2.5, and the anti-corrosion coating treatment involves spraying an epoxy zinc-rich primer with a dry film thickness of not less than 60 μm.

[0008] Furthermore, the size of the secondary lifting hole is determined based on the maximum size of the discrete raw materials to ensure that all raw materials can pass through smoothly.

[0009] Furthermore, the lifting equipment is an electric hoist pre-installed on the basement roof slab.

[0010] Furthermore, the electric hoist is installed on a pre-set track below the basement ceiling.

[0011] Furthermore, the handling equipment is a forklift, suitable for transportation operations within the limited space of a basement.

[0012] Furthermore, on-site assembly includes the following steps: Use an electric hoist to lift and position the steel profiles; Use a forklift to assist in adjusting the posture of the steel profile; Welding forms the fuel tank frame structure; The steel plates were hoisted and welded to form the box body.

[0013] Furthermore, during the welding process, visual inspection and non-destructive testing of the weld seams are carried out to ensure the sealing performance and structural strength of the fuel tank. The non-destructive testing includes magnetic particle testing or liquid penetration testing of critical weld seams, and ultrasonic testing or radiographic testing of full penetration weld seams.

[0014] Furthermore, it also includes conducting a kerosene leakage test after the fuel tank is manufactured, with the test lasting no less than 24 hours.

[0015] Furthermore, the secondary hoisting hole in step S1 is a reserved hole originally designed for equipment maintenance and material hoisting.

[0016] The present invention has the following beneficial effects: First, this invention solves the transportation bottleneck of ultra-large finished fuel tanks. By breaking down the massive finished product into standardized steel sections and steel plate raw materials, it can be delivered to the site using conventional transportation tools. Vertical transport via pre-reserved lifting holes completely avoids the size limitations of roads and factory access routes, enabling the construction of large fuel tanks that were previously impossible to transport as a whole.

[0017] Secondly, this invention significantly simplifies the construction process, shortens the construction period, and reduces costs. This method eliminates the need for temporary protective supports erected / removed in traditional processes to protect the installed fuel tank, saving on labor and material costs. Simultaneously, by utilizing existing building hoisting holes and permanent electric hoists, it avoids the need for secondary drilling and sealing of the roof slab for hoisting, eliminating the potential risk of structural cracking and saving time and costs associated with this step.

[0018] This invention also improves construction coordination and on-site work quality. The construction of the roof slab and the fabrication of the fuel tank have a clear sequence, avoiding overlapping work by multiple trades and streamlining management. Welding operations are carried out on-site in ample space, providing a superior welding environment compared to the final assembly welding of segmented fuel tanks in confined spaces. This facilitates quality control and non-destructive testing, thereby ensuring the overall sealing and structural strength of the fuel tank. Attached Figure Description

[0019] Figure 1 The schematic diagram of the basement layout provided for an embodiment of the present invention mainly shows the position of the secondary hoisting hole on the top slab, as well as the relationship between the oil tank installation area and the internal passage; Figure 2 A schematic diagram of the basement elevation provided in an embodiment of the present invention. Figure 1 This mainly illustrates the process of transporting discrete raw materials from the ground to the basement through a secondary hoisting hole; Figure 3 A schematic diagram of the basement elevation provided in an embodiment of the present invention. Figure 2 The main illustration shows the on-site assembly of fuel tanks using a pre-set electric hoist and forklift in collaboration inside the basement.

[0020] Figures 1 to 3 The reference numerals in the attached drawings are respectively: 1-basement roof slab; 2-section steel; 3-steel plate; 4-forklift; 5-electric hoist; 6-oil tank; 7-secondary hoisting hole. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments: Please refer to Figure 1-3The technical solution of the present invention will be described in detail and completely below with reference to the accompanying drawings, so that those skilled in the art can understand and implement it. The present invention aims to provide a manufacturing and installation method that can fundamentally solve the transportation limitations caused by the oversized dimensions of finished fuel tanks. The description of this embodiment corresponds to the scope of protection claimed in the claims, and fully discloses the technical details involved to ensure the reproducibility of the solution.

[0022] A method for manufacturing and installing a large fuel tank in a basement includes the following steps: S1. During the structural construction phase of the basement roof slab 1, a secondary hoisting hole 7 is simultaneously formed and reserved for through hoisting.

[0023] During the civil construction of the factory building, when pouring the reinforced concrete for the basement roof slab 1, a through hole was pre-reserved within the slab structure. This hole was not drilled later, but was pre-designed and shaped during formwork erection and rebar tying, and its wall can be structurally reinforced. This hole is defined as the secondary hoisting hole 7, and its design load must meet the requirements of subsequent hoisting operations, and it must remain open until the fuel tank is installed.

[0024] S2. The surface-treated discrete raw materials used to construct the oil tank are hoisted into the basement through the secondary hoisting hole 7. The maximum external dimensions of the discrete raw materials are smaller than the finished oil tank and are adapted to the secondary hoisting hole 7.

[0025] All the basic components constituting the final fuel tank 6 are pre-processed in the factory and then transported to the site as "discrete raw materials". Among these raw materials, the largest single item, such as the longest section of steel or the widest steel plate, must have a smaller than the net size of the secondary lifting hole 7 reserved in step S1 to ensure that each raw material can be lowered vertically into the basement without obstruction through the hole. On-site ground lifting equipment such as truck cranes or factory overhead cranes are used to complete the lifting through the secondary lifting hole 7.

[0026] S3. Use handling equipment inside the basement to transfer the discrete raw materials to the preset installation location.

[0027] Once the raw materials are hoisted to the bottom of the basement, they are transferred from below the hoisting hole 7 to the precise location where the fuel tank is to be assembled by handling equipment such as small transport vehicles operating in the basement.

[0028] S4. At the installation location, using lifting equipment and handling equipment, the discrete raw materials are assembled and welded on-site into a complete oil tank 6.

[0029] At the installation location, operators use lifting equipment located in the basement for the main hoisting, while using handling equipment for auxiliary positioning and support. According to the design drawings, all discrete raw materials are assembled and spliced ​​on site, and then welded together to form a complete oil tank 6 with the intended function.

[0030] The discrete raw materials mainly include structural steel sections 2, such as I-beams, channel steel, and angle steel, and steel plates 3, which form the tank walls. To ensure the long-term corrosion resistance of the fuel tank and reduce on-site painting pollution in underground confined spaces, all structural steel sections 2 and steel plates 3 undergo pretreatment at the manufacturing plant. This pretreatment includes: Rust removal: Shot blasting or sandblasting is used to achieve a surface cleanliness of Sa2.5, with no grease, dirt, scale, rust, paint coatings, or other contaminants.

[0031] Anti-corrosion coating treatment: Apply epoxy zinc-rich primer as an anti-corrosion coating to the surface that has passed the rust removal process. The dry film thickness of the primer layer shall not be less than 60 micrometers (μm).

[0032] The raw materials treated in this way have a good anti-corrosion base, and only local cleaning and touch-up painting are required in the welded joint area after they are transported to the site.

[0033] Furthermore, to ensure the smooth hoisting of all raw materials, the dimensions of the secondary hoisting hole 7 are determined as follows: After the fuel tank design is completed, a list of all raw materials that need to be hoisted into the basement is compiled, identifying the largest single raw material, which is usually the longest steel section or the widest steel plate. Using the length and width of this largest single material as a benchmark, and adding the necessary safety space for hoisting equipment, typically 100-300mm on each side, the minimum length and width required for the secondary hoisting hole 7 are calculated. This dimension needs to be provided during the civil engineering design phase and incorporated into the roof slab construction drawings.

[0034] Furthermore, the lifting equipment in step S4 is specifically an electric hoist 5 pre-installed on the basement roof slab 1. "Pre-installed" means that the electric hoist 5 and its supporting rail were planned as fixed equipment during the initial design phase of the factory building. Its rail beam (usually an I-beam) was installed during the structural construction of the basement roof slab 1, and the electric hoist 5 is mounted on this rail. Therefore, during the fuel tank installation operation, this pre-installed fixed equipment can be used directly, without the need for additional temporary lifting facilities.

[0035] Furthermore, the handling equipment mentioned in steps S3 and S4 is specifically a forklift 4 suitable for transportation operations within the limited space of a basement.

[0036] The specific operation procedure for on-site assembly is as follows: a) Hoist and position the section steel 2 using the electric hoist 5: The electric hoist 5 hoists the section steel 2 and moves it above the installation reference line.

[0037] b) Use the forklift 4 to assist in adjusting the attitude of the section steel 2: The forklift 4 uses the forklift forks to assist in pushing or supporting the section steel 2 to help finely adjust its horizontal position and verticality to ensure accurate positioning.

[0038] c) Weld to form the fuel tank frame structure: Weld the positioned section steels 2 together to form the basic framework of the fuel tank.

[0039] d) Hoist and weld the steel plates 3 to form the box body: Use the electric hoist 5 to hoist the steel plates 3 such as the bottom plate and side plates in sequence, and also position them with the assistance of the forklift 4, and then weld them to the frame to form a sealed box body.

[0040] Furthermore, during and after the above assembly and welding process, strict quality inspections are carried out. First, conduct visual inspection of the welds to ensure that the welds are well formed and have no surface defects. Second, conduct non-destructive testing, specifically including: using magnetic particle testing or liquid penetration testing for key welds such as important fillet welds to check for surface and near-surface defects; using ultrasonic testing or radiographic testing for full penetration butt welds between the box body plates to check for internal defects. In this way, the sealing performance and structural strength of the fuel tank are ensured.

[0041] Furthermore, after all welding, inspection of the fuel tank 6 is completed and the accessories are installed, a final sealing verification - kerosene leakage test is carried out. The test method is: Plug all openings except the fuel injection port, inject kerosene into the fuel tank to the designed liquid level height, and let it stand for at least 24 hours. During and after the standing period, check all welds and connection surfaces to observe whether there are traces of kerosene leakage. If there is no leakage, it is considered qualified.

[0042] Furthermore, the secondary lifting hole 7 is a reserved hole in the original design for equipment maintenance and material hoisting. The secondary lifting hole 7 reserved in step S1 can be sourced from making full use of the reserved hole in the original design of the basement roof 1 of the industrial building for equipment maintenance and material hoisting. The present invention requires that during the project design coordination stage, according to the hoisting requirements of the fuel tank raw materials, the position and size of this reserved hole are reviewed and confirmed so that it can perfectly adapt to the hoisting requirements of this method, thereby realizing the reuse of design resources and avoiding specially adding structural openings for this installation.

[0043] In summary, this specific embodiment provides a detailed and clear description of each technical feature claimed in the claims, including specific process parameters, material requirements, equipment selection, operating procedures, and quality control standards. Based on the above description, and in conjunction with well-known crane operation safety regulations, welding technical standards, and general knowledge of civil engineering construction, those skilled in the art can reproduce the method of this invention and solve the problem of transporting ultra-large fuel tanks as mentioned in the background art, while simultaneously achieving the beneficial effects of shortening the construction period, reducing costs, and ensuring quality.

[0044] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing and installing a large fuel tank in a basement, characterized in that, Includes the following steps: S1. During the structural construction stage of the basement roof slab (1), a secondary hoisting hole (7) for through hoisting is simultaneously formed and reserved. S2. The discrete raw materials that have undergone surface treatment and are used to form the oil tank are hoisted into the basement through the secondary hoisting hole (7). The maximum external dimensions of the discrete raw materials are smaller than the finished oil tank and are adapted to the secondary hoisting hole (7). S3. Use handling equipment inside the basement to transfer the discrete raw materials to the preset installation location; S4. At the installation location, the discrete raw materials are assembled and welded into a complete oil tank (6) on site using the lifting equipment and the handling equipment.

2. The method for manufacturing and installing a large basement oil tank according to claim 1, characterized in that, The discrete raw materials include structural steel (2) and steel plate (3), which undergo rust removal and anti-corrosion coating treatment at the manufacturing plant. The rust removal treatment achieves a cleanliness level of Sa2.5, and the anti-corrosion coating treatment is spraying epoxy zinc-rich primer with a dry film thickness of not less than 60μm.

3. The method for manufacturing and installing a large basement oil tank according to claim 1, characterized in that, The size of the secondary hoisting hole (7) is determined according to the maximum size of the discrete raw materials to ensure that all raw materials can pass through smoothly.

4. The method for manufacturing and installing a large basement oil tank according to claim 1, characterized in that, The lifting equipment is an electric hoist (5) pre-installed on the roof slab (1) of the basement.

5. The method for manufacturing and installing a large basement oil tank according to claim 4, characterized in that, The electric hoist (5) is installed on a pre-set track below the basement roof slab (1).

6. The method for manufacturing and installing a large basement oil tank according to claim 5, characterized in that, The handling equipment is a forklift (4), which is suitable for transportation operations in the limited space of the basement.

7. The method for manufacturing and installing a large basement oil tank according to claim 6, characterized in that, The on-site assembly includes the following steps: Use an electric hoist (5) to lift and position the steel section (2); Use a forklift (4) to assist in adjusting the posture of the steel section (2); Welding forms the fuel tank frame structure; The steel plates (3) are hoisted and welded to form the box body.

8. The method for manufacturing and installing a large basement oil tank according to claim 7, characterized in that, During the welding process, visual inspection and non-destructive testing of the weld seams are carried out to ensure the sealing performance and structural strength of the fuel tank. The non-destructive testing includes magnetic particle testing or liquid penetration testing of critical weld seams, and ultrasonic testing or radiographic testing of full penetration weld seams.

9. The method for manufacturing and installing a large basement oil tank according to claim 1, characterized in that, It also includes conducting a kerosene leakage test after the fuel tank is manufactured, with the test lasting no less than 24 hours.

10. The method for manufacturing and installing a large basement oil tank according to claim 1, characterized in that, The secondary hoisting hole (7) mentioned in step S1 is a reserved hole in the original design for equipment maintenance and material hoisting.

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