A large cyclone separator quick assembly device and construction method

Abstract

The application discloses a large cyclone separator fast combination device and a construction method, wherein the fast combination device comprises a first circular-arc support, a second circular-arc support, a third circular-arc support and a fourth circular-arc support; a bottom support of an integrated structure is welded to the bottom of each circular-arc support; the bottom support is connected and fixed with the base through a pressing plate and a bolt; a lower connecting plate is arranged between adjacent bottom supports; a cross beam, a vertical rod and an inclined support are arranged in each circular-arc support; two upper connecting plates are arranged at the upper part between the first circular-arc support and the third circular-arc support; and at least five horizontal supports are arranged at the top of the two upper connecting plates. The four circular-arc supports are prefabricated, the cylinder section is hoisted into the position, the time for on-site radial adjustment and round finding is saved, and the assembling speed is improved by several times; meanwhile, the overall support is firm, without shaking and deformation, the risk of sliding and overturning of the pipe screen in the assembling process is avoided, and the safety hidden danger caused by the traditional temporary support is completely eliminated.

Description

Technical Field

[0001] This invention relates to a separator construction platform, and more particularly to a rapid assembly device and construction method for a large cyclone separator, belonging to the field of power equipment installation technology. Background Technology

[0002] Large cyclone separators are key equipment in circulating fluidized bed boilers and chemical plants. They typically have a diameter greater than 3 meters and, due to transportation limitations, must be prefabricated in multiple sections at the factory. These sections are then hoisted, assembled, and welded on-site. Currently, on-site assembly mainly uses temporary welding supports, jacks, and wedges for adjustment, which presents the following significant problems: ① Low efficiency: Positioning, rounding, and verticality adjustment of each section requires repeated measurements and hammering by multiple people, which is extremely time-consuming. Connecting straight sections to conical sections is even more difficult. ② Difficulty in ensuring accuracy: It is highly dependent on worker experience; controlling the roundness, concentricity, and verticality of the sections is difficult, and excessive misalignment affects welding quality and equipment performance. ③ Safety hazards: The sections are in a temporary, unstable support state, making them prone to overturning or sliding during adjustment, posing a high risk of working at height. ④ Poor adaptability: Different specifications require different temporary tooling, which cannot be reused, resulting in significant material waste. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a rapid assembly device and construction method for large cyclone separators, so as to achieve stable support, rapid adjustment and precise alignment of the cylinder sections, thereby improving assembly efficiency and accuracy, ensuring construction safety and reducing labor intensity.

[0004] The technical solution adopted by this invention to solve the technical problem is as follows: A rapid assembly device for a large cyclone separator includes a first arc support, a second arc support, a third arc support, and a fourth arc support. Each of the first, second, third, and fourth arc supports has an integrally structured base frame at its bottom. At least two lower connecting plates are provided between adjacent base frames. Bases are provided at the bottom of both ends of each base frame and are fixedly connected to the bases via pressure plates and bolts. The bases are fixedly connected to the ground via anchor bolts. Two upper connecting plates are spaced apart between the upper parts of the first and second arc supports, and between the upper parts of the second and third arc supports. At least five cross braces are spaced apart on the top of the two upper connecting plates.

[0005] The arc-shaped surface formed by the first, second, and third arc supports matches the interior of the cyclone separator cylinder; the arc radius of the third and fourth arc supports gradually decreases downward along the axial direction to form a conical support surface that matches the cone profile of the cyclone separator.

[0006] The inner walls of the first, second, third, and fourth arc supports each have two parallel horizontal beams welded on. Vertical rods are provided at intervals between the horizontal beams and the inner walls of the arc supports, between adjacent horizontal beams, and between the horizontal beams and the base frame, dividing the inner wall space of each arc support into multiple grid-like structures, and diagonal bracing is provided in each grid.

[0007] The angle between the diagonal brace and the horizontal plane is 45° to 60°, and the diagonal braces in adjacent grids have opposite inclination directions to form a cross-support structure.

[0008] The two ends of the lower connecting plate are fixedly connected to the base frame at the bottom of the arc bracket by pressure plates and bolts, and the top surface of the lower connecting plate is flush with the top surface of the base frame to form a continuous bottom support platform.

[0009] The two ends of the upper connecting plate are fixedly connected to the crossbeam between the inner wall of the arc bracket by pressure plates and bolts.

[0010] The ends of the cross brace are fixedly connected to the upper connecting plate by bolts, thereby forming a stable construction platform.

[0011] The construction method of the large cyclone separator rapid assembly device includes the following steps: S1. Construction Preparation ① At the following locations: 300 mm down from the inflection point of the upper pipe opening of the tube panel, 1000 mm up from the weld joint between the cylinder and the cone, 1000 mm down from the weld joint between the cylinder and the cone, and 1000 mm up from the lower header of the cone, four arc-shaped supports are fabricated. Each arc-shaped support is made of rolled channel steel, and the radius of the rolled channel steel is based on the length of the longest castable pin from the center of the circle to the inner wall of the tube panel. ② Weld a base frame to the bottom of each arc-shaped support, with both ends of the base frame extending outside the arc-shaped support; weld horizontal beams, vertical rods, and diagonal braces between the inner walls of the arc-shaped support to ensure its stability; ③ According to the location of the equipment, install the base on the ground at both ends of the base frame, and fix the base to the ground firmly with bolts or positioning pins; S2. Installation and connection of the bracket ① Place the prefabricated arc-shaped bracket on the installed base and fix it with pressure plates and bolts; ② Install the lower connecting plate between adjacent base frames and fix it by connecting and fixing with pressure plates and bolts; ③ Install two upper connecting plates at intervals between the crossbeams on the inner wall of adjacent arc supports, and install multiple cross braces at intervals between the two upper connecting plates to form a stable construction platform; S3, Tube Screen Combination ① Place the component tube panels onto the arc support in the order of first the cylinder and then the cone, so that the inner wall of the component tube panel is in close contact with the upper surface of the arc channel steel of the support. If there are any places where the inner wall is not in close contact, use a jack or a hand hoist to tighten it. ② The inner walls of the joints between the cylinders must be flush, and the misalignment should not exceed 10% of the wall thickness and should not be greater than 1mm; the misalignment of the joints should be checked with a ruler, and the gap at 200mm from the center of the weld should generally not be greater than 2mm; the paint, stains, and rust on the bevels of the pipe joints and within 10-15mm of the inner and outer walls should be cleaned and made to have a metallic luster. ③ When assembling the tube panel, check the arc length and chord length of each tube panel assembly component at both ends and in the middle. S4, tube screen and junction box combination After the tube panel assembly is completed and accepted, a gantry frame is made as a hoisting point for welding the separator tube panel and header assembly. A hand chain hoist is used as a tool to adjust the alignment of the tube panel and header. S5, Tube Screen Sealing After the pipe panel and header weld joints are completed, the vertical splice welds of the pipe panel are first spot welded. Each splice weld is first spot welded, and then the vertical welds are fully welded inside and out. A kerosene penetration test is performed until it passes the test to ensure its tightness. S6, Ring Beam Splicing After the ground welding of the ring beam of the hanging device is completed, it is inspected to check whether the levelness and geometric dimensions meet the specifications. After the inspection, it is then installed with the separator cylinder.

[0012] The positive and beneficial effects of this invention are: 1. This invention sets up four arc-shaped supports and sets up upper and lower connecting plates between the four arc-shaped supports, which makes it easy for workers to quickly assemble the separator cylinder and cone. On-site, only bolts and pressure plates are needed to complete the quick splicing. There is no need for a large amount of welding and cutting of temporary tools on-site. The installation process is simplified. Compared with the traditional temporary bracket support method, the construction cycle is shortened by more than 50%, and the labor input is greatly reduced.

[0013] 2. In this invention, the arc-shaped surface formed between the first and third arc-shaped supports matches the interior of the cyclone separator cylinder. The arc radius of the third and fourth arc-shaped supports gradually decreases downward along the axial direction to form a conical support surface that matches the cone profile of the cyclone separator. When the tube panel is placed on the assembly device, it can automatically fit and find the circle without repeated tapping and adjustment. This achieves positioning as soon as the cylinder section is hoisted in, saving the time of on-site radial adjustment and finding the circle. The assembly speed is increased several times, significantly improving welding quality and equipment operating performance.

[0014] 3. This invention forms a grid-reinforced structure by setting horizontal beams, vertical rods and diagonal braces between the inner walls of the arc support. The bottom is rigidly connected to the base through the base frame and the lower connecting plate, and the upper part forms a stable construction platform through the upper connecting plate and the horizontal brace. The overall support is firm, without shaking or deformation, avoiding the risk of slippage and overturning of the tube screen during the assembly process, and completely eliminating the safety hazards caused by traditional temporary supports.

[0015] 4. This invention adopts a quick connection method using pressure plates and bolts, which is convenient for assembly and disassembly. The upper construction platform provides workers with a stable standing and operating surface. With the help of jacks or hand-operated hoists, the fit of the tube screen can be easily adjusted. The whole process is quick to install, accurate in positioning, and highly stable, which can significantly shorten the construction cycle, improve the installation quality, and reduce safety risks and construction costs. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the combined device of the present invention; Figure 2 This is a schematic diagram of the structure of the first arc-shaped bracket of the present invention; Figure 3 This is a schematic diagram of the structure of the pressure plate and bolts of the present invention; Figure 4 This is a schematic diagram of the upper connecting plate and cross brace of the present invention; Wherein: 1-First arc support, 2-Second arc support, 3-Third arc support, 4-Fourth arc support, 5-Base frame, 6-Base, 7-Pressure plate, 8-Bolt, 9-Lower connecting plate, 10-Upper connecting plate, 11-Horizontal brace, 12-Horizontal beam, 13-Vertical rod, 14-Diagonal brace. Detailed Implementation

[0017] The invention will be further explained and described below with reference to the accompanying drawings: Example 1, Participation Figures 1-4 A rapid assembly device for a large cyclone separator includes a first arc support 1, a second arc support 2, a third arc support 3, and a fourth arc support 4. An integral base frame 5 is provided at the bottom of each of the first arc support 1, second arc support 2, third arc support 3, and fourth arc support 4. At least two lower connecting plates 9 are provided between adjacent base frames 5. Bases 6 are provided at the bottom of both ends of the base frame 5 and are fixedly connected to the bases 6 by pressure plates 7 and bolts 8. The bases 6 are fixedly connected to the ground by anchor bolts. Two upper connecting plates 10 are provided at intervals between the upper parts of the first arc support 1 and the second arc support 2, and between the upper parts of the second arc support 2 and the third arc support 3. At least five cross braces 11 are provided at intervals on the top of the two upper connecting plates 10.

[0018] The arc-shaped surface formed between the first arc support 1, the second arc support 2, and the third arc support 3 matches the interior of the cyclone separator cylinder; the arc radius of the third arc support 3 and the fourth arc support 4 gradually decreases downward along the axial direction to form a conical support surface that matches the cone profile of the cyclone separator.

[0019] The inner walls of the first arc support 1, the second arc support 2, the third arc support 3, and the fourth arc support 4 are each welded with two parallel horizontal beams 12. Vertical rods 13 are provided at intervals between the horizontal beams 12 and the inner wall of the arc support, between adjacent horizontal beams 12, and between the horizontal beams 12 and the base frame 5, dividing the inner wall space of each arc support into multiple grid-like structures, and diagonal braces 14 are provided in each grid.

[0020] The angle between the diagonal brace 14 and the horizontal plane is 45° to 60°, and the diagonal braces 14 in adjacent grids have opposite inclination directions to form a cross support structure.

[0021] The top surfaces of the two ends of the lower connecting plate 9 are flush with the top surface of the base frame 5 to form a continuous bottom support platform.

[0022] The two ends of the upper connecting plate 10 are fixedly connected to the crossbeam 12 between the inner wall of the arc bracket by pressure plate 7 and bolt 8 respectively.

[0023] The end of the cross brace 11 is fixedly connected to the upper connecting plate 10 by bolts, thereby forming a stable construction platform.

[0024] In the above description, the first, second, third, and fourth arc supports are all made of channel steel.

[0025] In the above description, the base frame, base, upper connecting plate, lower connecting plate, cross brace, cross beam, vertical rod and diagonal brace are all made of channel steel.

[0026] Example 2, the construction method of the above-mentioned large cyclone separator rapid assembly device includes the following steps: S1. Construction Preparation ① At the following locations: 300 mm down from the inflection point of the upper pipe opening of the tube panel, 1000 mm up from the weld joint between the cylinder and the cone, 1000 mm down from the weld joint between the cylinder and the cone, and 1000 mm up from the lower header of the cone, four arc-shaped supports are fabricated. Each arc-shaped support is made of rolled channel steel, and the radius of the rolled channel steel is based on the length of the longest castable pin from the center of the circle to the inner wall of the tube panel. ② Weld a base frame 5 to the bottom of each arc-shaped bracket, with both ends of the base frame 5 extending outside the arc-shaped bracket; weld a crossbeam 12, a vertical rod 13, and a diagonal brace 14 between the inner walls of the arc-shaped bracket to ensure its stability. ③ According to the location of the equipment, install the base 6 on the ground at both ends of the base frame 5, and fix the base 6 to the ground securely with bolts or positioning pins; S2. Installation and connection of the bracket ① Place the prefabricated arc-shaped bracket on the installed base 6 and fix it by connecting and fixing it with pressure plate 7 and bolts 8; ② Install the lower connecting plate 9 between adjacent base frames 5, and connect and fix it with pressure plate 7 and bolts 8; ③ Install two upper connecting plates 10 at intervals between the crossbeams 12 on the inner wall of adjacent arc supports, and install multiple cross braces 11 at intervals between the two upper connecting plates 10 to form a stable construction platform. S3, Tube Screen Combination ① Place the component tube panels onto the arc support in the order of first the cylinder and then the cone, so that the inner wall of the component tube panel is in close contact with the upper surface of the arc channel steel of the support. If there are any places where the inner wall is not in close contact, use a jack or a hand hoist to tighten it. ② The inner walls of the joints between the cylinders must be flush, and the misalignment should not exceed 10% of the wall thickness and should not be greater than 1mm; the misalignment of the joints should be checked with a ruler, and the gap at 200mm from the center of the weld should generally not be greater than 2mm; the paint, stains, and rust on the bevels of the pipe joints and within 10-15mm of the inner and outer walls should be cleaned and made to have a metallic luster. ③ When assembling the tube panel, check the arc length and chord length of each tube panel assembly component at both ends and in the middle. S4, tube screen and junction box combination After the tube panel assembly is completed and accepted, a gantry frame is made as a hoisting point for welding the separator tube panel and header assembly. A hand chain hoist is used as a tool to adjust the alignment of the tube panel and header. S5, Tube Screen Sealing After the pipe panel and header weld joints are completed, the vertical splice welds of the pipe panel are first spot welded. Each splice weld is first spot welded, and then the vertical welds are fully welded inside and out. A kerosene penetration test is performed until it passes the test to ensure its tightness. S6, Ring Beam Splicing After the ground welding of the ring beam of the hanging device is completed, it is inspected to check whether the levelness and geometric dimensions meet the specifications. After the inspection, it is then installed with the separator cylinder.

[0027] This invention achieves immediate positioning of the cylinder section upon hoisting by setting prefabricated arc supports at four key locations: 300mm below the upper inflection point of the tube panel, 1000mm above and below the weld joint of the cone body, and 1000mm above the lower header of the cone body. This eliminates the time required for on-site radial adjustment and rounding, increasing the assembly speed several times over. By setting horizontal beams, vertical rods, and diagonal braces between the inner walls of the arc supports, a grid-reinforced structure is formed. The bottom is rigidly connected to the base through the base frame and lower connecting plate, while the upper part forms a stable construction platform through the upper connecting plate and horizontal braces. The overall support is firm, without shaking or deformation, avoiding the risk of slippage and overturning of the tube panel during assembly and completely eliminating the safety hazards caused by traditional temporary supports.

Claims

1. A rapid assembly device for a large cyclone separator, comprising a first arc support (1), a second arc support (2), a third arc support (3), and a fourth arc support (4), characterized in that: The bottom of the first arc bracket (1), the second arc bracket (2), the third arc bracket (3), and the fourth arc bracket (4) are respectively provided with an integral base frame (5). At least two lower connecting plates (9) are provided between adjacent base frames (5). The bottom of both ends of the base frame (5) are respectively provided with a base (6), and are fixedly connected to the base (6) by a pressure plate (7) and a bolt (8). The base (6) is fixedly connected to the ground by an anchor bolt. Two upper connecting plates (10) are provided at intervals between the upper parts of the first arc bracket (1) and the second arc bracket (2), and between the upper parts of the second arc bracket (2) and the third arc bracket (3). At least five cross braces (11) are provided at intervals on the top of the two upper connecting plates (10).

2. The rapid assembly device for a large cyclone separator according to claim 1, characterized in that: The arc surface formed between the first arc support (1), the second arc support (2), and the third arc support (3) matches the interior of the cyclone separator cylinder; the arc radius of the third arc support (3) and the fourth arc support (4) gradually decreases downward along the axial direction to form a conical support surface that matches the cone profile of the cyclone separator.

3. The rapid assembly device for a large cyclone separator according to claim 1, characterized in that: The inner walls of the first arc bracket (1), the second arc bracket (2), the third arc bracket (3), and the fourth arc bracket (4) are each welded with two parallel horizontal beams (12). Vertical rods (13) are provided at intervals between the horizontal beams (12) and the inner wall of the arc bracket, between adjacent horizontal beams (12), and between the horizontal beams (12) and the base frame (5). The inner wall space of each arc bracket is divided into multiple grid structures, and diagonal braces (14) are provided in each grid.

4. A rapid assembly device for a large cyclone separator according to claim 3, characterized in that: The angle between the diagonal brace (14) and the horizontal plane is 45° to 60°, and the diagonal braces (14) in adjacent grids have opposite inclination directions to form a cross support structure.

5. A rapid assembly device for a large cyclone separator according to claim 1, characterized in that: The two ends of the lower connecting plate (9) are fixedly connected to the base frame (5) at the bottom of the arc bracket by pressure plate (7) and bolt (8), respectively, and the top surface of the lower connecting plate (9) is flush with the top surface of the base frame (5) to form a continuous bottom support platform.

6. The rapid assembly device for a large cyclone separator according to claim 1, characterized in that: The two ends of the upper connecting plate (10) are fixedly connected to the crossbeam (12) between the inner wall of the arc bracket by pressure plate (7) and bolt (8).

7. A rapid assembly device for a large cyclone separator according to claim 1, characterized in that: The end of the cross brace (11) is fixedly connected to the upper connecting plate (10) by bolts, thereby forming a stable construction platform.

8. A construction method for a rapid assembly device for a large cyclone separator as described in any one of claims 1-7, characterized in that, Includes the following steps: S1. Construction Preparation ① At the following locations: 300 mm down from the inflection point of the upper pipe opening of the tube panel, 1000 mm up from the weld joint between the cylinder and the cone, 1000 mm down from the weld joint between the cylinder and the cone, and 1000 mm up from the lower header of the cone, four arc-shaped supports are fabricated. Each arc-shaped support is made of rolled channel steel, and the radius of the rolled channel steel is based on the length of the longest castable pin from the center of the circle to the inner wall of the tube panel. ② Weld a base frame (5) to the bottom of each arc-shaped bracket, with both ends of the base frame (5) extending out of the arc-shaped bracket; weld a crossbeam (12), a vertical rod (13), and a diagonal brace (14) between the inner walls of the arc-shaped bracket to ensure its stability; ③ According to the location of the equipment, install the base (6) on the ground at both ends of the base frame (5), and fix the base (6) to the ground firmly with bolts or positioning pins; S2. Installation and connection of the bracket ① Place the prefabricated arc-shaped bracket on the installed base (6) and fix it by connecting and fixing it with pressure plate (7) and bolts (8); ② Install the lower connecting plate (9) between adjacent base frames (5) and connect and fix it with pressure plate (7) and bolts (8); ③ Install two upper connecting plates (10) at intervals between the crossbeams (12) on the inner wall of the adjacent arc support, and install multiple cross braces (11) at intervals between the two upper connecting plates (10) to form a stable construction platform; S3, Tube Screen Combination ① Place the component tube panels onto the arc support in the order of first the cylinder and then the cone, so that the inner wall of the component tube panel is in close contact with the upper surface of the arc channel steel of the support. If there are any places where the inner wall is not in close contact, use a jack or a hand hoist to tighten it. ② The inner walls of the joints between the cylinders must be flush, and the misalignment should not exceed 10% of the wall thickness and should not be greater than 1mm; the misalignment of the joints should be checked with a ruler, and the gap at 200mm from the center of the weld should generally not be greater than 2mm; the paint, stains, and rust on the bevels of the pipe joints and within 10-15mm of the inner and outer walls should be cleaned and made to have a metallic luster. ③ When assembling the tube panel, check the arc length and chord length of each tube panel assembly component at both ends and in the middle. S4, tube screen and junction box combination After the tube panel assembly is completed and accepted, a gantry frame is made as a hoisting point for welding the separator tube panel and header assembly. A hand chain hoist is used as a tool to adjust the alignment of the tube panel and header. S5, Tube Screen Sealing After the pipe panel and header weld joints are completed, the vertical splice welds of the pipe panel are first spot welded. Each splice weld is first spot welded, and then the vertical welds are fully welded inside and out. A kerosene penetration test is performed until it passes the test to ensure its tightness. S6, Ring Beam Splicing After the ground welding of the ring beam of the hanging device is completed, it is inspected to check whether the levelness and geometric dimensions meet the specifications. After the inspection, it is then installed with the separator cylinder.

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