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CN-121980840-A - Method for splicing large-scale industrial module equipment

CN121980840ACN 121980840 ACN121980840 ACN 121980840ACN-121980840-A

Abstract

The invention discloses a method for splicing large-scale industrial module equipment, belongs to the technical field of large-scale industrial module construction, and aims to solve the problems of low splicing precision, poor quality control, weak tooling universality and the like in the prior art. The method comprises the steps of module early-stage preparation, construction site arrangement, module hoisting and positioning, module splicing operation, quality detection and acceptance inspection, digital filing and the like. The high-precision splicing of the module to the seam misalignment amount which is less than or equal to 0.5mm is realized by establishing a full life cycle database of the module, constructing a high-precision measurement control network and adopting an adjustable universal support tool and intelligent equipment, and the defect rate of the welding seam is reduced to below 1 percent by combining BIM simulation, real-time monitoring and automatic welding technology. The invention can be adapted to heavy modules of 50-500 tons and 10-50 meters, reduces the tooling cost by more than 60%, shortens the construction period by more than 40%, and is suitable for the fields of high-precision requirements of nuclear industry, petrochemical industry and the like.

Inventors

  • YANG HE
  • ZHANG DONGKAI
  • Wan Bingjie
  • LI MINGHUI

Assignees

  • 上海利柏特工程技术有限公司

Dates

Publication Date
20260505
Application Date
20251215

Claims (10)

  1. 1. A method for splicing large industrial module devices, comprising the steps of: S1, module early-stage preparation, namely establishing a module full life cycle database, and performing pre-detection and splicing scheme simulation on the module; s2, construction site arrangement, namely planning a construction site, establishing a high-precision measurement control network, deploying intelligent equipment and an adjustable universal support tool; s3, module hoisting positioning, namely realizing module coarse positioning through an intelligent hoisting robot, and finishing fine positioning by combining a supporting tool and a monitoring system; s4, module splicing operation, namely selecting a welding or bolting mode according to module characteristics, and finishing splicing by adopting automatic equipment; S5, quality detection acceptance, namely confirming splicing quality through appearance detection, nondestructive detection and mechanical property test; S6, digitally archiving, namely archiving the ID of the whole process data binding module and establishing an operation and maintenance early warning mechanism.
  2. 2. The method for splicing large industrial module devices according to claim 1, wherein the pre-module preparation in step S1 includes: s1.1, distributing unique IDs of two-dimensional codes and RFID double identifications for modules, wherein a database covers design, manufacturing, transportation and construction information; S1.2, acquiring an actual three-dimensional model of the module by adopting a three-dimensional laser scanner with the precision of 0.02mm/m, and comparing the model with a design model to ensure that the dimensional deviation is less than or equal to 1mm and the deformation is less than or equal to 0.5mm/m; S1.3, constructing a three-dimensional simulation scene based on a BIM system, and optimizing the hoisting points and the tooling arrangement parameters through finite element analysis.
  3. 3. The method for splicing large industrial module equipment according to claim 1, wherein in the step S2, a high-precision measurement control network is constructed by using a total station and a GNSS, the plane precision reaches +/-1 mm, the elevation precision reaches +/-0.5 mm, at least 4 permanent measurement control points are arranged in a splicing area, and the distance between temporary control points is not more than 5m.
  4. 4. The method for splicing large industrial module equipment according to claim 1, wherein the adjustable universal support tool comprises a base, a lifting adjusting mechanism, a horizontal adjusting mechanism, a positioning clamping mechanism and a sensor monitoring mechanism, wherein the base is welded by H-shaped steel of HW400×400×13×21, and the adjustable universal support tool can be adapted to modules in the range of 50-500 tons and 10-50 meters.
  5. 5. The method for splicing large industrial module equipment according to claim 4, wherein the lifting adjusting mechanism adopts a double-acting hydraulic jack with rated pressure of 31.5MPa, lifting precision is +/-0.1 mm, the horizontal adjusting mechanism drives a ball screw through a 2.2kW servo motor, positioning precision is +/-0.05 mm, and X, Y-direction displacement adjustment is achieved.
  6. 6. The method for splicing large industrial module equipment according to claim 1 is characterized in that in the step S3, the intelligent hoisting robot adopts 6-degree-of-freedom mixed pose adjustment hoisting robot, the leveling precision is +/-0.1 mm, the hoisting efficiency is improved by more than 3 times compared with that of a traditional crane, the misalignment of a joint of a module after accurate positioning is less than or equal to 0.5mm, and the flatness is less than or equal to 0.3mm/m.
  7. 7. The method for splicing large industrial module equipment according to claim 1, wherein in the step S4, an automatic welding robot equipped with a laser tracking system is adopted for welding operation, welding parameters are automatically matched by a BIM system according to module materials, interlayer temperature is controlled to be 200-250 ℃ for P91 and P92 heat-resistant steel modules, and weld defect rate is reduced to be less than 1%.
  8. 8. The method for splicing large industrial module equipment according to claim 1, wherein the bolting operation bolt pre-tightening torque in the step S4 is set according to the weight of the module, wherein the 50-100 ton module is 800-1200 N.m, the 300-500 ton module is 2000-3000 N.m, and the bolt pre-tightening force deviation is less than or equal to 5%.
  9. 9. The method for splicing large industrial module equipment according to claim 1, wherein in the step S5, nondestructive testing is performed by combining UT with RT, the detection depth of UT is 0-500mm, the defect detection rate is more than or equal to 99%, RT covers all welding seam areas, and the tensile strength in mechanical property test is not lower than 90% of that of a base material.
  10. 10. The method for splicing large industrial module equipment according to claim 1, wherein in the step S6, data is stored in a cloud database in an encrypted mode, and an operation and maintenance early warning model is built by combining module operation real-time data, so that full life cycle data tracing and abnormal early warning are realized.

Description

Method for splicing large-scale industrial module equipment Technical Field The invention relates to the technical field of large industrial module construction, in particular to a method for splicing large industrial module equipment, which is particularly suitable for high-precision splicing operation of heavy modules with the weight of more than 50 tons and the size of more than 10 meters, such as a nuclear industrial reactor pressure vessel module, a power station turbo generator unit module, a petrochemical engineering huge tower module and the like, and can be widely applied to the fields with extremely high requirements on module splicing precision and structural stability, such as nuclear industry, thermal power generation, hydroelectric power generation, petrochemical engineering, ocean engineering and the like. In the above field, the splicing quality of large industrial module devices directly determines the safety, reliability and service life of the whole project. For example, if the splicing sealing performance of a reactor pressure vessel module in the nuclear industry has defects, the great potential safety hazard of radioactive substance leakage can be caused, the problem of increased medium conveying resistance, aggravated equipment vibration and the like can be caused due to insufficient splicing precision of a huge tower module in the petrochemical industry, and the equipment can be broken and exploded when serious. Therefore, the splicing method provided by the invention aims at the characteristics of modules in different fields, establishes a differentiated splicing strategy and provides technical support for the safe splicing of various large-scale industrial modules. Background With the continuous rise of global industrial manufacturing level, modularization and integration have become the dominant trend of large industrial equipment development. The modular design is characterized in that complex industrial equipment is disassembled into a plurality of module units with independent functions and complete structures, the modules are manufactured, assembled and pre-debugged in a factory, and then transported to a construction site for splicing and assembling. According to industry data statistics, large-scale industrial projects of modularized construction are adopted, the field operation period is shortened by more than 30%, the construction cost is reduced by 20% -25%, and the construction quality qualification rate is improved to more than 99%. In the field of nuclear industry, after the modularized construction technology is adopted in the AP1000 nuclear power station in the United states, the construction period of a first unit is shortened to 42 months from 60 months in the traditional method, in the field of petrochemical industry, the large-scale module project of the petrochemical park in Saint Zhu Baile is realized, and the aim of improving annual output energy by 50 ten thousand tons is fulfilled through modularized splicing. The existing splicing mode of large industrial module equipment mainly comprises three modes of welding, bolting and direct stacking, wherein the direct stacking is only suitable for the scene of temporary storage or extremely low requirement on structural stability, and the welding and bolting are the main stream splicing modes at present in the formal engineering. The welding splice is formed by melting the metal material of the connecting part of the module at high temperature, so that the module is solidified to form an integral structure, and the welding splice has the advantages of high connecting strength, good sealing performance, strong structural integrity and the like, and is suitable for splicing heavy and large modules. Common welding modes include butt welding, fillet welding, submerged arc welding, gas shielded welding and the like, wherein the butt welding is most widely applied in module splicing, and the integral strength and structural stability of equipment can be ensured. The butt welding has higher production efficiency, can realize a rapid and stable welding process, can reduce the production cost, is suitable for metal materials of various materials such as carbon steel, stainless steel, alloy steel and the like, and meets the welding requirements of complex structures and severe working conditions. In practical application, the welding quality of butt welding directly influences the reliability of module splicing, and the high-quality butt welding seam has attractive appearance, high reliability and capability of remarkably improving the durability and service life of equipment. The bolting splice is used for connecting and fixing two or more modules through bolts and nuts, has the advantages of being detachable, convenient to maintain, flexible in construction and the like, and is suitable for a scene requiring later maintenance or module replacement. The bolting and splicing has higher precision requirement, and the positioni