CN119635045A - Construction method of three-machine unstressed piping of ethylene device - Google Patents
Construction method of three-machine unstressed piping of ethylene device Download PDFInfo
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- CN119635045A CN119635045A CN202411938704.3A CN202411938704A CN119635045A CN 119635045 A CN119635045 A CN 119635045A CN 202411938704 A CN202411938704 A CN 202411938704A CN 119635045 A CN119635045 A CN 119635045A
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Abstract
本发明提供了一种乙烯装置三机无应力配管施工方法，根据管线图，将连接管道划分为水平段、立管段、调整段，并分别进行预制；通过挂百分表及台架辅助手段，依次将调整段、水平段、与立管段组对拼接；将管道焊口焊接移至最后焊口位置通过对称焊工焊接，管道安装连接处于自由垂直状态，消除管道安装带来的应力，有效保证了设备与管道连接的安装精度及施工进度。
The invention provides a stress-free piping construction method for three machines of an ethylene device. According to a pipeline diagram, a connecting pipeline is divided into a horizontal section, a vertical pipe section and an adjustment section, and the sections are prefabricated respectively; the adjustment section, the horizontal section and the vertical pipe section are sequentially connected and spliced by hanging a dial indicator and a stand auxiliary means; the pipeline weld joint is moved to the last weld joint position and welded by a symmetrical welder, the pipeline installation connection is in a free vertical state, the stress caused by the pipeline installation is eliminated, and the installation accuracy and construction progress of the connection between the equipment and the pipeline are effectively guaranteed.
Description
Technical Field
The invention relates to the technical field of chemical equipment installation, in particular to a construction method of a three-machine non-stress piping of an ethylene device.
Background
Ethylene units are the core units of the petrochemical industry and are the main facilities for producing ethylene. The three machines (a cracking gas compressor, an ethylene compressor and a propylene compressor) in the ethylene device are key equipment of the whole device, power is provided for material circulation, the three machines run stably, and the stress of a pipeline system cannot be transmitted to the three machines, so that the stress-free piping construction of the pipeline system is a key ring.
In the conventional piping construction, stress is often generated when the pipe is connected to the three machines. When the pipeline expands with heat and contracts with cold due to temperature change in the operation process, the expansion or contraction of the pipeline can generate tensile force or pressure on the interface of the three-machine equipment because the traditional pipeline does not fully consider the change. Such additional stresses may lead to deformation, damage at the equipment interface and even affect the mechanical structure and sealing performance inside the equipment. Under the environment of high temperature and high pressure, the damage of the ethylene device can further cause problems of leakage, vibration aggravation and the like, and the service life of equipment and the safety of the device are seriously affected.
Disclosure of Invention
The invention aims to solve the technical problem of providing a construction method of a three-machine non-stress piping of an ethylene device, which realizes the installation of the non-stress piping of a pipeline at a device port, reduces overhead operation and ensures the high-precision installation of the pipeline.
In order to solve the technical problems, the technical scheme adopted by the invention is that the construction method of the three-machine unstressed piping of the ethylene device comprises the following steps:
Dividing a connecting pipeline into a horizontal section, a vertical pipe section and an adjusting section according to a pipeline diagram, and prefabricating the horizontal section, the vertical pipe section and the adjusting section respectively;
Step two, arranging a rack on the periphery of the compressor, arranging a plurality of lifting hoists on the top of the rack, connecting the lifting hoists with the outer wall of the vertical pipe section of the sling, and conveying the prefabricated vertical pipe section to the lower part of the installation position by utilizing the lifting hoists and the sling;
The rack comprises a hoisting rack, the hoisting rack comprises a plurality of upright posts arranged around the compressor, a top hanging bracket is arranged at the top of each upright post, an operation hanging bracket is arranged at the middle part of each upright post, a hoisting hoist is arranged on each top hanging bracket, and a supporting frame is arranged at the upper part of each operation hanging bracket;
step three, removing a lifting hoist and a sling, positioning a vertical pipe on a sizing block on a support frame, measuring the clearance and the non-parallelism between two flanges of a compressor and a main pipe by using a feeler gauge, adjusting the sizing block according to the measured value, moving a pipe section for alignment, adding a formal gasket between the flanges, and installing bolts;
And fourthly, assembling and welding the horizontal section, the adjusting section and the vertical pipe section.
Further, in the first step, when the riser section is prefabricated, the length of the riser section is lengthened by 20mm to adjust the cutting allowance.
In the first step, when the horizontal section, the vertical section and the adjusting section are prefabricated, the rack is used as a processing platform.
In the first step, before the riser is formally installed, a flange opening of the riser is pre-connected with a flange opening of a compressor, a temporary gasket is added between the flange of the riser and the flange of the compressor, the parallelism of the flange is checked, and a dial indicator test machine body is erected on a coupler to test radial and axial displacement.
Further, in the second step, the lifting hoist is hung on the top hanging frame to connect the riser section, the riser section is lifted to 5-10 mm away from the flange of the compressor by using the lifting hoist, the bolt hole centers of the upper flange and the lower flange are initially aligned, connecting bolts are inserted, and the bolts are only used for centering and guiding and do not bear the weight of the riser section.
In the third step, the gap between the riser flange and the compressor flange is 3mm and the non-parallelism is within 0.1mm by adjusting the sizing block and moving the riser section to find.
In the fourth step, during assembly welding, the parallelism of the flange of the compressor and the flange of the vertical pipe and whether the inserted bolts can be loosened freely are checked, if the flange of the compressor and the flange of the vertical pipe are found to be unsatisfactory, the flange of the vertical pipe are processed and adjusted to the specified requirements, and a dial indicator is arranged on the support on two sides of the compressor and the axial flexible supporting leg to monitor whether the radial displacement and the axial displacement of the compressor are generated due to stress.
In the fourth step, the final assembly pipe orifice is a transverse welding port, and 2 welders are symmetrically staggered at the same time during welding.
The invention realizes the construction method of the high-power large-caliber equipment pipeline stress-free piping by adopting the hanging meter and the rack setting method, and compared with the traditional construction method of the movable equipment piping from the far end of the pipe section to the equipment end, the construction method saves the construction cost of the scaffold, reduces the overhead operation, shortens the construction period and saves the cost. The pipeline is installed and connected in a free vertical state through the actual measurement of the hanging meter, so that the stress brought by the pipeline installation is eliminated, and the installation precision and the construction progress of the equipment and the pipeline connection are effectively ensured.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the principles of the application.
FIG. 1 is a schematic illustration of a pipe weld according to the present invention;
FIG. 2 is a section steel handling bench according to the invention;
Fig. 3 is a final fixed port welding sequence diagram.
In the figure, a 1-compressor flange, a 2-guide bolt, a 3-lifting hoist, a 4-positioning jackscrew, a 5-operation hanging bracket, a 6-riser section, a 7-sizing block, an 8-gasket plug gauge, a 9-supporting frame, a 10-top hanging bracket and an 11-riser flange.
Detailed Description
The main inlet and outlet pipelines of the pyrolysis gas compressor, the ethylene compressor and the propylene compressor of the ethylene device are arranged intensively and have higher installation height, the connection of the compressor unit and the pipeline system requires the stress of the pipeline system and cannot be transferred to compressor equipment, and the unit must realize stress-free connection. The basic concept of the invention is that the connecting pipeline is divided into a horizontal section, a vertical section and an adjusting section according to a pipeline diagram, numbering is carried out, the flange of the equipment body is used as a reference point, the pipeline is fixed by a bench, the verticality and the levelness of the pipeline are adjusted by a hanging dial indicator, and the gap of the flange surface of the pipe orifice is ensured to be freely vertical so as to realize stress-free connection of the pipeline, the pipe orifice of the equipment is ensured not to be under the weight and the tensile force of the pipeline, thus the stress-free operation of the equipment is ensured, and the operation is convenient when the pipeline is installed.
The technical scheme to be protected of the present invention will be further clearly and completely described below by taking an ethylene compressor K1650 as an example. The ethylene compressor K1650 connection pipe segment comprises:
k1650 three stage G3702 Inlet 48"-RE16012-A71KEO-AC
K1650 third stage G3702 Outlet 24"-RE16013-A71KEO-AC
K1650 Low pressure inlet 30"-RE16001-A71KEO-AC
K1650 high pressure inlet 24"-RE16170-A71KEO-AC
K1650 high pressure outlet 16"-RE16115-A71KEO-AH.
Step one, dividing a connecting pipeline into a horizontal section, a vertical pipe section and an adjusting section according to a pipeline diagram, and prefabricating the connecting pipeline respectively.
Before the riser is formally installed, the flange opening of the riser is pre-connected with the flange opening of the compressor, a temporary gasket is added between the flange 11 of the riser and the flange 1 of the compressor, the parallelism of the flange is checked, and a dial indicator test machine body is erected on the coupler for radial and axial displacement.
Illustratively, as shown in FIG. 1, for example, a middle pipeline 24' -RE16010-A81KEO-AC is used, a riser section 6 is arranged between 1# and 4# craters, a horizontal section is arranged between 4# and 6# craters, an adjustment section is arranged in a transverse pipe between 4# and 6# craters, and the last crater of an inlet is arranged at the 4# crater. It should be noted that, the exemplary pipeline does not include a spanning section, but includes a spanning section in other pipelines, and the pipeline at the equipment port should be divided into an adjusting section, a horizontal section, a vertical section and a spanning section of the pipeline in advance according to a single line diagram below the type of pipeline.
When the adjusting section is prefabricated, the hanging wire measurement is carried out according to the actual azimuth and the actual elevation of the machine body interface flange. The levelness of the powder line is checked by a level gauge for prefabrication of the horizontal pipe, and the length can be measured and the powder line is discharged after the powder line is qualified. The length of the riser section should be lengthened by 20mm as an adjustment cutting allowance, and the inside of the pipe should be cleaned after the allowance is cut.
The riser sections 6 of the 1# to 4# ports on the pipeline 24' -RE16010-A81KEO-AC are connected with the compressor flange 1, the reducing pipe welded junctions 2# and 3# are prefabricated in advance, temporary gaskets are added between the riser flange 11 and the compressor flange 1, bolts are not required to be too tight, and meanwhile, the parallelism of the flanges is checked. Four clamps are symmetrically welded around the No. 4 and No. 6 weld junctions, then the No. 6 weld junctions are assembled and spot welded, each weld junction is symmetrically welded by two welders, and the welding is carried out while closely paying attention to the pipe misalignment amount at the No. 4 weld junction, and the adjustment is carried out in a symmetrical welding mode. And finally, symmetrically assembling the No. 4 welded junctions by two welders, erecting a dial indicator on the coupler by a fitter to test the radial and axial displacement of the machine body while welding, immediately stopping welding by the welders if the radial and axial displacement exceeds the standard, adjusting the welding position according to the property of deviation until the welding is finished, checking and checking to be qualified, and finally removing the fixture.
After the welded junction is welded, loosening the fastening bolt, and removing the temporary gasket, wherein the temporary gasket is 10# steel, and the surface finish is 6.3. And checking the flange parallel deviation, radial deviation and sealing surface spacing by using a gasket gauge, and if the flange is unqualified, re-grinding one side, and performing adjustment welding to reach the standard of qualified measurement.
In this step, the compressor inlet line must be cleaned before installation. When the impurities are removed, the method can be carried out by adopting a manual (sanding) treatment or manual rust removal mode, and then the plastic cloth is used for sealing. After cleaning, the branch pipe sections are confirmed by workshops before installation. Before the adjusting section is installed, whether the sealing surfaces of the machine body flange and the piping flange are parallel or not is checked, whether the bolt holes are concentric. After quality inspection personnel check the product to be qualified, the product can be installed. When the compressor piping is performed, the piping should be performed from the periphery toward the machine body, and the piping is thrown at the weld near the machine body.
Step two, the periphery of the compressor is provided with a rack, the top of the rack is provided with a plurality of lifting hoists 3, the lifting hoists 3 are connected with the outer wall of the vertical pipe section 6 of the sling, and the prefabricated vertical pipe section 6 is conveyed to the lower part of the installation position by the aid of the lifting hoists 3 and the sling.
As shown in fig. 2, the rack comprises a hoisting rack, the hoisting rack comprises a plurality of upright posts arranged around the compressor, a top hanging bracket 10 is arranged at the top of each upright post, an operation hanging bracket 5 is arranged in the middle of each upright post, a lifting hoist 3 is arranged on each top hanging bracket 10, and a supporting frame 9 is arranged on the upper part of each operation hanging bracket 5.
The temporary rack is used as an installation adjustment platform, the flange opening of the pipeline is pre-connected with the equipment opening, the dial indicator is hung for checking, the equipment is well processed and is not stressed, so that the assembly welding is performed under the condition that the pipeline is not stressed, the rack is used for guaranteeing the levelness and the verticality of the pipeline, the lifting lugs and auxiliary tools are arranged in advance to guarantee the assembly level of the pipeline, and the high-altitude installation work of the stress-free connection of the flange opening of the equipment is guaranteed.
In this step, because the main inlet and outlet pipelines of the compressor are arranged more intensively and have higher installation height, in order to facilitate the operation when the piping is installed, the hoisting positioning weight is not attached to the compressor body, firstly, two layers of steel operation benches are arranged at proper heights of the compressor unit, a top hanging bracket 10 is arranged at the top position of the benches, and then, the prefabricated riser section 6 is conveyed to the lower side of the installation position by using a lifting hoist 3 and a sling.
Illustratively, 4 lifting blocks 3 are hung on the top hanging frame 10 to be connected with the vertical pipe section 6, the vertical pipe section 6 is lifted to be 5-10 mm away from the flange of the compressor by using the lifting blocks 3, the centers of bolt holes of the upper flange and the lower flange are initially aligned, the connecting guide bolts 2 are inserted, and the guide bolts 2 are only used for centering and guiding and do not bear the weight of the vertical pipe section 6.
Step three, after the riser section 6 is sent to the below of the installation position, the supporting frame 9 on the operation hanging bracket 5 is erected, the sizing block 7 is arranged on the supporting frame 9, the lifting hoist 3 and the lifting rigging are removed, the riser is positioned on the sizing block 7 on the supporting frame 9, then the gap and the non-parallelism between the compressor and the two flanges of the main pipe are measured by the gasket feeler gauge 8, the measurement is performed in a four-point symmetry mode, the sizing block 7 is adjusted according to the measured numerical value, the pipe section is moved for alignment, the gap is 3mm, and the non-parallelism is within 0.1 mm.
A formal spacer is then added between the flanges and bolts 2 are installed. Bolts of the inserted bolt holes can be loosened freely, a formal gasket is added before the bolts are inserted, and the sealing surfaces of the two flanges and the gasket are checked before the formal gasket is added, so that damage and defects are avoided. The riser after alignment is not only prevented from moving arbitrarily, but also kept in a free state.
And fourthly, assembling and welding the horizontal section, the adjusting section and the vertical pipe section 6.
The butt-splice of horizontal, riser and cross-section in a single line drawing is critical to ensure that the pipeline does not stress the compressor unit. Especially, the final connection of the fixed weld joint directly influences the non-parallelism between the two flanges of the compressor and the vertical pipe section and the centring degree of the bolt hole, thereby influencing the concentricity of the unit.
When the crossing section is installed, the crossing section is spliced and positioned with the horizontal pipe section, the verticality and the parallelism of the vertical pipe are checked by taking the vertical pipe as a reference, the result is correct, the crossing section and the vertical pipe section are pre-assembled, the assembly welding port is adjusted, and the uniform gaps around the pipe orifice and the staggered edge quantity are ensured to meet the requirements.
The final assembly pipe orifice is basically defined as a transverse welding seam so as to reduce welding deformation, the pipe orifice is welded by spot welding, 2 qualified welders need to carry out the welding at the same time in a symmetrical and staggered mode, and the welding current and the welding speed of two people are basically consistent when the welding is carried out (as shown in figure 3). And spot welding is carried out, professional staff is respectively arranged during the welding, the parallelism of the compressor and the flange at the end of the vertical pipe is measured, and whether the inserted bolt can be loosened freely is checked. The dial indicators are arranged on the supports on the two sides of the compressor and the axial flexible supporting legs, and whether the compressor generates radial displacement and axial displacement due to stress is monitored through the change of readings of the dial indicators. And (3) timely adjusting and selecting welding positions, sequence, time and speed, adjusting stress generated by welding until the welding is finished, and ensuring that the monitoring data are in a specified required range.
In the embodiment, accurate installation guidance and dynamic construction monitoring are realized through a dial indicator. (1) In the pipeline installation process, the dial indicator can display displacement change of the pipeline interface in real time, and provides accurate adjustment basis for constructors. When the pipeline is connected with the equipment, by observing the data of the dial indicator, constructors can timely adjust the position and the angle of the pipeline, ensure that the pipeline is in butt joint with the equipment in a stress-free state, and avoid stress concentration caused by forced butt joint. (2) In the pipeline welding process, the micro displacement of the pipeline is monitored through a dial indicator, and the influence of the welding thermal stress on the pipeline is judged. If the displacement is found to be beyond the allowable range, the welding sequence or parameters can be timely adjusted, and the welding quality and the stability of the pipeline are ensured.
In this embodiment, the segmentation makes the pipe installation more systematic and controllable. Each segment has definite installation position and interface requirements, and constructors can operate according to a preset installation sequence and standard, so that confusion and errors in the installation process are reduced. In the key segmentation that pipeline and equipment are connected, through accurate measurement and location, with the installation deviation control in minimum scope (like + -1 mm), ensure the pipeline and the inseparable laminating of interface of equipment, improved piping system's installation quality and leakproofness.
The segmented pipelines can be processed and preassembled with high precision in a prefabrication stage, including pipeline cutting, groove manufacturing, pipe fitting assembly and the like, and the processing precision can reach +/-0.5 mm. Therefore, when the pipeline system is installed on site, the sections can be quickly and accurately abutted, the workload of on-site adjustment and correction is reduced, the overall straightness and concentricity of the pipeline system are guaranteed, and the fluid conveying efficiency and the operation stability of the pipeline are improved.
In this embodiment, the rack can be equipped with multiple appurtenance, and these instruments can make the pipeline fix in prefabrication in-process conveniently, and the constructor of being convenient for welds and processes from different angles, has reduced constructor's intensity of labour, has improved prefabrication quality simultaneously.
The gantry may serve as a temporary support and adjustment platform for the pipeline during the pipeline installation stage. Through the height of rack, angle regulation function, can be with pipeline accurate adjustment to with equipment interface or adjacent pipeline assorted position, make things convenient for the butt joint and the connection of pipeline.
The rack is used as a temporary supporting structure of the pipeline and provides stable support for the pipeline. The rack can ensure the safety of the pipeline in the installation process and prevent the pipeline from deforming due to the action of dead weight or external force. When the large pipeline is hoisted, the pipeline is placed on the bench for adjustment and butt joint, so that the residence time of the pipeline in the air is reduced, and the installation efficiency and the safety are improved.
The rack can help constructors to accurately adjust the position and the angle of the pipeline through the self adjusting function. Through positioner and measuring tool on the rack, constructor can control the installation deviation of pipeline in minimum within range, realizes the accurate butt joint of pipeline and equipment or adjacent pipeline. The high-precision mounting mode can effectively reduce the mounting stress of the pipeline and prolong the service life of the pipeline.
And the bench is in seamless connection with the whole construction flow of the stress-free piping. In the pipeline prefabrication stage, the rack is used as a high-precision processing platform for pipeline segmentation, in the pipeline installation process, the rack can rapidly and accurately transport the pipeline segmentation to an installation position, provide stable support and positioning, facilitate the butt joint and welding operation of a constructor, and in the pipeline stress adjustment stage, the rack can be used as an operation platform for stress monitoring and adjustment and is tightly matched with a dial indicator monitoring system, so that the accurate control and optimization of the pipeline segmentation stress are realized. The whole construction process of the stress-free piping is smoother and more efficient, errors and stress changes caused by construction link conversion are reduced, and the construction quality and the stability of a pipeline system are further improved.
In summary, the method for constructing the stress-free piping of the high-power large-caliber equipment pipeline is realized by adopting the hanging meter and the rack setting method, so that the construction method saves the construction cost of the scaffold, shortens the construction period and saves the cost compared with the traditional construction method for constructing the piping from the far end of the pipe section to the equipment end of the movable equipment piping. The construction method for eliminating stress, which can not reach the installation precision compared with the prior tubing, is changed, and provides technical reference for the construction of the same type of engineering in the future. The pipeline installation is connected in a free vertical state through the actual measurement of the hanging meter, and the stress brought by the pipeline installation is eliminated through auxiliary facilities, so that the construction quality and the construction progress of the pipeline are effectively ensured.
Claims (8)
1. The construction method of the three-machine unstressed piping of the ethylene device is characterized by comprising the following steps of:
Dividing a connecting pipeline into a horizontal section, a vertical pipe section and an adjusting section according to a pipeline diagram, and prefabricating the horizontal section, the vertical pipe section and the adjusting section respectively;
Step two, arranging a rack on the periphery of the compressor, arranging a plurality of lifting hoists on the top of the rack, connecting the lifting hoists with the outer wall of the vertical pipe section of the sling, and conveying the prefabricated vertical pipe section to the lower part of the installation position by utilizing the lifting hoists and the sling;
The rack comprises a hoisting rack, the hoisting rack comprises a plurality of upright posts arranged around the compressor, a top hanging bracket is arranged at the top of each upright post, an operation hanging bracket is arranged at the middle part of each upright post, a hoisting hoist is arranged on each top hanging bracket, and a supporting frame is arranged at the upper part of each operation hanging bracket;
Step three, removing lifting hoist and sling, positioning a vertical pipe on a sizing block on a support frame, measuring the clearance and the non-parallelism between the compressor and two flanges of a main pipe by using a gasket feeler gauge, adjusting the sizing block according to the measured value, moving a pipe section for alignment, and adding a formal gasket between the flanges and installing bolts;
And fourthly, assembling and welding the horizontal section, the adjusting section and the vertical pipe section.
2. The method of claim 1, wherein in step one, the length of the riser section is increased by 20mm as an adjustment cutting allowance during prefabrication.
3. The method according to claim 1 or 2, wherein in the first step, the bench is used as a processing platform when the horizontal section, the vertical section and the adjusting section are prefabricated.
4. The method of claim 3, wherein in the first step, before the riser is formally installed, the flange opening of the riser is pre-connected with the flange opening of the compressor, a temporary gasket is plugged between the flange of the riser and the flange of the compressor, the parallelism of the flange is checked, and a dial indicator is erected on the coupler to test the radial and axial displacement of the machine body.
5. The method of claim 1 or 4, wherein in the second step, lifting blocks are hung on the top hanging frame to be connected with the vertical pipe sections respectively, the vertical pipe sections are lifted to be 5-10 mm away from the flanges of the compressor by using the lifting blocks, the centers of bolt holes of the upper flange and the lower flange are initially aligned, connecting bolts are inserted, and the bolts are only used for centering and guiding and do not bear the weight of the vertical pipe sections.
6. The method of claim 5, wherein in step three, the riser flange and the compressor flange are positioned with a gap of 3mm and a non-parallelism of less than 0.1mm by adjusting the sizing block and moving the riser section.
7. A method according to claim 1 or 6, wherein in step four, during assembly welding, parallelism of the flange of the compressor and the flange of the vertical pipe and whether the inserted bolts can be loosened freely are checked, if no requirements are found, the flange is processed and adjusted to the specified requirements, and a dial indicator is arranged on the support on two sides and the axial flexible supporting leg of the compressor to monitor whether radial displacement and axial displacement of the compressor are generated due to stress.
8. The method of claim 7, wherein in the fourth step, the final assembly of the pipe orifices is a transverse welding port, and the welding is performed by 2 welders symmetrically and simultaneously.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202411938704.3A CN119635045A (en) | 2024-12-26 | 2024-12-26 | Construction method of three-machine unstressed piping of ethylene device |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202411938704.3A CN119635045A (en) | 2024-12-26 | 2024-12-26 | Construction method of three-machine unstressed piping of ethylene device |
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