A manufacturing device for multi-stream multi-pipe long spiral heat exchanger

Abstract

The application discloses a manufacturing equipment of a multi-flow long-structure different-pipe long-winding heat exchanger. The equipment comprises a winding rotating mechanism for winding heat exchange pipes and a traction device matched with the winding rotating mechanism to pull the heat exchange pipes, a front roller frame located at one side of the winding rotating mechanism and a rear roller frame located at one side of the traction device are arranged between the winding rotating mechanism and the traction device, a front pipe plate is supported on the front roller frame, a rear pipe plate is supported on the rear roller frame, and a center cylinder is arranged between the front pipe plate and the rear pipe plate. The multi-flow long-structure different-pipe structure manufactured by the equipment is characterized in that the length of the heat exchange pipe of each pipe passage is matched according to the heat transfer requirement difference of the shell passage / tube passage medium, the length of the heat exchange pipe of each flow is independently designed, the long pipe passage corresponding to the high-temperature and high-pressure medium is used to prolong the heat exchange time, and the short pipe passage is used for the low-heat-capacity medium to avoid excessive pressure drop, so that the heat transfer requirement difference of the multi-flow fluid is effectively adapted, and the heat exchange efficiency is obviously improved.

Description

Technical Field

[0001] This invention relates to a manufacturing technology for heat exchange equipment components, specifically a manufacturing equipment for a multi-stream, multi-tube, long-wound heat exchanger. Background Technology

[0002] The spiral heat exchanger is a highly efficient, energy-saving, and compact heat exchange device. Its heat exchange tubes are alternately wound in a spiral shape in the space between the central cylinder and the shell. Compared with the traditional shell and tube heat exchanger, this structure has the following advantages: wide applicable temperature range, strong resistance to thermal shock, high compactness, self-elimination of thermal stress, and no flow dead zone. It is especially suitable for simultaneous heat exchange of multiple fluids and high temperature and high pressure conditions.

[0003] As industrial systems become increasingly complex, traditional coiled tube heat exchangers have revealed their limitations in meeting the demands of multi-medium synergistic heat exchange. For example, a single tube length design is difficult to adapt to the heat transfer requirements of different fluids (such as different specific heat capacity, flow rate, and temperature change curves). Fixed structures cannot meet the need for flexible switching between multiple operating conditions. Furthermore, breakthroughs in manufacturing technology are required to determine which tube length to use, how to accurately match the differentiated heat transfer requirements of multiple fluids, and how to manufacture structures with varying tube lengths. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a manufacturing equipment for a multi-flow heterogeneous tube long-wound tube heat exchanger that can accurately match the differentiated heat exchange requirements of multiple fluids.

[0005] To solve the above-mentioned technical problems, the manufacturing equipment for the multi-stream long-winding tube heat exchanger of the present invention includes a tube-winding rotation mechanism for winding heat exchange tubes and a traction device that cooperates with the tube-winding rotation mechanism to pull the heat exchange tubes. A front roller frame located on one side of the tube-winding rotation mechanism and a rear roller frame located on one side of the traction device are respectively provided between the tube-winding rotation mechanism and the traction device. A front tube plate is supported on the front roller frame and a rear tube plate is supported on the rear roller frame. A central cylinder is installed between the front tube plate and the rear tube plate. The central cylinder is driven to rotate forward or backward by the tube-winding rotation mechanism, so that each heat exchange tube is sequentially wound around the central cylinder by the traction device.

[0006] The traction device includes a fixed bracket, an adjustable stroke transmission device, and a traction head. The traction head is welded to the end of the heat exchange tube and passes through one side of the tube sheet to straighten the other side.

[0007] Both the front roller frame and the rear roller frame include a frame and rollers mounted on the frame.

[0008] The front tube sheet is welded with fastening fixtures and is connected to the drive shaft fasteners of the tube rotation mechanism.

[0009] The transmission device is a hand chain hoist.

[0010] The fixed bracket is placed on the ground, and the transmission device is fixedly installed on the fixed bracket.

[0011] The advantages of this invention are:

[0012] The multi-flow, multi-tube structure manufactured by this equipment allows for the matching of heat exchange tube lengths for each tube side according to the differentiated heat transfer requirements of the shell-side / tube-side media. Each heat exchange tube length is independently designed, with long tubes for high-temperature and high-pressure media to extend heat transfer time, and short tubes for low-heat-capacity media to avoid excessive pressure drop. This replaces the traditional single-tube length structure, effectively adapting to the differentiated heat transfer requirements of multiple fluids and significantly improving heat transfer efficiency. Furthermore, heat exchange tubes of the same length are arranged in the same layer to form a layered winding arrangement. By adjusting the winding angle and number, it is ensured that each layer is evenly wound around the central cylinder, enhancing structural stability. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the manufacturing equipment for the multi-stream heterogeneous tube long-wound tube heat exchanger of the present invention;

[0014] Figure 2 This is a tube layout diagram of the layered tube layout method for the multi-stream heterogeneous tube long-wound tube heat exchanger of the present invention;

[0015] Figure 3 for Figure 2 Schematic diagram of the AA section structure;

[0016] Figure 4 for Figure 1 A magnified structural diagram at point A. Detailed Implementation

[0017] The manufacturing equipment for the multi-stream, multi-tube, long-wound heat exchanger of the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0018] Example 1:

[0019] like Figure 1 As shown, the layered tube arrangement method for the multi-stream, multi-tube long-wound heat exchanger in this embodiment includes the following steps:

[0020] (1) During the heat exchange tube winding preparation stage, the heat exchange tubes are grouped by length and each group is independently marked (such as high temperature long tube group, low temperature short tube group) to distinguish them and ensure that the tubes in the same layer are of consistent length.

[0021] (2) The inner surface of the tube sheet is coded. During coding, the orifice corresponding to different tube passes is marked according to the flow zone (e.g., Figure 3 (As shown, Zone II corresponds to the long pipe section, and Zone III corresponds to the short pipe section) to avoid misalignment of the pipes.

[0022] (3) Only the same tube length group is wound in each layer. By adjusting the number of coils and lead of the layer, the heat exchange needs can be adapted. The number of coils is determined by the formula: N=H / (n×e)), where H is the coil height, n is the number of heat exchange tubes in a single layer, and e is the axial spacing of the heat exchange tubes.

[0023] This technology solves the calculation of various parameters (lead, number of turns, actual length, etc.) when actually winding heat exchanger tubes for multi-stream flow heat exchangers with varying tube lengths. See the figure below.

[0024]

[0025] (a) Required input parameters:

[0026] outer diameter of heat exchange tube -- d

[0027] Axial spacing of heat exchange tubes -- e

[0028] Pad thickness -- t

[0029] Number of heat exchanger tubes per layer -- n

[0030] One side to tube sheet surface -- h1

[0031] The other side to the tube sheet surface -- h2

[0032] Extended margin at both ends -- L

[0033] Coiling height -- H

[0034] (II) Calculated parameters:

[0035] The center diameter of each coil layer, B, = upper layer diameter + (d + t) × 2, number of coil turns (N) = H / (n × e)

[0036] Coiling angle

[0037] The parameters obtained from the above formula can be used for manufacturing, and the actual length can be purchased using heat exchange tubes (this data effectively reduces the procurement cost of heat exchange tubes).

[0038] Furthermore, before step (1), a pipe layout diagram is drawn at a 1:1 scale based on all pipe layout parameters, and the heat exchange tubes are grouped by length according to the drawn pipe layout diagram. The purpose of this pipe layout diagram is to clearly represent the parameters and dimensions required for production and manufacturing. Compared with the design drawings, the arrangement of gaskets and clamps is clearly indicated, which plays a crucial role in controlling production costs and improving quality. By standardizing the pipe layout diagram, the same layer of tube bundles can be wound sequentially, reducing installation errors.

[0039] Furthermore, this new layered tube routing technology achieves sequential winding of tube bundles within the same layer through standardized routing diagrams, reducing installation errors. The routing diagram is drawn according to the number of layers of the tube bundle, with each layer including the number and distribution angle of spacers, the installation distance of irregularly shaped spacers, lead, winding height, the number of heat exchanger tubes coiled, the coiling angle, the number and distribution of full and half clamps, the inlet and outlet orientation of the heat exchanger tubes, and the marking parameters of the first slot for each tube. This integrated design enables "construction according to the diagram," significantly reducing winding errors.

[0040] Example 2:

[0041] The tube winding method for a multi-flow, multi-tube, long-winding heat exchanger in this embodiment includes the following steps:

[0042] 1. Preparation for heat exchanger tube processing and manufacturing

[0043] (1) Pre-assembly of the central tube and tube sheet: After assembly according to the drawing requirements, mark the azimuth angles equally along the axial direction (number of marks = total number of first-layer irregular pads + flat pads).

[0044] (2) Tube sheet inner surface coding: The holes on the inner surface of the tube sheet are numbered and marked according to the tube layout diagram.

[0045] (3) Installation of gaskets: Install special-shaped gaskets and flat gaskets according to the pipe layout diagram. The first special-shaped gasket needs to be marked with a positioning slot.

[0046] (III) Heat exchanger tube processing technology:

[0047] A. Straightening: Use a straightener to straighten the front end of the heat exchange tube (straightening length = tube sheet thickness + 200mm);

[0048] B. At the starting end: Calculate the lead-out length of the heat exchange tube, use a hydraulic tube bending machine to bend the starting lead-out section, and after bending, insert the heat exchange tube into the front tube sheet and extend it out of the tube sheet by no less than 200mm.

[0049] C. Depending on the required winding direction, use the tube winding rotation mechanism to rotate the central cylinder forward or backward. By adjusting the position of the heat exchange tube entering the central cylinder, the winding direction of the heat exchange tube is controlled in conjunction with the tube winding rotation mechanism. During the winding process, the corresponding clamps and gaskets need to be installed and welded according to the tube layout diagram to ensure that the heat exchange tube and the central cylinder are tightly connected. It is not necessary to frequently change the position of the tube sheet entry end (the original manufacturing process was that the central cylinder only rotated forward), which is convenient for operation.

[0050] D. At the end, reserve clamp position B, calculate the lead-out length of the heat exchange tube, cut the remaining heat exchange tube, use a hydraulic tube bending machine to bend the lead-out section at the end, straighten the remaining heat exchange tube and insert it into the rear tube sheet, and extend it out of the tube sheet by no less than 200mm.

[0051] E. Use a heat exchange tube traction device to pull the heat exchange tube, and after ensuring that the heat exchange tube is tightly wound, install the remaining clamps to fix it.

[0052] F. Perform a hydrostatic test on each heat exchanger tube, using a high-pressure hydrostatic quick-connect device for sealing. After passing the test, cut off any excess tube sections. This method uses a high-pressure hydrostatic quick-connect device to pressure the heat exchanger tubes. Employing a single-tube pressure testing mode, unlike the usual layer-by-layer series welding of heat exchanger tubes, saves the time of series welding and avoids the impact of welding quality on the pressure testing results, resulting in a significant leap in overall efficiency.

[0053] G. After winding all the heat exchange tubes in this layer according to steps A to F, arrange the next layer of gaskets according to the tube layout diagram and mark the first slot, and carry out the interlayer arrangement.

[0054] H. After all layers have completed the tube bundle forming, the wrapping tube and support are installed to finally form the tube body.

[0055] I. Connection of heat exchange tubes to tube sheet: The extension length of the heat exchange tubes is processed according to the required extension requirements. After processing, the welding area of ​​the tube sheet is cleaned with alcohol or acetone. The tube sheet is automatically welded according to the welding process. After welding, the surface is inspected for non-destructive testing. Then, a flexible expansion process is used for expansion. A split tube expander is selected for the expansion head, and the tube is expanded and formed in one step.

[0056] Example 3:

[0057] Currently available tube winding machines use a chuck to fix one end of the tube sheet for transmission, suitable for situations where the tube sheet holes are concentrated and the outer diameter of the tube sheet is much smaller than the shell diameter (a common design for single-flow tube winding). However, multi-flow tube winding heat exchangers, due to their structural design, have tube sheet outer diameters equal to the shell outer diameters and the tube sheet holes are more dispersed. When using a tube winding machine, the large tube sheet diameter makes chuck fixation difficult, resulting in insufficient transmission power and affecting the winding rotation. Therefore, the manufacturing equipment for a multi-flow long-winded tube heat exchanger of the present invention includes a tube winding rotation mechanism 1 for winding the heat exchange tubes and a traction device 2 that works in conjunction with the tube winding rotation mechanism to pull the heat exchange tubes. A front roller frame 3 located on one side of the tube winding rotation mechanism 1 and a traction device 2 located on the traction device 2 are respectively provided between the tube winding rotation mechanism 1 and the traction device 2. A front tube plate 5 is supported on the rear roller frame 4 on one side, and a rear tube plate 6 is supported on the front roller frame 3. A central cylinder 5 is installed between the front tube plate 5 and the rear tube plate 6. The front tube plate 5 is welded with fastening fixtures and connected to the drive shaft of the tube winding mechanism 1 with fasteners. The central cylinder is driven to rotate forward or backward by the tube winding mechanism, so that each heat exchange tube is wound onto the central cylinder in sequence by the traction device. The front and rear tube plates are supported by the front and rear roller frames (reducing the load on the tube winding machine). The tube plate is welded with fastening fixtures and connected to the drive shaft of the tube winding mechanism 1 with fasteners. Therefore, it no longer bears the weight of the equipment body. In particular, it does not have a chuck. The fixing method is fastener connection, which improves the transmission stability, avoids overload damage to the tube winding machine, and reduces maintenance costs.

[0058] Furthermore, the traction device 2 includes a fixed bracket 12, a transmission device (such as a hand-operated hoist) 8, and a traction head 9. The fixed bracket is placed on the ground, and the transmission device is fixedly installed on the fixed bracket. The tail of the traction head 9 is hooked with a wire rope. The traction head is welded to the end of the heat exchange tube 11. It passes through the tube sheet from one side and straightens the other side. This traction device is mainly used to solve the problem of difficulty in passing one end of the heat exchange tube through the tube sheet after the heat exchange tube is wound. Since the wound heat exchange tube is usually supplied in multiple lengths of coil, the straightness of the heat exchange tube cannot meet the requirements for the tube hole to be inserted and exited. Since the initial section has not been wound, it can be straightened using a mechanical tube straightener. However, since the end section has been wound on the central body, it cannot be straightened using a machine. The traction head is welded to the end of the heat exchange tube, passes through the tube sheet from one side and straightens the other side until the required dimensions are reached. The front roller frame 3 and the rear roller frame 4 both include a frame and rollers installed on the frame.

[0059] In addition, a synchronous moving tube feeding mechanism 10 is set between the tube winding rotation mechanism and the traction device. This synchronous moving tube feeding mechanism consists of a moving trolley and a track. The trolley's travel on the track is synchronized with the tube winding rotation mechanism. Once it rotates, the trolley moves at a set speed. The heat exchange tubes are installed on the trolley in a coil form. Its manufacturing process is reasonable, employing a multi-channel flow arrangement and a new tooling system, significantly improving the heat transfer efficiency of the heat exchanger and enhancing its adaptability to operating conditions. Simultaneously, combined with the new tooling system and standardized tube layout diagram, it solves problems such as low winding precision, cumbersome processes, and low efficiency in hydrostatic testing in traditional manufacturing, achieving a dual breakthrough in manufacturing quality and production efficiency.

[0060] The tube layout diagram clarifies the winding orientation of the first tube in each layer and the groove for the irregularly shaped gasket, with the remaining heat exchange tubes wound sequentially. This standardizes the winding order of heat exchange tubes in the same layer and also clarifies the corresponding tube sheet hole position for each heat exchange tube.

[0061] Of course, the above description is not intended to limit the present utility model, and the present utility model is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present utility model should also fall within the protection scope of the present utility model.

Claims

1. A manufacturing apparatus for a multi-flow, multi-tube long-winding heat exchanger, comprising a winding rotation mechanism (1) for winding heat exchange tubes and a traction device (2) cooperating with the winding rotation mechanism to traction the heat exchange tubes (11), characterized in that: Between the tube-winding rotation mechanism (1) and the traction device (2), there is a front roller frame (3) on one side of the tube-winding rotation mechanism (1) and a rear roller frame (4) on one side of the traction device. A front tube plate (5) is supported on the front roller frame (3), and a rear tube plate (6) is supported on the rear roller frame (4). A central cylinder (7) is installed between the front tube plate (5) and the rear tube plate (6). The central cylinder is driven to rotate forward or backward by the tube-winding rotation mechanism, so that each heat exchange tube is wound around the central cylinder in sequence by the traction device.

2. The manufacturing equipment for the multi-stream, multi-tube, long-wound heat exchanger according to claim 1, characterized in that: The traction device (2) includes a fixed bracket (12), a transmission device (8), and a traction head (9). The traction head (9) is welded to the end of the heat exchange tube and passes through the tube sheet from one side to straighten the other side.

3. The manufacturing equipment for the multi-stream, multi-tube, long-wound heat exchanger according to claim 2, characterized in that: Both the front roller frame (3) and the rear roller frame (4) include a frame and rollers mounted on the frame.

4. The manufacturing equipment for the multi-stream, multi-tube, long-wound heat exchanger according to claim 3, characterized in that: A synchronous moving pipe feeding mechanism (10) is provided between the pipe winding rotation mechanism and the traction device.

5. The manufacturing equipment for the multi-stream, multi-tube, long-wound heat exchanger according to claim 4, characterized in that: The front tube sheet (5) is welded with fastening fixtures and is connected to the drive shaft fasteners of the tube rotation mechanism (1).

6. The manufacturing equipment for the multi-stream, multi-tube, long-wound heat exchanger according to claim 5, characterized in that: The transmission device (8) is a hand chain hoist.

7. The manufacturing equipment for the multi-stream, multi-tube, long-wound heat exchanger according to claim 6, characterized in that: The fixed bracket (12) is placed on the ground, and the transmission device (8) is fixedly installed on the fixed bracket (12).

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