A water-cooled wall butting device for thermal power generating units and a construction method thereof

Abstract

The application discloses a water cooling wall butting device of a thermal power unit and a construction method, wherein the butting device comprises an upper corner frame, a lower corner frame and an adjusting screw rod, an upper connecting plate is arranged at the top of the upper corner frame, a lower connecting plate is arranged at the bottom of the lower corner frame, through holes are formed in the upper connecting plate and the lower connecting plate correspondingly, the adjusting screw rod penetrates through the two through holes, matched nuts are arranged at the upper end and the lower end of the adjusting screw rod respectively, and arc-shaped bottom plates are arranged at the two ends of the upper corner frame and the lower corner frame. The V-shaped plates are arranged on the upper and lower water cooling wall components respectively, the adjusting screw rod is used, the traditional multiple hand-operated hoists are replaced, the gap between the water cooling wall pipe openings and the gap amount are accurately and controllably adjusted, the water cooling wall welding opening forming quality and the one-time welding qualification rate are greatly improved, and the butting device is convenient to disassemble and assemble and simple to operate.

Description

Technical Field

[0001] This invention relates to a pipe alignment device, and more particularly to a pipe alignment device and construction method for water-cooled walls of thermal power units, belonging to the field of pipe welding technology. Background Technology

[0002] The water-cooled walls of thermal power unit boilers are manufactured in sections from multiple alloy steel tube panels and assembled and welded on-site. The gap and misalignment of the pipe joints between the upper and lower water-cooled wall components directly determine the weld quality. Water-cooled wall tubes are mostly made of heat-resistant alloys, and the welding process control standards are stringent. Deviations in the joint gap or excessive misalignment at the pipe joints can cause internal defects in the weld, significantly reducing the first-pass yield rate. Current on-site conventional jointing process relies on multiple hand-operated hoists for adjustment: during construction, eight or more hand-operated hoists are hung at the upper water-cooled wall fins, and connected to the lower water-cooled wall components. The hoists are then manually pulled synchronously to change the joint gap between the upper and lower water-cooled walls. This construction method has several drawbacks: ① It is difficult to operate multiple manual chain hoists simultaneously, and it is difficult to maintain uniform tension on each hoist. This can lead to unilateral displacement of the water-cooled wall tubes, misalignment of the tube ends, and unstable control of alignment accuracy, resulting in a high rate of weld rework. ② With multiple manual chain hoists deployed simultaneously inside the high-altitude furnace, slippage and load shifting are likely to occur during hoisting and pulling, posing a high-altitude safety hazard of component falling and personnel collisions. ③ The arrangement of manual chain hoist points is cumbersome, requiring repeated disassembly and reassembly of lifting points for each alignment operation. This process is time-consuming and results in low overall construction efficiency. 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 water-cooled wall fitting device and construction method for thermal power units. By replacing multiple hand-operated hoists with an integrated adjustable tooling, the gap between the water-cooled wall pipe openings can be precisely adjusted, ensuring uniform stress on the entire pipe screen and reducing safety hazards during high-altitude construction.

[0004] The technical solution adopted by this invention to solve the technical problem is as follows: A water-cooled wall fitting device for a thermal power unit includes an upper corner bracket, a lower corner bracket, and an adjusting screw. The upper corner bracket has an upper connecting plate at its top and a lower connecting plate at its bottom. The upper and lower connecting plates have corresponding through holes, and the adjusting screw passes through the two through holes. The upper and lower ends of the adjusting screw are respectively provided with matching nuts. The upper and lower corner brackets are respectively provided with arc-shaped base plates at both ends.

[0005] The arc-shaped base plates at both ends of the upper corner bracket are welded to a position 50mm away from the bottom of the upper water-cooled wall assembly.

[0006] The arc-shaped base plates at both ends of the lower corner bracket are welded to a position 50mm away from the top of the lower water-cooled wall assembly.

[0007] The upper and lower corner brackets are two identical V-shaped plates, both formed from 30mm thick steel plates; the through holes in the upper and lower connecting plates have a diameter of Φ40mm.

[0008] There are four nuts. Two matching nuts are provided on the adjusting screw above the upper connecting plate, and two matching nuts are provided on the adjusting screw below the lower connecting plate.

[0009] The adjusting screw consists of a non-wire section and a wire section. The total length of the adjusting screw is 1000mm. The middle part of the adjusting screw is a non-wire section with a length of 400mm, and the two ends of the adjusting screw are wire sections, each with a length of 300mm.

[0010] The adjusting screw has a diameter of Φ36mm and is made of Q355 steel; the nut is an M36 specification 8.8 grade high-strength nut.

[0011] The construction method of the water-cooled wall mating device for a thermal power unit includes the following steps: S1, Tool Pre-fabrication: ① Process the upper and lower corner frames according to the size specifications. Both are made of 30mm thick steel plates to form the same V-shaped structure. Weld arc-shaped base plates to both ends of the V-shaped structure. Fix and weld the upper connecting plate to the top of the upper corner frame and fix and weld the lower connecting plate to the bottom of the lower corner frame. Make Φ40mm through holes in the center of the upper and lower connecting plates. ② Machining the adjusting screw, the adjusting screw is 1000mm long in total, the middle 400mm is a non-threaded section, and the two ends are threaded sections of 300mm each. The adjusting screw has a diameter of Φ36mm and is made of Q355 steel; four M36, 8.8 grade nuts are machined to match. S2. Tool Installation: ① Attach the arc-shaped base plates at both ends of the upper corner bracket to the outer wall of the bottom pipe of the upper water-cooled wall assembly, and complete the welding and fixing by using the bevel full welding process. The overall installation position of the upper corner bracket is 50mm away from the bottom of the upper water-cooled wall assembly. ② Attach the arc-shaped base plates at both ends of the lower corner bracket to the outer wall of the top pipe of the lower water-cooled wall assembly, and complete the welding and fixing by using the bevel full welding process. The overall installation position of the lower corner bracket is 50mm away from the top of the lower water-cooled wall assembly. ③ Evenly arrange 8 sets of upper and lower corner brackets along the width of the water-cooled wall tube panel, and equip them with adjusting screws and nuts; S3, Pre-installation of adjusting screw Pass the adjusting screw through the through holes on the upper and lower connecting plates from top to bottom. First, install two matching nuts on the threaded section at the lower end of the adjusting screw and pre-tighten to lock it in place to prevent the adjusting screw from falling off. Then, install the remaining two matching nuts on the threaded section at the upper end of the adjusting screw and complete the assembly of the single set of mating devices. S4. Synchronous adjustment of the gap between water-cooled walls. Hoist the lower water-cooled wall assembly to the docking position with the upper water-cooled wall assembly, and simultaneously and uniformly tighten the two nuts at the top of all adjusting screws; rely on the nuts to press the upper connecting plate to drive the upper corner bracket to move, and accurately adjust the docking gap and misalignment of the upper and lower water-cooled wall pipe openings; control the tightening speed of all adjusting screws and matching nuts to be consistent, so as to ensure that the water-cooled wall is subjected to uniform force. S5. Welding construction of water-cooled wall pipe joints After the gap and misalignment of the upper and lower water-cooled wall tube openings meet the welding process standards for thermal power plants, tighten all nuts and fix the position of the adjusting screw before starting the welding operation of the water-cooled wall tube openings. S6. Tool removal: After the water-cooled wall weld has completely cooled, grind away the weld scars on the outer wall of the arc-shaped base plate and the water-cooled wall fittings; remove all the nuts at both ends of the adjusting screw in sequence, pull out the adjusting screw, and separate the upper and lower corner brackets; clean the surface of the tooling and remove welding slag and debris. The entire mating device can be reused for subsequent water-cooled wall mating construction.

[0012] The positive and beneficial effects of this invention are: 1. This invention replaces the traditional method of pulling with multiple hand-operated hoists by setting V-shaped plates on the upper and lower water-cooled wall components and using adjusting screws. This allows for precise and controllable adjustment of the gap and misalignment of the water-cooled wall pipe openings, significantly improving the weld formation quality and first-time welding pass rate of the water-cooled wall.

[0013] 2. When using this invention, by evenly arranging multiple sets of V-shaped plates and adjusting screws on the water-cooled wall tube panel, the overall force on the tube panel is uniform and the adjustment is synchronized, effectively avoiding the problems of unilateral deviation and uneven load, reducing the safety risks of high-altitude joint operations, and improving construction stability.

[0014] 3. The adjusting screw of the present invention consists of a screw section and a screwless section, and is locked with upper and lower double nuts to achieve reliable locking of the position after alignment adjustment, avoid gap rebound, and ensure continuous and stable alignment accuracy; the whole assembly and disassembly are convenient, the operation is simple, it can be reused, reduce the investment of disposable consumables, effectively reduce the construction cost of water-cooled wall alignment, and improve the overall construction efficiency. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the adjusting screw of the present invention; Figure 3 This is a diagram showing the usage state of the present invention; Wherein: 1-Upper corner frame, 2-Lower corner frame, 3-Arc-shaped base plate, 4-Upper connecting plate, 5-Lower connecting plate, 6-Adjusting screw, 7-Nut, A-Upper water-cooled wall assembly, B-Lower water-cooled wall assembly. Detailed Implementation

[0016] The invention will be further explained and described below with reference to the accompanying drawings: Example 1, see Figures 1-3 A water-cooled wall fitting device for a thermal power unit includes an upper corner bracket 1, a lower corner bracket 2, and an adjusting screw 6. An upper connecting plate 4 is provided at the top of the upper corner bracket 1, and a lower connecting plate 5 is provided at the bottom of the lower corner bracket 2. Through holes are provided on the upper connecting plate 4 and the lower connecting plate 5 respectively, and the adjusting screw 6 passes through the two through holes. Matching nuts 7 are provided at the upper and lower ends of the adjusting screw 6 respectively. Arc-shaped base plates 3 are provided at both ends of the upper corner bracket 1 and the lower corner bracket 2 respectively.

[0017] The arc-shaped base plates 3 at both ends of the upper corner bracket 1 are welded to a position 50mm away from the bottom of the upper water-cooled wall assembly A.

[0018] The arc-shaped base plates 3 at both ends of the lower corner bracket 2 are welded to a position 50mm away from the top of the lower water-cooled wall assembly B.

[0019] The upper corner frame 1 and the lower corner frame 2 are two identical V-shaped plates, both made of 30mm thick steel plates; the through holes in the upper connecting plate 4 and the lower connecting plate 5 have a diameter of Φ40mm.

[0020] There are four nuts 7. Two matching nuts 7 are provided on the adjusting screw 6 above the upper connecting plate 4, and two matching nuts 7 are provided on the adjusting screw 6 below the lower connecting plate 5.

[0021] The adjusting screw 6 consists of a non-wired section and a wired section. The total length of the adjusting screw 6 is 1000mm. The middle part of the adjusting screw 6 is the non-wired section with a length of 400mm, and the two ends of the adjusting screw 6 are wired sections with a length of 300mm each.

[0022] The adjusting screw 6 has a diameter of Φ36mm and is made of Q355 steel; the nut 7 is an M36 specification 8.8 grade high strength nut.

[0023] Example 2, the construction method of the above-mentioned water-cooled wall mating device for thermal power units includes the following steps: S1, Tool Pre-fabrication: ① Process the upper corner frame 1 and lower corner frame 2 according to the size specifications. Both are made of 30mm thick steel plate to form the same V-shaped structure. Weld arc-shaped bottom plates 3 to both ends of the V-shaped structure. Fix and weld the upper connecting plate 4 to the top of the upper corner frame 1 and fix and weld the lower connecting plate 5 to the bottom of the lower corner frame 2. Make Φ40mm through holes in the center of the upper connecting plate 4 and the lower connecting plate 5. ② Machining the adjusting screw 6, which is 1000mm long in total, with a 400mm section without threads in the middle and 300mm sections with threads at each end. The adjusting screw has a diameter of Φ36mm and is made of Q355 steel. Four M36, 8.8 grade nuts are also machined. S2. Tool Installation: ① Attach the arc-shaped base plates 3 at both ends of the upper corner bracket 1 to the outer wall of the bottom pipe of the upper water-cooled wall assembly A, and complete the welding and fixing by using the bevel full welding process. The installation position of the upper corner bracket 1 is 50mm away from the bottom of the upper water-cooled wall assembly A. ② Attach the arc-shaped base plates 3 at both ends of the lower corner bracket 2 to the outer wall of the top pipe of the lower water-cooled wall assembly B, and complete the welding and fixing by using the bevel full welding process. The installation position of the lower corner bracket 2 is 50mm away from the top of the lower water-cooled wall assembly. ③Evenly arrange 8 sets of upper and lower corner brackets along the width of the water-cooled wall tube panel, and equip them with adjusting screws 6 and nuts 7; S3, Pre-installation of adjusting screw Pass the adjusting screw 6 through the through holes on the upper connecting plate 4 and the lower connecting plate 5 from top to bottom. First, install two matching nuts 7 on the threaded section at the lower end of the adjusting screw 6 and pre-tighten to lock it to prevent the adjusting screw 6 from falling off. Then, install the remaining two matching nuts 7 on the threaded section at the upper end of the adjusting screw 6 and complete the assembly of the single set of mating devices. S4. Synchronous adjustment of the gap between water-cooled walls. Hoist the lower water-cooled wall assembly B to the docking position with the upper water-cooled wall assembly A, and simultaneously and uniformly tighten the two nuts 7 at the upper end of all adjusting screws 6; rely on the nuts 7 to press the upper connecting plate 4 to drive the upper corner bracket 1 to move, and accurately adjust the docking gap and misalignment of the upper and lower water-cooled wall pipe openings; control the tightening speed of all adjusting screws and matching nuts to be consistent, and ensure that the water-cooled wall is subjected to uniform force as a whole; S5. Welding construction of water-cooled wall pipe joints After the gap and misalignment of the upper and lower water-cooled wall tube openings meet the welding process standards for thermal power plants, tighten all nuts 7 and fix the position of the adjusting screw 6 before carrying out the welding operation of the water-cooled wall tube openings. S6. Tool removal: After the water-cooled wall weld has completely cooled, grind away the weld scars on the outer wall of the arc-shaped base plate and the water-cooled wall fittings; remove all the nuts at both ends of the adjusting screw in sequence, pull out the adjusting screw, and separate the upper and lower corner brackets; clean the surface of the tooling and remove welding slag and debris. The entire mating device can be reused for subsequent water-cooled wall mating construction.

[0024] This invention utilizes symmetrically fixed upper and lower corner brackets at the upper and lower water-cooled wall components, respectively. A segmented adjusting screw and double-nut locking structure form an adjustable alignment fixture. By employing a work method of evenly distributing and synchronously adjusting multiple sets of fixtures, tightening the screw nuts drives fine-tuning of the upper and lower water-cooled wall components, precisely correcting pipe gaps and misalignments. Simultaneously, the double-nut locking structure reliably locks the alignment position, avoiding the problem of springback in alignment dimensions. This ensures uniform and stable stress on the water-cooled wall tubes throughout the process. The fixture is easy to assemble and disassemble and can be reused, effectively replacing the crude alignment process of traditional hand-operated hoists.

[0025] This invention features a simple overall structure, convenient assembly and disassembly, and strong adaptability. By replacing the traditional method of multiple hand-operated hoists with a dedicated integrated screw-adjusting fixture, it completely solves the problems of poor alignment accuracy, uneven stress on the tube wall, and high safety risks associated with high-altitude operations. It enables precise and controllable alignment of water-cooled wall tube ends, significantly improving weld quality and first-pass yield. Simultaneously, relying on uniformly distributed synchronous adjustment and a double-locking limiting structure, it ensures balanced stress and stable alignment dimensions without springback during the alignment process, significantly improving construction safety and alignment accuracy stability. Furthermore, the fixture is detachable, recyclable, and reusable, simplifying construction procedures, shortening the work cycle, and effectively reducing labor and material costs for water-cooled wall alignment in thermal power units, resulting in significantly improved overall construction efficiency. The alignment device can be reused for subsequent water-cooled wall alignment work.

Claims

1. A water-cooled wall fitting device for a thermal power unit, comprising an upper corner bracket (1), a lower corner bracket (2), and an adjusting screw (6), characterized in that: The upper corner bracket (1) is provided with an upper connecting plate (4) at the top, and the lower corner bracket (2) is provided with a lower connecting plate (5) at the bottom. The upper connecting plate (4) and the lower connecting plate (5) are respectively provided with through holes, and an adjusting screw (6) passes through the two through holes. The upper end and the lower end of the adjusting screw (6) are respectively provided with matching nuts (7). The upper corner bracket (1) and the lower corner bracket (2) are respectively provided with arc-shaped bottom plates (3).

2. The water-cooled wall fitting device for a thermal power unit according to claim 1, characterized in that: The arc-shaped base plates (3) at both ends of the upper corner bracket (1) are welded to a position 50mm away from the bottom of the upper water-cooled wall assembly (A).

3. The water-cooled wall fitting device for a thermal power unit according to claim 1, characterized in that: The arc-shaped base plates (3) at both ends of the lower corner bracket (2) are welded to a position 50mm away from the top of the lower water-cooled wall assembly (B).

4. The water-cooled wall fitting device for a thermal power unit according to claim 1, characterized in that: The upper corner bracket (1) and lower corner bracket (2) are two identical V-shaped plates, both made of 30mm thick steel plates; the through holes in the upper connecting plate (4) and lower connecting plate (5) have a diameter of Φ40mm.

5. The water-cooled wall fitting device for a thermal power unit according to claim 1, characterized in that: There are four nuts (7). Two matching nuts (7) are provided on the adjusting screw (6) above the upper connecting plate (4), and two matching nuts (7) are provided on the adjusting screw (6) below the lower connecting plate (5).

6. The water-cooled wall fitting device for a thermal power unit according to claim 1, characterized in that: The adjusting screw (6) consists of a non-wire section and a wire section. The total length of the adjusting screw (6) is 1000mm. The middle part of the adjusting screw (6) is a non-wire section with a length of 400mm, and the two ends of the adjusting screw (6) are wire sections with a length of 300mm each.

7. The water-cooled wall fitting device for a thermal power unit according to claim 6, characterized in that: The adjusting screw (6) has a diameter of Φ36mm and is made of Q355 steel; the nut (7) is an M36 specification 8.8 grade high strength nut.

8. A construction method for a water-cooled wall mating device for a thermal power unit according to any one of claims 1-7, characterized in that, Includes the following steps: S1, Tool Pre-fabrication: ① Process the upper corner frame (1) and lower corner frame (2) according to the size specifications. Both are made of steel plate with a thickness of 30mm to form the same V-shaped structure. Weld arc-shaped bottom plates (3) to both ends of the V-shaped structure. Fix and weld the upper connecting plate (4) to the top of the upper corner frame (1) and fix and weld the lower connecting plate (5) to the bottom of the lower corner frame (2). Open Φ40mm through holes in the center of the upper connecting plate (4) and the lower connecting plate (5). ② Machining the adjusting screw (6), the adjusting screw (6) is 1000mm long in total, with the middle 400mm being a non-threaded section and the two ends each being a threaded section of 300mm. The adjusting screw has a diameter of Φ36mm and is made of Q355 steel. Four M36, 8.8 grade nuts are also machined. S2. Tool Installation: ① The arc-shaped base plates (3) at both ends of the upper corner bracket (1) are attached to the outer wall of the bottom pipe of the upper water-cooled wall assembly (A), and the welding is completed by using the bevel full welding process. The overall installation position of the upper corner bracket (1) is 50mm away from the bottom of the upper water-cooled wall assembly (A). ②, attach the arc-shaped base plates (3) at both ends of the lower corner bracket (2) to the outer wall of the top pipe of the lower water-cooled wall assembly (B), and complete the welding and fixing by using the bevel full welding process. The overall installation position of the lower corner bracket (2) is 50mm away from the top of the lower water-cooled wall assembly. ③Evenly arrange 8 sets of upper and lower corner brackets along the width of the water-cooled wall tube panel, and equip them with adjusting screws (6) and nuts (7); S3, Pre-installation of adjusting screw Pass the adjusting screw (6) through the through holes on the upper connecting plate (4) and the lower connecting plate (5) from top to bottom. First, put two matching nuts (7) on the threaded section at the lower end of the adjusting screw (6) and tighten them to prevent the adjusting screw (6) from falling off. Then, put the remaining two matching nuts (7) on the threaded section at the upper end of the adjusting screw (6) and complete the assembly of the single set of mating devices. S4. Synchronous adjustment of the gap between water-cooled walls. Hoist the lower water-cooled wall assembly (B) to the docking position with the upper water-cooled wall assembly (A), and simultaneously and at a uniform speed tighten the two nuts (7) at the top of all the adjusting screws (6); rely on the nuts (7) to press the upper connecting plate (4) to drive the upper corner bracket (1) to move, and accurately adjust the docking gap and misalignment of the upper and lower water-cooled wall pipe openings; control the tightening speed of all the adjusting screws and matching nuts to be consistent, and ensure that the water-cooled wall is subjected to uniform force as a whole; S5. Welding construction of water-cooled wall pipe joints After the gap and misalignment of the upper and lower water-cooled wall pipe openings meet the welding process standards for thermal power plants, tighten all nuts (7) and fix the position of the adjusting screw (6) to carry out the welding operation of the water-cooled wall pipe openings. S6. Tool removal: After the water-cooled wall weld has completely cooled, grind away the weld scars on the outer wall of the arc-shaped base plate and the water-cooled wall fittings; remove all the nuts at both ends of the adjusting screw in sequence, pull out the adjusting screw, and separate the upper and lower corner brackets; clean the surface of the tooling and remove welding slag and debris. The entire mating device can be reused for subsequent water-cooled wall mating construction.

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