阅读说明：本技术 一种管板与换热管的套装方法 (Sleeving method of tube plate and heat exchange tube ) 是由 徐晓星 李家鲁 刘银河 王立昆 杜国珠 窦炳程 于 2020-04-16 设计创作，主要内容包括：一种管板与换热管的套装方法,为解决异形换热管穿入管板困难及换热管逐根进入管板效率低,操作复杂,操作人员劳动工作强度高的问题,本发明采用先逐根布置所有换热管,采用引导头或管板本身对换热管定位,控制换热管间距；套装管板,保持换热管基本不动,管板向管束中套入。随着管板前进,所有换热管同时就位；本方法在自由状态下装配换热管,换热管间完全不干涉,操作难度小,效率高。同时,由于换热管与管孔间隙小,换热管进入管孔时间占穿管比重较大,采用该方法后所有换热管一次进入管孔,缩短了穿管周期,由于管板和换热管后装配,只要换热管能实现定位,立管架、穿管可以和管板制造同步进行,极大缩短换热器制造周期。(A method for sleeving a tube plate and a heat exchange tube aims to solve the problems that a special-shaped heat exchange tube is difficult to penetrate into the tube plate, the efficiency of the heat exchange tubes entering the tube plate one by one is low, the operation is complex, and the labor intensity of operators is high; sleeving the tube plate, keeping the heat exchange tube basically still, and sleeving the tube plate into the tube bundle. All the heat exchange tubes are in place simultaneously along with the advance of the tube plate; the method is used for assembling the heat exchange tubes in a free state, the heat exchange tubes are not interfered with each other completely, the operation difficulty is small, and the efficiency is high. Meanwhile, the clearance between the heat exchange tube and the tube hole is small, the time of the heat exchange tube entering the tube hole accounts for a large proportion of the tube penetrating, all the heat exchange tubes enter the tube hole once after the method is adopted, the tube penetrating period is shortened, and the manufacture of the vertical tube frame and the tube penetrating can be synchronously carried out with the tube plate as long as the heat exchange tubes can realize positioning due to the assembly of the tube plate and the heat exchange tubes, so that the manufacture period of the heat exchanger is greatly shortened.)

1. A method for sleeving a tube plate and a heat exchange tube is characterized in that: it comprises the following steps:

the method comprises the following steps: detecting the current state of the heat exchange tube, confirming whether the heat exchange tube structure has the condition of sleeving the tube plate, and selecting a positioning mode according to the confirmed result;

when the heat exchange tube structure has the condition of sleeving the tube plate, the tube plate is used for positioning when the tube is penetrated, and the guide head is used for positioning when the tube is penetrated; if the structure does not allow, positioning by using a guide head;

step two: positioning the heat exchange tube and the first tube plate according to a positioning mode;

when the positioning of the tube plates is selected, one end of each heat exchange tube is directly inserted into a first tube plate, when the positioning of the guide head is selected, the guide head is firstly inserted into the tube hole of the first tube plate, and then one end of each heat exchange tube is sleeved on the guide head;

step three: adjusting the direction;

adjusting the directions of the first tube plate and the heat exchange plate to enable the heat exchange tubes to be arranged in parallel;

step four: mounting strip materials, and fixing gaps between rows and columns;

keeping the position of the tube plate relatively static, and inserting hard strips into gaps between rows and columns of the heat exchange tube at the position 1.5-2.5 times the depth of the tube hole away from the end part of the heat exchange tube;

step five: connecting a second tube plate;

when the guide head is positioned, the other end of each heat exchange tube is inserted into the tube hole of the second tube plate, and each heat exchange tube is inserted into the tube hole of the other tube plate and corresponds to the tube opening, connected with the guide head, of the first tube plate;

when the tube plates are positioned, the other end of each heat exchange tube is inserted into the tube hole of the second tube plate, and each heat exchange tube is inserted into the tube hole of the other tube plate and corresponds to the tube opening of the first tube plate into which the heat exchange tube is inserted;

step six: connecting an auxiliary member;

3 or 4 7-shaped copying plates are uniformly distributed and welded on the outer circumference of the first tube plate, auxiliary lifting lugs are welded on the two horizontal sides of the circumference of the first tube plate, and the second tube plate and the first tube plate are processed in the same way;

step seven: adjusting the construction position;

fixing the first tube plate, hoisting the second tube plate, adjusting the height and ensuring that the heat exchange tube is freely inserted into the tube hole of the second tube plate;

step eight: installing an operating tool;

a jack is arranged at each profile plate, and the jack is fixed after the force releasing direction is kept horizontal;

step nine: installing a second tube plate;

the positioning head is the same as the tube plate in positioning; pushing the second tube plate by using a jack, so that the second tube plate moves towards the first tube plate, and stopping pushing the second tube plate by using the jack after each heat exchange tube passes through the second tube plate;

step ten: installing a first tube plate;

when the positioning head is positioned, a jack is used for pushing the first tube plate to enable the first tube plate to move towards the second tube plate, the head to be positioned penetrates through the first tube plate, and after each heat exchange tube penetrates through the first tube plate, the jack is stopped from pushing the first tube plate;

when the tube plates are positioned, a jack is used for pushing the first tube plate to enable the first tube plate to move towards the second tube plate, and after each heat exchange tube penetrates through the first tube plate, the jack is stopped from pushing the first tube plate;

step eleven: machining allowance;

and cutting and removing the redundant heat exchange tubes at the outer edges of the first tube plate and the second tube plate.

2. The sleeving method of the tube plate and the heat exchange tube according to claim 1, wherein the sleeving method comprises the following steps: and step four, inserting the hard strip materials into the heat exchanger, wherein the thickness of the hard strip materials is 1-2mm smaller than the gaps between the rows or the columns, the width of the hard strip materials is 1/40-1/60 of the length of the longest row or the longest column of heat exchange tubes, and the length of the hard strip materials is + 400-600 mm of the length of the longest row or the longest column.

3. The sleeving method of the tube plate and the heat exchange tube according to claim 1, wherein the sleeving method comprises the following steps: in the ninth step and the tenth step, a specially-assigned person observes the gaps between the rows and the columns of the straight sections at the two sides of the heat exchange tube, and if the gaps become smaller, the heat exchange tube deforms to find out a deformed tube; the heat exchange tube is drawn or a batten with higher rigidity is inserted into the gap, so that the deformation of the heat exchange tube is eliminated, and the original state is recovered.

4. The sleeving method of the tube plate and the heat exchange tube according to claim 1, wherein the sleeving method comprises the following steps: when the jack is pushed in the ninth step and the tenth step, a plurality of persons synchronously shake the jack, the jack stops when shaking for 10-20 times, the line and row gaps are observed, if the jack is not qualified, the jack is adjusted to be qualified, and the adjustment mode is as follows:

the first method is as follows: the four (or three) jack fulcrums of the tube plate are pushed synchronously so as to prevent the tube plate from inclining and advancing, whether the four jack fulcrums of the tube plate are synchronously pushed is measured by taking an adjacent tube plate as a reference when the adjacent tube plate is pushed for 10mm, the pushing depth difference of any two points is less than or equal to 5mm, otherwise, the tube plate needs to be supported and leveled by a single point;

the second method comprises the following steps: when the tube plate is pushed, the flashlight is used for checking the gaps between the rows and the gaps between the rows at any time, and the flashlight is used for observing whether the heat exchange tube deforms or not in the transverse and vertical directions. If the deformation of the heat exchange tube is found or the visual inspection clearance at the position of the flat steel bar is smaller than (drawing clearance/2) mm, the propulsion must be stopped and the clearance is adjusted;

the third method comprises the following steps: when the tube plate is pushed, if the resistance of the jack is too large, the operation of the pressure lever is difficult, the pushing must be stopped, the tube bundle tube plate is adjusted, and the force is released until the tube plate is pushed finally.

5. The sleeving method of the tube plate and the heat exchange tube according to claim 4, wherein the sleeving method comprises the following steps: the method for adjusting the tube plate of the tube bundle comprises the following steps:

the method comprises the following steps: knocking the heat exchange tube by the wood beams, and vibrating the tube bundle;

the second method comprises the following steps: the deformed heat exchange tube on the outer side of the periphery can be recovered by prying the deformed tube by a crowbar, and the heat exchange tube cannot be scratched;

the third method comprises the following steps: the approximate position of the heat exchange tube is visually observed from the tube hole, and the heat exchange tube which is obviously asynchronous is found out, namely the difference between the depth of the tube hole and the depth of most of the heat exchange tubes is more than 40mm, and a copper bar is used for knocking or pulling the tube extractor outwards to enable the tube to be approximately flush with the rest heat exchange tubes; attention is paid to control force, and individual heat exchange tubes are prevented from being separated from the tube plate;

the method four comprises the following steps: a crane is used for assistance. The tube plate can be slightly shaken up and down by using the small hook of the crane, or the large hook and the small hook can be used for respectively hanging the lug plates at the two sides of the tube plate horizontally, and the tube plate is slightly shaken circumferentially. The hook is used for indicating the number at any time when the crane is assisted, so that the hook is not too large, and the deformation of the pipe is avoided;

the method five comprises the following steps: if the adjusting mode is invalid, the jack is loosened or the tube plate is pushed back, and the adjusting process is continued.

Technical Field

The invention relates to the field of sleeving of tube plates and heat exchange tubes, in particular to a method for sleeving a tube plate and a heat exchange tube.

Background

In the radial flow methanol reactor adopting the wear-maintenance technology, because the heat exchange tubes and the supporting structure thereof have special shapes and the bent sections between the heat exchange tubes are interfered, the prior tube penetrating adopts powerful assembly, the heat exchange tubes are easy to generate plastic deformation and surface scratch, the performance of the heat exchange tubes is influenced, in addition, the tube penetrating efficiency is low, and the labor intensity is high.

When a single tube plate needs to be replaced during the repair of a conventional tube type heat exchanger, the mode that the whole heat exchanger is eliminated or two tube plates are replaced simultaneously is adopted in the past, so that the progress of the whole repair process is not influenced.

The conventional tube sheet of the tube type heat exchange tube has long purchase and manufacture period, the tube frame is erected after the tube sheet is manufactured in the prior art, and the manufacture period of the whole heat exchanger is long.

Disclosure of Invention

The invention discloses the following purposes: the novel method for sleeving the tube plate and the heat exchange tube is provided for solving the problems that the special-shaped heat exchange tube is difficult to penetrate into the tube plate, the efficiency of the heat exchange tubes entering the tube plate one by one is low, the operation is complex, and the labor intensity of operators is high.

In order to realize the purpose, the sleeving method of the tube plate and the heat exchange tube comprises the following steps:

the method comprises the following steps: detecting the current state of the heat exchange tube, confirming whether the heat exchange tube structure has the condition of sleeving the tube plate, and selecting a positioning mode according to the confirmed result;

when the heat exchange tube structure has the condition of sleeving the tube plate, the tube plate is used for positioning when the tube is penetrated, and the guide head is used for positioning when the tube is penetrated; if the structure does not allow, positioning by using a guide head;

step two: positioning the heat exchange tube and the first tube plate according to a positioning mode;

when the positioning of the tube plates is selected, one end of each heat exchange tube is directly inserted into a first tube plate, when the positioning of the guide head is selected, the guide head is firstly inserted into the tube hole of the first tube plate, and then one end of each heat exchange tube is sleeved on the guide head;

step three: adjusting the direction;

adjusting the directions of the first tube plate and the heat exchange plate to enable the heat exchange tubes to be arranged in parallel;

step four: mounting strip materials, and fixing gaps between rows and columns;

keeping the position of the tube plate relatively static, and inserting hard strips into gaps between rows and columns of the heat exchange tube at the position 1.5-2.5 times the depth of the tube hole away from the end part of the heat exchange tube;

step five: connecting a second tube plate;

when the guide head is positioned, the other end of each heat exchange tube is inserted into the tube hole of the second tube plate, and each heat exchange tube is inserted into the tube hole of the other tube plate and corresponds to the tube opening, connected with the guide head, of the first tube plate;

when the tube plates are positioned, the other end of each heat exchange tube is inserted into the tube hole of the second tube plate, and each heat exchange tube is inserted into the tube hole of the other tube plate and corresponds to the tube opening of the first tube plate into which the heat exchange tube is inserted;

step six: connecting an auxiliary member;

3 or 4 7-shaped copying plates are uniformly distributed and welded on the outer circumference of the first tube plate, auxiliary lifting lugs are welded on the two horizontal sides of the circumference of the first tube plate, and the second tube plate and the first tube plate are processed in the same way;

step seven: adjusting the construction position;

step seven: adjusting the construction position;

fixing the first tube plate, hoisting the second tube plate, adjusting the height and ensuring that the heat exchange tube is freely inserted into the tube hole of the second tube plate;

step eight: installing an operating tool;

a jack is arranged at each profile plate, and the plurality of jacks are fixed after the force releasing directions are kept horizontal;

step nine: installing a second tube plate;

the positioning head is the same as the tube plate in positioning; pushing the second tube plate by using a jack, so that the second tube plate moves towards the first tube plate, and stopping pushing the second tube plate by using the jack after each heat exchange tube passes through the second tube plate;

step ten: installing a first tube plate;

when the positioning head is positioned, a jack is used for pushing the first tube plate to enable the first tube plate to move towards the second tube plate, the head to be positioned penetrates through the first tube plate, and after each heat exchange tube penetrates through the first tube plate, the jack is stopped from pushing the first tube plate;

when the tube plates are positioned, a jack is used for pushing the first tube plate to enable the first tube plate to move towards the second tube plate, and after each heat exchange tube penetrates through the first tube plate, the jack is stopped from pushing the first tube plate;

step eleven: machining allowance;

and cutting and removing the redundant heat exchange tubes at the outer edges of the first tube plate and the second tube plate.

And furthermore, the hard strip inserted in the fourth step is flat steel, the thickness of the hard strip is 1-2mm smaller than the gaps between the rows or the columns, the width of the hard strip is 1/40-1/60 of the length of the longest row or the longest column of heat exchange tubes, and the length of the hard strip is + 400-600 mm of the length of the longest row or the longest column.

Furthermore, in the ninth and tenth steps, a specially-assigned person observes the gaps between the rows and the columns of the straight sections at the two sides of the heat exchange tube, and if the gaps become smaller, the heat exchange tube deforms to find out a deformed tube; the heat exchange tube is drawn or a batten with higher rigidity is inserted into the gap, so that the deformation of the heat exchange tube is eliminated, and the original state is recovered.

Further, when the jack is pushed in the ninth step and the tenth step, a plurality of persons synchronously shake the jack, the jack is stopped after shaking for 10-20 times, the clearance between the rows and the columns is observed, if the jack is not qualified, the jack is adjusted to be qualified, and the adjustment mode is as follows:

the first method is as follows: four (or three) jack fulcrums of the tube plate are required to be synchronously pushed so as to prevent the tube plate from inclining and advancing, whether the four jack fulcrums of the tube plate are synchronously pushed is measured by taking a jack rooting tool (a bent plate tool or a triangular bracket) or an adjacent tube plate as a reference when the tube plate is pushed for 10mm, the pushing depth difference of any two points is less than or equal to 5mm, and otherwise, the tube plate needs to be supported and leveled by a single point;

the bending plate tool and the triangular support can be selected to be one, the bending plate tool and the triangular support are used for enabling a jack to take root when the tube plate is pushed, one side of the jack pushes the tube plate, the other side of the jack pushes the reference surface, and when the jack is shaken, the reference surface is fixed, and the tube plate is pushed.

The second method comprises the following steps: when the tube plate is pushed, the flashlight is used for checking the gaps between the rows and the gaps between the rows at any time, and the flashlight is used for observing whether the heat exchange tube deforms or not in the transverse and vertical directions. If the deformation of the heat exchange tube is found or the visual inspection clearance at the position of the flat steel bar is smaller than (drawing clearance/2) mm, the propulsion must be stopped and the clearance is adjusted;

the heat pipes are arranged in rows and columns, and gaps are reserved between the rows and the columns, and if the gaps are 8mm in an example, the heat pipes need to be stopped and adjusted when the gaps are actually observed to be less than 4mm

The third method comprises the following steps: when the tube plate is pushed, if the resistance of the jack is too large, the operation of the pressure lever is difficult, the pushing must be stopped, the tube bundle tube plate is adjusted, and the force is released until the tube plate is pushed finally;

still further, the method for adjusting the tube bundle tube plate comprises the following steps:

the method comprises the following steps: knocking the heat exchange tube by the wood beams, and vibrating the tube bundle;

the second method comprises the following steps: the deformed heat exchange tube on the outer side of the periphery can be recovered by prying the deformed tube by a crowbar, and the heat exchange tube cannot be scratched;

the third method comprises the following steps: the approximate position of the heat exchange tube is visually observed from the tube hole, and the heat exchange tube which is obviously asynchronous is found out, namely the difference between the depth of the tube hole and the depth of most of the heat exchange tubes is more than 40mm, and a copper bar is used for knocking or pulling the tube extractor outwards to enable the tube to be approximately flush with the rest heat exchange tubes; attention is paid to control force, and individual heat exchange tubes are prevented from being separated from the tube plate;

the method four comprises the following steps: a crane is used for assistance. The tube plate can be slightly shaken up and down by using the small hook of the crane, or the large hook and the small hook can be used for respectively hanging the lug plates at the two sides of the tube plate horizontally, and the tube plate is slightly shaken circumferentially. The hook is used for indicating the number at any time when the crane is assisted, so that the hook is not too large, and the deformation of the pipe is avoided;

the method five comprises the following steps: if the adjusting mode is invalid, the jack is loosened or the tube plate is pushed back, and the adjusting process is continued.

Has the advantages that: the method is used for assembling the heat exchange tubes in a free state, the heat exchange tubes are not interfered with each other completely, the operation difficulty is small, and the efficiency is high. Meanwhile, the clearance between the heat exchange tube and the tube hole is small, the time for the heat exchange tube to enter the tube hole accounts for a large proportion of the tube, and after the method is adopted, all the heat exchange tubes enter the tube hole at one time, so that the tube penetrating period is shortened.

Because the tube plate and the heat exchange tube are assembled, as long as the heat exchange tube can realize positioning (such as the positioning of a clapboard of a tube type heat exchanger), the vertical tube frame and the tube penetrating can be synchronously manufactured with the tube plate, and the manufacturing period of the heat exchanger is greatly shortened.

Drawings

FIG. 1 is a schematic perspective view of a connected bundle of heat exchange tubes;

FIG. 2 is a schematic plan view of a connected bundle of heat exchange tubes;

FIG. 3 is a schematic view of a heat exchange tube installation;

FIG. 4 is an operational reference detail view;

FIG. 5 is a schematic view of the mounting strip;

FIG. 6 is a schematic view of the heat exchange tube in connection with a tube sheet;

fig. 7 is a schematic view using a guide head.

Detailed Description

The sleeving method of the tube plate and the heat exchange tube is described by combining the attached drawings 1-7, and comprises the following steps:

the method comprises the following steps: detecting the current state of the heat exchange tube, confirming whether the heat exchange tube structure has the condition of sleeving the tube plate, and selecting a positioning mode according to the confirmed result;

when the heat exchange tube structure has the condition of sleeving the tube plate, the tube plate is used for positioning when the tube is penetrated, and the guide head is used for positioning when the tube is penetrated; if the structure does not allow, positioning by using a guide head;

step two: positioning the heat exchange tube and the first tube plate according to a positioning mode;

when the positioning of the tube plates is selected, one end of each heat exchange tube is directly inserted into a first tube plate, when the positioning of the guide head is selected, the guide head is firstly inserted into the tube hole of the first tube plate, and then one end of each heat exchange tube is sleeved on the guide head;

step three: adjusting the direction;

adjusting the directions of the first tube plate and the heat exchange plate to enable the heat exchange tubes to be arranged in parallel;

step four: mounting strip materials, and fixing gaps between rows and columns;

keeping the position of the tube plate relatively static, and inserting hard strips into gaps between rows and columns of the heat exchange tube at the position 1.5-2.5 times the depth of the tube hole away from the end part of the heat exchange tube;

step five: connecting a second tube plate;

when the guide head is positioned, the other end of each heat exchange tube is inserted into the tube hole of the second tube plate, and each heat exchange tube is inserted into the tube hole of the other tube plate and corresponds to the tube opening, connected with the guide head, of the first tube plate;

when the tube plates are positioned, the other end of each heat exchange tube is inserted into the tube hole of the second tube plate, and each heat exchange tube is inserted into the tube hole of the other tube plate and corresponds to the tube opening of the first tube plate into which the heat exchange tube is inserted;

step six: connecting an auxiliary member;

3 or 4 7-shaped copying plates are uniformly distributed and welded on the outer circumference of the first tube plate, auxiliary lifting lugs are welded on the two horizontal sides of the circumference of the first tube plate, and the second tube plate and the first tube plate are processed in the same way;

step seven: adjusting the construction position;

fixing the first tube plate, hoisting the second tube plate, adjusting the height and ensuring that the heat exchange tube is freely inserted into the tube hole of the second tube plate;

step eight: installing an operating tool;

a jack is arranged at each profile plate, and the jack is fixed after the force releasing direction is kept horizontal;

step nine: installing a second tube plate;

the positioning head is the same as the tube plate in positioning; pushing the second tube plate by using a jack, so that the second tube plate moves towards the first tube plate, and stopping pushing the second tube plate by using the jack after each heat exchange tube passes through the second tube plate;

step ten: installing a first tube plate;

when the positioning head is positioned, a jack is used for pushing the first tube plate to enable the first tube plate to move towards the second tube plate, the head to be positioned penetrates through the first tube plate, and after each heat exchange tube penetrates through the first tube plate, the jack is stopped from pushing the first tube plate;

when the tube plates are positioned, a jack is used for pushing the first tube plate to enable the first tube plate to move towards the second tube plate, and after each heat exchange tube penetrates through the first tube plate, the jack is stopped from pushing the first tube plate;

step eleven: machining allowance;

and cutting and removing the redundant heat exchange tubes at the outer edges of the first tube plate and the second tube plate.