preface

The dust collector shall be installed by the installation unit after manufacturing. The installation unit is responsible for the assembly, on-site installation and painting of split components.

The equipment must be unpacked for inspection at the installation site. Check the box number, equipment name, drawing number (or specification) and number of pieces one by one according to the packing list or other forms of delivery list, and record the parts, tools, accessories (or materials), factory certificate and other technical documents one by one. After the inspection, go through relevant procedures and keep them properly. If there is any damage, it shall be repaired and corrected in time.

All accessories, tools and technical documents shall be kept by the equipment subordinate unit.

When unpacking, the cover shall be removed according to the diagram and requirements of the box surface, and the equipment shall not be damaged.

All kinds of hoisting equipment, tools, auxiliary materials and all kinds of temporary reinforcements necessary for the installation process are not supplied by the manufacturer, but are the responsibility of the installation unit. Under the premise that the installation quality of the equipment can be changed according to the instructions of the installation unit, other installation methods can be used as appropriate to ensure the installation quality of the equipment.

Chapter general matters

1、 Scope of application

The scope of application of this installation manual is the steel structure of the dust collector (including maintenance platform and ladder) and the scope of installation works from the assembly operation on the construction site to the completion of the overall installation works after leaving the factory separately by the manufacturer. The construction unit can determine the construction scheme accordingly.

2、 Relevant codes, regulations and standards

During the installation of the steel structure of the dust collector (including the maintenance platform and ladder), in addition to the specific provisions and requirements put forward in the installation manual, it shall also comply with the issued relevant specifications, procedures and standards:

1. Code for design of steel structures (gb-2003);

2. Code for construction and acceptance of steel structures (gb-2001);

3. JB / t8471-96 technical requirements and acceptance specification for bag filter installation;

4. Gbj235-82 code for construction and acceptance of industrial pipeline engineering;

5. Gb985 ~ 986-88 basic forms and dimensions of welded joints.

3、 General precautions

Before the installation of the project, the installation instructions, relevant installation drawings and technical instructions shall be understood. While fully mastering the type and quantity of materials required and the contents of relevant parts and accessories, various mechanical equipment and tools in the installation process shall be prepared, and the construction and installation facilities on the construction site shall be organized to make the installation work proceed smoothly and ensure the project quality. At the same time, the results of various installation operations shall be strictly checked according to the requirements of installation standards. In case of exceeding the standard and error, it shall be corrected in time.

Chapter II installation works

1、 Installation sequence

Considering the hoisting sequence and installation space, generally, the installation operation shall be carried out according to the following process:

Ground work

Body installation

Body calibration measurement

Foundation inspection and acceptance

Lower frame installation

Calibration of diagonal level of foundation plane

Ash hopper assembly

Installation of upper frame of ash hopper

Diagonal calibration and plane calibration of ash hopper

Middle box assembly

Installation of middle box

Diagonal calibration and plane calibration of the upper plane of the middle box

Assembly of air inlet pipe and air inlet regulating valve

Installation of air inlet pipe and air inlet regulating valve

Upper box assembly

Installation of upper box, air outlet system and bypass air duct

Assembly of poppet valve, bypass valve and valve plate (if any)

Installation of bypass valve, poppet valve and gas distribution box

Installation of platform and railing

Installation of compressor pipeline, electromagnetic pulse valve and differential pressure device

Installation of gate valve, ash unloading system, air monitor and electric heater of ash hopper

Installation of overall insulation (if any)

Installation of filter bag and bag cage

Filter bag inspection and final installation of spray pipe

Surface paint

2、 Foundation inspection and acceptance

1. The foundation shall be inspected and verified according to the following items:

(1) Get the foundation Checklist (provided by the construction unit).

(2) Origin, height and center mark position. Open dust removal

(3) Ink line (each center line, row and column line).

(4) The foundation surface shall be flat without obvious inclination or concave convex, and the surfaces of all parts of the foundation shall also be smooth and flat.

(5) Position, size and reserved height of embedded anchor bolts.

(6) Size and depth of middle reserved hole.

(7) Based on the origin or datum point, the measured column centerline and foundation height must be consistent with the drawing.

(8) The size of each row of column lines shall be consistent with the drawing, and the diagonal lines of the same size shall be equal.

(9) Measuring tools: steel ruler and level.

2. Foundation acceptance:

The acceptance of the foundation shall be carried out by the equipment user, the foundation construction unit and the equipment installation unit on the site together, and the acceptance shall be carried out according to the above requirements, and the foundation checklist shall be filled in.

3、 Column installation

1. Check whether all components are deformed. If there is deformation, it shall be corrected and transported to the stacking place on the construction site.

2. Check the part number in the drawing according to the column installation drawing, and sort out the components transported to the site. Stack the same parts around the assembly site, crane and work area respectively.

3. The accuracy requirements for column, beam and diagonal brace assembly are as follows:

1) Column

Distance between row and column lines: + 2.5mm

Perpendicularity: (0.5 ~ 1) H / 1000

Horizontal diagonal difference: L / 1000, no more than 10mm

2) Crossbeam

Installation levelness: L / 1000

Lateral bending: L / 1000, no more than 10mm

3) Diagonal bracing: tolerance + 5mm

4. Hoisting of column:

1) Crane configuration: set the crane at the center of the outer side of the foundation, so that the operating radius of the crane can effectively hoist each column line frame.

2) Hang the column on the foundation, connect and fix the column bottom plate with the anchor bolt, and fix the top with temporary steel rope.

3) After the next column is hoisted, it shall be fixed as the previous column, and then connected with the beam. At the same time, measure the column spacing with a steel ruler, adjust the diagonal to be equal, and remove the steel rope at the end. Hoist the columns in turn.

5. Center positioning and fixing of frame:

1) Temporary scaffolds shall be erected at the position where bolts are installed and welded (the position higher than 2m).

2) Column center positioning:

a. Use two theodolites to measure the verticality of each column at the same time from the X and Y directions.

b. If the center line is determined at the lower part of the column, move the viewpoint to the upper part of the column and confirm whether its offset is within the allowable range.

c. If there is some deviation, the adjusting base plate shall be placed under the column base plate for adjustment until the design requirements are met.

d. Measure the size of each diagonal and check whether the installation meets the design requirements. The size of each diagonal to be measured is:

(I) diagonal dimensions of frames in columns a, B, C and D;

(II) allowable error: the difference between diagonal lines is less than 7mm;

(III) correction method: hang the steel wire rope in the diagonal direction, hang the pulley chain on the top, and adjust the diagonal size by adjusting the length of the steel wire rope.

3) Fixed:

After the center positioning and diagonal adjustment are completed, start to tighten all connecting bolts and then weld (including the welding with the split interface of Zhejiang University frame).

4、 Ash hopper installation

1. Due to the limitation of transportation, the ash hopper is manufactured in pieces in the factory. It needs to be assembled on the ground at the installation site before being hoisted and put on the shelf.

2. Ash hopper assembly welding:

1) Assemble three ash separators in columns A-B or C-D respectively according to the installation drawing of the ash hopper, and weld the connection according to the requirements of the drawing (Note: the adjustment flange between the air inlet of the ash hopper and the ash hopper is not welded, but welded after connecting with the air inlet regulating valve).

2) All ash hoppers shall be installed on the rack after passing the inspection, and shall be installed according to the position in the ash hopper installation drawing.

3) During the test run of the dust collector as a whole, install the sealing strip on the manhole door of the ash hopper to ensure the sealing.

3. Installation of upper frame of ash hopper:

1) During installation, attention must be paid to hoisting the qualified ash hopper on the lower frame according to the position shown in the figure.

2) After all the ash hoppers are hoisted in place, measure the center of the lower ash opening and the position of the upper plane. After adjustment, the bottom plate of the ash hopper support and the top of the lower frame column are connected and positioned with fixed bolts. Before connection, molybdenum disulfide high temperature gear paste is added between them.

3) The fixing bolts between the bottom plate of the ash hopper support and the top of the lower frame column shall not be tightened too tightly, but shall be tightened after the project is completed. (Note: fixed points are welded, and other sliding points are not welded)

5、 Installation of platform railing of ash hopper

1. Weld the ash bucket platform and frame beam after the platform is laid and corrected according to the installation drawing of stair platform.

2. Install the handrail of the platform on the platform according to the drawing. When docking the handrail, cut the steel pipe or round steel according to the needs of the site.

6、 Installation of middle box

1. Installation of middle box:

1) The middle boxes are manufactured from the factory with sheet plates. The box plates are assembled into large pieces on the ground according to the middle box drawing. After assembly, the flanges of each box are corrected and welded to form after meeting the requirements. Hang all the assembled boxes on the ash hopper, and then correct the flange plane on the middle box.

2) Sealed continuous welding is adopted for the interior of the middle box. If there is an opening in the weld that cannot be penetrated due to the intersection of structural welds, the sealing plate shall be used to seal the sealing welding, and special attention shall be paid.

3) All close welded welds must be inspected by kerosene leakage inspection method. Repair welding must be carried out where there is leakage to ensure that there is no leakage in the close welded welds on site.

7、 Installation of air inlet pipe and air volume regulating valve

1. The three-way pipe between the air volume regulating valve and the air inlet pipe shall be assembled on the ground according to the installation drawing. Asbestos board or asbestos rope shall be used as sealing material between flanges, and pay attention to the position of the operating handle of the air volume regulating valve. The valve plate shall rotate flexibly. If it is jammed, it shall be repaired and cut. Assemble according to the maintenance platform and air flow direction set in the figure.

2. Align the components with the air inlet of the ash hopper, adjust the air inlet flange of the air inlet of the ash hopper and fix it with the ash hopper, and then seal weld the adjusting flange of the short pipe of the air inlet of the ash hopper with each ash hopper. Information release and query of dust removal equipment and dust removal accessories

8、 Upper box installation

1. Considering the requirements of shipping and manufacturing accuracy, the upper box is delivered in the form of warehouse division in the factory.

2. Weld the bolts between the box body and the plane of the box body one by one according to the requirements of the lifting drawing, and then install them on the plane of the box body one by one.

3. Sealing continuous welding is adopted for all the interior of the upper box. If there is an opening in the weld that cannot be penetrated due to the intersection of structural welds, the sealing plate shall be used to seal the sealing welding, and special attention shall be paid.

9、 Installation of air outlet system

1. Considering the requirements of shipping and manufacturing accuracy, the poppet shell of the air outlet system is manufactured in the factory.

2. Hoist the air outlet, air outlet sealing plate and air outlet pipe bottom plate of the air outlet system on the lower fixed angle steel between the two rows of boxes according to the drawing, and then use electric welding for tight welding after adjusting the size.

3. Then hoist the lifting valve shell of the air outlet system between the two rows of upper boxes, adjust the size with the side plate or diaphragm of the upper box with a sealing plate, and then weld it tightly.

4. After the air inlet duct and air outlet system are installed, the bypass air duct connecting them can be installed in place according to the position of the general drawing.

10、 Installation of platforms, stairs and railings

1. Install according to the stair landing drawing.

2. The platform railing shall be installed according to the drawing and the nodes in the drawing. When docking the railing, the steel pipe or round steel can be cut according to the needs of the site.

11、 Installation of poppet valve, bypass valve and gas distribution box

1. The lift valve and bypass valve shall be installed under the guidance of on-site technicians.

2. Install the pulse gas distribution box and support according to the node requirements of the injection system, and adjust them according to the drawing or the requirements of the company's on-site technical service personnel. After meeting the requirements, weld the on-site welding parts in the node. During the welding process, pay attention not to let the welding spatter splash on the edge of the flower plate hole or damage the flower plate hole.

12、 Installation of compressor pipeline, electromagnetic pulse valve and differential pressure device

1. Preparation of piping:

1) Count the number of pipes and accessories (including various original parts of imported devices), and prepare pipe threading machine, pipe thread die, wrench and other tools.

2) Check the delivery quality of various pneumatic valves, and pay attention to whether the threads at the inlet and outlet are British or metric, so as to correctly prepare the joints.

3) Measure and determine the piping position and support position according to the installation drawing of each component, and draw necessary ink lines.

4) All pipes and pipe fittings shall be cleaned of sundries and rust before installation.

2. Pipeline installation:

1) Connect the pipes according to the nodes in the installation drawing of each component.

2) All piping adopts flange connection or pipe thread piping.

3) According to the connecting short pipes between various pipe fittings (elbows, tees, unions, etc.) shown in the installation drawing, the size shall be measured in advance to make threaded short pipes.

4) The threaded joint shall be wrapped with oil hemp wire to prevent air leakage. It shall not be screwed too tightly to prevent damage to the pipe fittings. Open dust removal

5) The rubber pipe shall be formally connected with the inlet of the working cylinder after ventilation, so as to remove the sundries in the pipe during ventilation.

3. The electromagnetic pulse valve shall be installed according to the node requirements in the installation drawing.

4. The differential pressure device shall be installed according to the node requirements in the installation drawing.

If there is no oil leakage in the air pressure pipe, remove the air pressure pipe after 1.5 times the pressure in the figure. If there is no air leakage, reinstall it after 30 minutes.

13、 Installation of gate valve, ash unloading system, air monitor and electric heater of ash hopper

1. The flange on the gate valve is connected with the ash outlet of the ash hopper.

2. In the ash unloading system, the upper interface flange of the cut-out conveyor is connected with the lower flange of the plug-in valve, and the ash unloading valve is connected with the outlet of the cut-out conveyor and the inlet of the collective conveyor. The boundary of ash conveying system shall be subject to the technical agreement.

3. Graphite rope sealing material shall be filled between flanges.