大型转炉本体设备安装技术研究
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摘要
转炉本体设备主要由托圈、耳轴轴承座、耳轴轴承支座、炉壳、倾动装置等主要部件组成,是炼钢车间的核心设备。由于生产工艺平面布置的需要,转炉本体设备一般布置在加料跨和炉子跨之间,且单件设备的外形尺寸和质量庞大,设备的安装、检修、技术改造等工作受空间和起重设备的限制,施工难度比较大,因此安全、有序、高效、优质的进行本体设备安装,尽量减少对外部条件的约束,对于节约施工时间,降低项目成本,降低维护费用等有着十分重要的意义。
本文分析了近年来新开发出的大型转炉线外组装、整体安装工艺,与传统安装工艺的对比,介绍了新工艺的主要施工工艺流程,不从设备安装基础检查、挚板选择、耳轴轴承安装、滑移梁设计、托圈、炉壳、倾动装置的组装等进行了全面、详细的方案讨论和相关计算,对于新工艺在工程中的应用及在以往安装过程中尚未形成系统工艺的成对切向键的安装进行了技术攻关,系统阐述了大型转炉线外组装工艺安装过程中的关键技术的设计研究和实施过程。
1、转炉线外组装滑移装置方面的技术研究;将新工艺与本工程具体设备相结合,设计合适的滑移支撑结构,安排合理的组装工序,充分利用现有的结构、场地和吊装条件,使组装的托圈、炉壳及倾动装置满足顺利滑移的需要。
2、三点球面支撑装置安装的关键技术;由于三点球面支撑装置的结构特点,安装时不易直接检查,通过控制和检查炉壳与托圈间的相关尺寸,以保证该装置的正确安装。
3、耳轴成对切向键的安装关键技术;成对切向键的安装质量对转炉正常的生产有着重要的影响,设计出切线键的安装前检查、研磨、精加工、安装等过程的合理、严密的施工工艺,确保成对切向键的安装质量达到设计要求。
The body of the converter is mainly consisted of support ring, trunnion chock, trunnion bearing support, shell, tilting device and the other major parts, and it is the key equipment of the steel-making plant. According to the requirement of producing process plan layout, the converter is usually settled between the feeding area and the furnace area; additionally, the single equipment of the converter is huge both in size and weight, the construction for erection, maintenance and modification is relatively difficult as the limit of space and capability of cranes. Therefore, a safe, orderly, efficient, good erection of the converter body and a reduction of boundaries of environmental conditions both are important and meaningful for the saving of construction time and reducing the cost and maintenance cost.
The article analyzed the newly developed huge converter off-line assembling and overall erection process, compared the new process with the traditional erection process, introduced the main procedures of the new process. The article has a detailed, overall plan discussion and related calculation from the equipment erection foundation inspection, shim plates selection, trunnion bearing erection, sliding beam design, support ring, shell and tilting device assembly, and conquered the technical difficulties of the application of new process and the erection of tangential keys in pairs which had not formed a system during the previous erection process, and systematically described the design, research and application procedures of key technologies of the new process.
1、The technology research of gliding device of converter off-line assembling; The new process and the detailed equipments of a particular project shall be considered together to design a suitable gliding and supporting frame and to organize a reasonable assembling process. The existed structure, field and lifting environment shall be fully utilized. And the assembled supporting ring, shell and tilting devices should surely meet the requirement for gliding.
2、The key technology for three-point sphere supporting device erection; as the structure of the three-point sphere supporting device, the inspection cannot be directly done during erection. The reference dimension between the shell and support ring shall be controlled and inspected to ensure the correct erection of the device.
3、The key technology of trunnion tangential keys in pairs; The erection quality of twin tangential keys has a important influence for the regular production of converter. A reasonable, specified construction process for inspection before erection, grinding, machining and erection of tangential keys shall be designed to ensure the erection quality of twin tangential keys will meet the design requirements.
本文分析了近年来新开发出的大型转炉线外组装、整体安装工艺,与传统安装工艺的对比,介绍了新工艺的主要施工工艺流程,不从设备安装基础检查、挚板选择、耳轴轴承安装、滑移梁设计、托圈、炉壳、倾动装置的组装等进行了全面、详细的方案讨论和相关计算,对于新工艺在工程中的应用及在以往安装过程中尚未形成系统工艺的成对切向键的安装进行了技术攻关,系统阐述了大型转炉线外组装工艺安装过程中的关键技术的设计研究和实施过程。
1、转炉线外组装滑移装置方面的技术研究;将新工艺与本工程具体设备相结合,设计合适的滑移支撑结构,安排合理的组装工序,充分利用现有的结构、场地和吊装条件,使组装的托圈、炉壳及倾动装置满足顺利滑移的需要。
2、三点球面支撑装置安装的关键技术;由于三点球面支撑装置的结构特点,安装时不易直接检查,通过控制和检查炉壳与托圈间的相关尺寸,以保证该装置的正确安装。
3、耳轴成对切向键的安装关键技术;成对切向键的安装质量对转炉正常的生产有着重要的影响,设计出切线键的安装前检查、研磨、精加工、安装等过程的合理、严密的施工工艺,确保成对切向键的安装质量达到设计要求。
The body of the converter is mainly consisted of support ring, trunnion chock, trunnion bearing support, shell, tilting device and the other major parts, and it is the key equipment of the steel-making plant. According to the requirement of producing process plan layout, the converter is usually settled between the feeding area and the furnace area; additionally, the single equipment of the converter is huge both in size and weight, the construction for erection, maintenance and modification is relatively difficult as the limit of space and capability of cranes. Therefore, a safe, orderly, efficient, good erection of the converter body and a reduction of boundaries of environmental conditions both are important and meaningful for the saving of construction time and reducing the cost and maintenance cost.
The article analyzed the newly developed huge converter off-line assembling and overall erection process, compared the new process with the traditional erection process, introduced the main procedures of the new process. The article has a detailed, overall plan discussion and related calculation from the equipment erection foundation inspection, shim plates selection, trunnion bearing erection, sliding beam design, support ring, shell and tilting device assembly, and conquered the technical difficulties of the application of new process and the erection of tangential keys in pairs which had not formed a system during the previous erection process, and systematically described the design, research and application procedures of key technologies of the new process.
1、The technology research of gliding device of converter off-line assembling; The new process and the detailed equipments of a particular project shall be considered together to design a suitable gliding and supporting frame and to organize a reasonable assembling process. The existed structure, field and lifting environment shall be fully utilized. And the assembled supporting ring, shell and tilting devices should surely meet the requirement for gliding.
2、The key technology for three-point sphere supporting device erection; as the structure of the three-point sphere supporting device, the inspection cannot be directly done during erection. The reference dimension between the shell and support ring shall be controlled and inspected to ensure the correct erection of the device.
3、The key technology of trunnion tangential keys in pairs; The erection quality of twin tangential keys has a important influence for the regular production of converter. A reasonable, specified construction process for inspection before erection, grinding, machining and erection of tangential keys shall be designed to ensure the erection quality of twin tangential keys will meet the design requirements.
引文
[1]GB50231-98.机械设备安装工程施工及验收通用规范[S].
[2]GB50403-2007.炼钢机械设备工程安装验收规范[S].
[3]GB50236-98.现场设备、工业管道焊接工程施工及验收规范[S].
[4]GB6067-85.起重机安全规程[S].
[5]杨文渊主编.实用起重吊装手册[M].上海科学技术出版社,1996.
[6]GB/T50326.建设工程项目管理规范[S].
[7]苏会德,姜雷,赵守林,刘文峰,姜秀梅.100吨转炉设备安装[J].莱钢科技,2006,(01).
[8]唐燕,王连军,郑小宝.大型炉钢转炉线外组装整体安装方法[P].上海宝冶建设有限公司,2007.
[9]王隆寿,陈军.宝钢300t转炉炉壳更换中的新技术[J].冶金设备,2002,(04).
[10]王跃峰.提钒转炉悬挂装置安装工艺开发[J].今日科苑,2008,(08).
[11]饶记珠.“滑移法”在大型转炉安装中的应用[J].宝钢技术,2007,(03).
[12]王吉勤,李文.2x50t转炉本体设备安装[J].安装,2005,(12).
[13]王隆寿.300t转炉炉体更新技术[J].宝钢技术,1998,(06).
[14]郑建华,田永奋.三点球铰吊挂转炉开发[J].冶金设备,2006,(05).
[15]戴钦诚.2号转炉改造性大修一次投产成功[J].鞍钢技术,1983,(02).
[16]冯东锋,于相龙.转炉三点球面支撑有限元静力学分析[J].2005中国钢铁年会论文集(第4卷)[C].
[17]张士红.120t转炉本体设备安装[J].安徽冶金科技职业学院学报,2006,(16).
[18]张益平.安装转炉托圈的新方法[J].钢铁研究学报,2006,(09).
[19]韩文哲,杜军科,徐兰柱,赵杨.转炉炉壳倒装液压提升方法[P].天津二十冶建设有限公司,2007.
[20]李强国,苏青.转炉托圈的更换[J].山西机械,2001,(01).
[21]田永奋,李志强.一种三点球铰吊挂倾动转炉[P].中国冶金建设集团包头钢铁设计研究总院,1999.
[22]G.Staudinger,R.Gruber.VAI-CON转炉连杆式悬挂系统[J].中国钢铁年会增刊,1999.
[23]王德宽,戈义彬,邱明罡,李强,宁欢,刘水池.转炉炉体下悬挂连接装置[P].中冶京诚工程技术有限公司,2007.
[24]黄其明,赵渭康.转炉炉壳吊挂装置[P].中冶赛迪工程技术股份有限公司,2004.
[25]焉永刚,李志强,杨撵上.转炉倾动装置的改进[J].冶金设备,2003,(06).
[26]王勇,肖鹏,杨宁川,赵运锋.我国大型转炉炼钢车间设备国产化问题的探讨[J].钢铁技术,2007,(01).
[27]胡卫国,汪厚华.转炉球铰的顶升更换方法[J].安徽冶金科技职业学院学报,2007,(04).
[28]罗振才主编.炼钢机械[M].冶金工业出版社,1989.
[29]杨俊良,冯玉刚.宝钢250t转炉氧枪设备的设计[J].一重技术,1996,(02).
[30]王英均,李亚松.宝钢三期炼钢生产工艺浅析[J].宝钢技术,2000,(01).
[31]潘秀兰,王艳红,郭艳玲,刘丽娟.国内外转炉炼钢技术的新进展[J].鞍钢技术,2004,(06).
[32]张昭,屈文胜,赵殿清.210t转炉顶底复吹技术的开发和应用[J].包钢科技,2004,(02).
[33]陈绍藩编著.钢结构设计原理(第三版).北京:科学出版社,2005.
[34]美国焊接协会标准.钢结构焊接规范AWS D1.1:2002.上海振华港口机械(集团)股份有限公司译丛,2003
[35]李和华编著.钢结构连接节点设计手册.北京:中国建筑工业出版社,1992.
[36]European Committee for Standardisation.Eurocode3:Design of Steel Structures (ENV1993-1-1).1992
[37]American Welding Society.Structural Welding Code:Steel(ANSI/AWS D1.1-86).1986.
[38]傅水龙编著.建筑施工项目经理手册.南昌:江西科学技术出版社,2002.
[39]王启广编著.螺纹连接预紧力控制(J).矿山机械,2001.
[40]工程测量规范(GB50026-2007).北京:中国计划出版社,2008.
[41]冶金机械设备液压、润滑和气动设备工程安装验收规范(GB50387-2006).北京:中国计划出版社,2007.
[42]成大先编著.机械设计手册.北京:化学工业出版社,2002.
[2]GB50403-2007.炼钢机械设备工程安装验收规范[S].
[3]GB50236-98.现场设备、工业管道焊接工程施工及验收规范[S].
[4]GB6067-85.起重机安全规程[S].
[5]杨文渊主编.实用起重吊装手册[M].上海科学技术出版社,1996.
[6]GB/T50326.建设工程项目管理规范[S].
[7]苏会德,姜雷,赵守林,刘文峰,姜秀梅.100吨转炉设备安装[J].莱钢科技,2006,(01).
[8]唐燕,王连军,郑小宝.大型炉钢转炉线外组装整体安装方法[P].上海宝冶建设有限公司,2007.
[9]王隆寿,陈军.宝钢300t转炉炉壳更换中的新技术[J].冶金设备,2002,(04).
[10]王跃峰.提钒转炉悬挂装置安装工艺开发[J].今日科苑,2008,(08).
[11]饶记珠.“滑移法”在大型转炉安装中的应用[J].宝钢技术,2007,(03).
[12]王吉勤,李文.2x50t转炉本体设备安装[J].安装,2005,(12).
[13]王隆寿.300t转炉炉体更新技术[J].宝钢技术,1998,(06).
[14]郑建华,田永奋.三点球铰吊挂转炉开发[J].冶金设备,2006,(05).
[15]戴钦诚.2号转炉改造性大修一次投产成功[J].鞍钢技术,1983,(02).
[16]冯东锋,于相龙.转炉三点球面支撑有限元静力学分析[J].2005中国钢铁年会论文集(第4卷)[C].
[17]张士红.120t转炉本体设备安装[J].安徽冶金科技职业学院学报,2006,(16).
[18]张益平.安装转炉托圈的新方法[J].钢铁研究学报,2006,(09).
[19]韩文哲,杜军科,徐兰柱,赵杨.转炉炉壳倒装液压提升方法[P].天津二十冶建设有限公司,2007.
[20]李强国,苏青.转炉托圈的更换[J].山西机械,2001,(01).
[21]田永奋,李志强.一种三点球铰吊挂倾动转炉[P].中国冶金建设集团包头钢铁设计研究总院,1999.
[22]G.Staudinger,R.Gruber.VAI-CON
[23]王德宽,戈义彬,邱明罡,李强,宁欢,刘水池.转炉炉体下悬挂连接装置[P].中冶京诚工程技术有限公司,2007.
[24]黄其明,赵渭康.转炉炉壳吊挂装置[P].中冶赛迪工程技术股份有限公司,2004.
[25]焉永刚,李志强,杨撵上.转炉倾动装置的改进[J].冶金设备,2003,(06).
[26]王勇,肖鹏,杨宁川,赵运锋.我国大型转炉炼钢车间设备国产化问题的探讨[J].钢铁技术,2007,(01).
[27]胡卫国,汪厚华.转炉球铰的顶升更换方法[J].安徽冶金科技职业学院学报,2007,(04).
[28]罗振才主编.炼钢机械[M].冶金工业出版社,1989.
[29]杨俊良,冯玉刚.宝钢250t转炉氧枪设备的设计[J].一重技术,1996,(02).
[30]王英均,李亚松.宝钢三期炼钢生产工艺浅析[J].宝钢技术,2000,(01).
[31]潘秀兰,王艳红,郭艳玲,刘丽娟.国内外转炉炼钢技术的新进展[J].鞍钢技术,2004,(06).
[32]张昭,屈文胜,赵殿清.210t转炉顶底复吹技术的开发和应用[J].包钢科技,2004,(02).
[33]陈绍藩编著.钢结构设计原理(第三版).北京:科学出版社,2005.
[34]美国焊接协会标准.钢结构焊接规范AWS D1.1:2002.上海振华港口机械(集团)股份有限公司译丛,2003
[35]李和华编著.钢结构连接节点设计手册.北京:中国建筑工业出版社,1992.
[36]European Committee for Standardisation.Eurocode3:Design of Steel Structures (ENV1993-1-1).1992
[37]American Welding Society.Structural Welding Code:Steel(ANSI/AWS D1.1-86).1986.
[38]傅水龙编著.建筑施工项目经理手册.南昌:江西科学技术出版社,2002.
[39]王启广编著.螺纹连接预紧力控制(J).矿山机械,2001.
[40]工程测量规范(GB50026-2007).北京:中国计划出版社,2008.
[41]冶金机械设备液压、润滑和气动设备工程安装验收规范(GB50387-2006).北京:中国计划出版社,2007.
[42]成大先编著.机械设计手册.北京:化学工业出版社,2002.