A method for assembling a wind turbine bottom section tower in a yard

Abstract

The invention discloses a method for assembling a bottom section tower of a wind turbine, which includes the following steps: construction preparation, S1: construction preparation refers to a series of necessary inspections, verifications and tests on a pre-assembly site, wind turbine equipment, lifting equipment, equipment tooling and slings, and a transport barge before the bottom tower turning over and buckling operation is carried out, so as to ensure the smooth implementation of the bottom tower turning over and buckling operation; S2: survey and treatment of the pre-assembly site, and clearing the roadblocks and interfering obstacles at the assembly site in advance, so that the entire pre-assembly site fully meets the operation requirements; S3: checking whether the equipment tooling and slings are intact and without damage, and trial operation of the lifting equipment, so as to avoid safety accidents such as the wind turbine equipment being unable to be used during the turning over and buckling process, and the wind turbine equipment being suspended in the air. The invention can be completed on shore in advance, and while saving the construction period of the main ship engine, it also ensures the construction quality, and has high economic benefits and promotion.

Description

Technical Field

[0001] The invention relates to the technical field of offshore wind turbine assembly, and in particular to a method for assembling a wind turbine bottom section tower in a yard. Background Art

[0002] Due to the rich offshore wind energy resources, vast sea area, and no land occupation, the offshore wind power industry has become an important area for my country to develop clean energy and change its energy structure. At present, my country's offshore wind power industry has entered a period of rapid expansion, but there is a clear shortage of domestic wind turbine installation ships. In addition, the offshore construction environment is complex and the wind turbine installation precision is high, which brings great difficulties to the installation of offshore wind turbines. Therefore, it is necessary to reasonably formulate the installation process of offshore wind turbines, and divide the installation of offshore wind turbines into land installation and offshore installation. Under this background, a construction plan that can be on land but not at sea and can be overall not dispersed is proposed, and the work of assembling scattered parts is placed in On shore, the offshore construction is integrated to reduce the impact of force majeure factors such as weather and sea conditions on the installation of offshore wind turbines. At present, the more commonly used installation methods in China are offshore split installation and post-assembly of electrical modules at the dock. The offshore split installation of offshore wind turbines is greatly affected by force majeure factors such as sea conditions and weather. In order to shorten the construction period of offshore wind turbine installation ships and effectively control costs, the post-assembly of electrical modules at the dock is limited by the narrow space of the bottom tower and the height of the bottom tower, which has high requirements for lifting equipment, low assembly efficiency, and difficult to ensure construction quality. A series of thorny problems, therefore, are urgently needed to propose a safe, efficient and convenient offshore wind turbine installation process.

[0003] In order to shorten the construction period of offshore wind turbine installation ships and effectively control costs, the present invention proposes to assemble electrical modules such as transformers and converters in a manufacturing plant or a storage yard, turn over and install the bottom tower section, and then install accessories, and then use a walking gantry crane to lift the bottom tower section to a transport barge, and then tie it up at sea and transport it to the machine position for overall installation. This bottom tower section turning over and installing process has reliable safety, convenient operation, and high construction efficiency. It can realize the pre-positioning of scattered and partial installation work on shore, making offshore construction integrated, which can better control construction quality, shorten offshore construction period, reduce offshore wind turbine installation costs, and provide strong guarantees for continuous and efficient operation of offshore wind power industrialization.

[0004] To this end, we propose a wind turbine bottom section tower yard assembly method. Summary of the invention

[0005] In view of the above problems and / or the problems existing in the existing method for assembling the bottom section tower of a wind turbine, the present invention is proposed.

[0006] Therefore, the purpose of the present invention is to provide a method for assembling the bottom section tower of a wind turbine in a yard, which can solve the above-mentioned existing problems through a new assembly process and method including construction preparation, transformer module assembly, converter module assembly, turning over of the bottom section tower, buckling of the bottom section tower, installation of the external tower platform system, acceptance of the whole machine and erection and lifting.

[0007] To solve the above technical problems, according to one aspect of the present invention, the present invention provides the following technical solutions:

[0008] A method for assembling a wind turbine bottom section tower in a yard, comprising the following steps:

[0009] Step 1: Construction preparation

[0010] S1: Construction preparation refers to a series of necessary inspections, verifications and tests on the pre-assembly site, wind turbine equipment, lifting equipment, equipment tooling and slings, and transport barges before the bottom tower turning over and fastening operation is carried out to ensure the smooth implementation of the bottom tower turning over and fastening operation;

[0011] S2: Survey and process the pre-assembly site. Roadblocks and interfering obstacles at the assembly site must be cleared in advance, and the entire pre-assembly site fully meets the operation requirements;

[0012] S3: Check whether the equipment tooling and slings are intact and undamaged, and conduct trial operation of the lifting equipment to avoid safety accidents such as the fan equipment being unable to be used during the turning and buckling process, causing it to be suspended in the air;

[0013] S4: The work in the construction preparation stage is complicated and tedious, but it is crucial. Any inadequate inspection of any link will affect the smooth implementation of the turning and fastening operation, causing delays in the fastening operation;

[0014] Step 2: Transformer module assembly

[0015] Prepare the bottom tower frame tooling in the installation area. The placement area must be flat and solid. Remove the transformer unit waterproof cloth before hoisting. Remove the tooling connection bolts between the transformer unit and the transport tooling. Then hoist the transformer unit onto the bottom tower frame tooling, tighten the tooling connection bolts, and remove the hoist.

[0016] Step 3: Inverter module assembly

[0017] S1: After the transformer unit is hoisted onto the bottom tower frame-type fixture and the connecting bolts are tightened as required, the converter unit is hoisted;

[0018] S2: Open the four small covers on the top platform of the converter and hoist it in the same way as when unloading; remove the connecting bolts between the unit and the transport tooling, tie the wind ropes at the two legs of the converter unit, hoist the converter unit above the transformer unit, observe the location of the converter cooling pipeline or the elevator guardrail, and pull the wind ropes to make the cooling pipelines of the converter and transformer units on the same side. When hoisting, be careful to avoid collision between the pipelines of the two units, and then connect the bolt installation holes of the columns on the four sides. After the installation holes are aligned, insert the connecting bolts from the bottom to the top from one side of the transformer and tighten them as required;

[0019] Step 4: Turn over the bottom tower

[0020] S1: Use the tower hoisting sling to lift the tower and turn it vertically. Install the tower hangers on the upper and lower flanges of the bottom tower respectively. The installation holes can be marked in advance before installing the hangers. Install 4 hangers on the upper flange with hanging points at 7:30, 10:30, 1:30, and 4:30. Install 2 hangers on the lower flange with hanging points at 10:30 and 1:30. The included angle is less than or equal to 90°.

[0021] S2: After the installation of the suspension seat is completed, the wire rope, single-wheel block, shackle and ring sling are assembled, and two single-wheel blocks are hung on the No. 1 hook of the 800t gantry crane to connect with the four suspension seats on the upper flange, and two tail suspension seats are hung on the No. 2 and No. 3 hooks respectively;

[0022] S3: Use the No. 1, No. 2 and No. 3 hooks of the walking 800t gantry crane to use the "three-point lifting" method to turn the bottom tower over and stand on the assembly site. After the bottom tower is turned over and upright, remove the two tail suspension seats on the lower flange and tie two guy ropes of no less than 15 meters in a 180° direction on the bottom flange of the tower;

[0023] Step 5: Install the bottom tower

[0024] S1: Two cables and wind ropes are tied to the lower flange of the bottom tower at 180°. The turned-over bottom tower is lifted and moved to the top of the bottom frame. The direction of the bottom tower is adjusted using the cables and wind ropes so that the direction of the tower door is consistent with the direction of the tower door of the bottom tower fastening tooling. The ladder is aligned with the elevator hole and slowly dropped. The hoisting commander in the tower observes and directs the crane to avoid rubbing and collision between the inner wall accessories of the tower and the edge of the bottom frame. During the falling process, attention should be paid to protecting the two-unit platform beams, enclosures, adjustment supports, etc., with emphasis on protecting the arc protection box of the transformer platform;

[0025] S2: Before the bottom flange of the bottom tower is fastened with the bottom tower tooling, use the cable wind rope or hand hoist to fine-tune the circumferential direction so that the connection point of the transformer unit is aligned with the connection point of the inner wall of the bottom tower. Before the bottom flange surface of the tower contacts the flange surface of the bottom frame-type tooling, fine-tune the circumferential direction so that the connection point of the converter unit is aligned with the connection point of the inner wall of the bottom tower. The tower continues to fall to align the flange holes of the tower flange tooling. After completing the precise alignment, lower the tower and connect the tooling bolts with the tower bottom flange with 12 M64 tooling bolts, and tighten them with an electric wrench of not less than 1000Nm;

[0026] Step 6: Installation of the platform system outside the tower

[0027] The installation of the tower door outer platform and cooling system is divided into three parts: the door outer platform frame, cooler, and cooling pipeline installation. Use a 25t truck crane, two 6-meter-long slings and a lever hoist to install the two frames of the door outer platform on the tower wall and fasten them with bolts; install the connecting beam between the two frames and tighten the bolts with an electric wrench or torque wrench;

[0028] Step 7: Acceptance and erection of the whole machine

[0029] After the bottom section of the tower is turned over and fastened, the electrical installation work inside the tower and the installation of the platform system outside the tower are carried out. After the installation is completed, the whole machine is inspected and accepted. After passing the inspection, it is erected and hoisted to the transport barge using an 800t walking gantry crane, loaded on board, and shipped at sea.

[0030] As a preferred solution of the wind turbine bottom section tower yard assembly method described in the present invention, the transformer module includes a transformer unit, and the transformer unit is arranged on the top of the basic ring layer.

[0031] As a preferred solution of the wind turbine bottom section tower yard assembly method described in the present invention, the transformer unit includes:

[0032] A tower base control cabinet, which is arranged at the right end of the surface of the transformer unit;

[0033] Ring main unit, which is arranged at the rear end of the tower base control cabinet;

[0034] The transformer is arranged at the left end of the tower base control cabinet.

[0035] As a preferred solution of the wind turbine bottom section tower yard assembly method described in the present invention, wherein: the converter module includes an AC unit, and the AC unit is arranged at the upper end of the transformer unit.

[0036] As a preferred solution of the wind turbine bottom section tower yard assembly method described in the present invention, the exchanger unit includes:

[0037] A communication cabinet, which is arranged on the front left side of the surface of the communicator unit;

[0038] An auxiliary transformer, which is arranged at the rear end of the communication cabinet;

[0039] A salt spray dehumidifier is arranged at the rear end of the auxiliary transformer;

[0040] A converter, which is arranged at the right end of the auxiliary transformer;

[0041] The automatic fire fighting system is arranged at the rear end of the converter.

[0042] As a preferred solution of the wind turbine bottom section tower yard assembly method described in the present invention, a No. 1 hook, a No. 2 hook and a No. 3 hook are installed at the bottom of the tower lifting sling.

[0043] As a preferred solution of the wind turbine bottom section tower yard assembly method described in the present invention, wherein: the No. 1 hook is hung with two single-wheel pulleys connected to four suspension seats on the upper flange at the right end of the bottom section tower.

[0044] As a preferred solution of the wind turbine bottom section tower yard assembly method described in the present invention, the No. 2 hook and the No. 3 hook are respectively hung with two tail suspension seats at the left end of the bottom section tower.

[0045] Compared with existing technologies:

[0046] When assembling offshore wind turbines, the bottom section tower turn-over and buckle installation process is the key to the quality and efficiency of the entire wind turbine installation. By comparing the two processes for assembling the bottom section tower, the bottom section tower turn-over and buckle installation process and vertical transportation and installation solution were finally selected. This solution maximizes the offshore installation work on land, greatly improving the safety, economy and efficiency of the construction, and shortening the assembly time of a single bottom section tower from the original 2 days to 1 day. This solution provides a new process for the assembly of the lower tower of the wind turbine, with significant effects, and is worthy of promotion in the installation of the lower tower of offshore wind turbines and other higher and larger equipment.

[0047] As an important part of offshore wind power construction, the bottom tower tube flipping and fastening installation can be completed on shore in advance. While saving the main ship engine construction period, it also ensures the construction quality and has high economic benefits and promotion. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 A process flow chart of turning over and fastening the bottom section tower provided by the present invention;

[0049] Figure 2 The internal accessory diagram of the bottom section tower provided by the present invention;

[0050] Figure 3A schematic diagram showing the connection between the converter and the transformer provided by the present invention;

[0051] Figure 4 A schematic diagram of turning over the bottom section tower provided by the present invention;

[0052] Figure 5 This is a schematic diagram of the hanging sling provided by the present invention.

[0053] In the figure: basic ring layer 1, transformer unit 2, tower base control cabinet 21, ring network cabinet 22, transformer 23, AC unit 3, communication cabinet 31, auxiliary transformer 32, salt spray dehumidifier 33, converter 34, automatic fire fighting system 35, tower hanging sling 4, No. 1 hook 5, No. 2 hook 6, No. 3 hook 7, bottom section tower 8. DETAILED DESCRIPTION

[0054] In order to make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0055] The present invention provides a method for assembling the bottom section tower of a wind turbine. Figure 1-5 ;

[0056] refer to Figure 1 : Assemble the slings of the transformer and converter module in advance, use a 150t mobile crane to assemble the transformer module to the bottom section of the tower and fix it with the transport tooling, replace the converter slings and install the converter module in position, use bolts to fasten the transformer module and the converter module to form an integral bottom frame, use the No. 1, No. 2 and No. 3 hooks of the walking 800t gantry crane to use the "three-point lifting" method to lift the bottom section of the tower until it is turned vertical, remove the two tail suspension seats on the lower flange, lift the bottom section of the tower to the top of the installed bottom frame, use the cable wind rope to adjust the tower rotation, adjust the direction, visually observe the position of the tower door ladder, align the ladder with the elevator hole and slowly drop it, pay attention to pulling the cable wind rope to stabilize the tower, and the personnel inside the tower should observe Observe and direct the crane to avoid scraping and collision between the inner wall accessories of the tower and the edge of the bottom equipment frame. Before the bottom flange of the tower contacts the bottom frame-type tooling flange surface, fine-tune the circumferential direction so that the bottom flange of the tower is basically aligned with the connection point of the bottom frame-type tooling flange. The tower continues to fall to align the tower flange tooling flange holes. After completing the precise alignment, lower the tower, connect the tooling bolts to the tooling and the bottom flange of the tower with 12 M64 tooling bolts, tighten them with an electric wrench of not less than 1000Nm, complete the flipping and buckling of the bottom section of the tower, carry out the electrical work inside the tower and the installation of the platform system outside the tower, and carry out the whole machine acceptance after the installation is completed. After passing the acceptance, use an 800t walking gantry crane to lift it upright to the transport barge for loading and sea tying for shipment;

[0057] refer to Figure 2 and 3: The internal accessories of the bottom tower include a basic ring layer 1, a transformer unit 2, an AC unit 3 and a tower sling 4. The transformer module includes a transformer unit 2, which is arranged on the top of the basic ring layer 1. The transformer unit 2 includes: a tower base control cabinet 21, a ring network cabinet 22 and a transformer 23. The tower base control cabinet 21 is arranged at the right end of the surface of the transformer unit 2, the ring network cabinet 22 is arranged at the rear end of the tower base control cabinet 21, and the transformer 23 is arranged at the left end of the tower base control cabinet 21;

[0058] The converter module includes an AC unit 3, which is arranged at the upper end of the transformer unit 2. The AC unit 3 includes: a communication cabinet 31, an auxiliary transformer 32, a salt spray dehumidifier 33, an inverter 34 and an automatic fire fighting system 35. The communication cabinet 31 is arranged at the front end of the left side of the surface of the AC unit 3, the auxiliary transformer 32 is arranged at the rear end of the communication cabinet 31, the salt spray dehumidifier 33 is arranged at the rear end of the auxiliary transformer 32, the inverter 34 is arranged at the right end of the auxiliary transformer 32, and the automatic fire fighting system 35 is arranged at the rear end of the inverter 34;

[0059] refer to Figure 4 and 5 : A No. 1 hook 5, a No. 2 hook 6 and a No. 3 hook 7 are installed at the bottom of the tower hanging sling 4. The No. 1 hook 5 is hung with two single-wheel pulleys and connected to four suspension seats on the right end of the bottom section tower 8. The No. 2 hook 6 and the No. 3 hook 7 are respectively hung with two tail suspension seats on the left end of the bottom section tower 8.

[0060] Although the present invention has been described above with reference to the embodiments, various modifications may be made thereto and parts thereof may be replaced by equivalents without departing from the scope of the present invention. In particular, as long as there is no structural conflict, the various features in the embodiments disclosed in the present invention may be used in combination with each other in any manner, and the fact that these combinations are not exhaustively described in this specification is only for the sake of omitting space and saving resources. Therefore, the present invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A method for assembling a wind turbine bottom section tower in a yard, characterized by: The steps include: Step 1: Construction preparation S1: Construction preparation refers to a series of necessary inspections, verifications and tests on the pre-assembly site, wind turbine equipment, lifting equipment, equipment tooling and slings, and transport barges before the bottom tower turning over and fastening operation is carried out to ensure the smooth implementation of the bottom tower turning over and fastening operation; S2: Survey and process the pre-assembly site. Roadblocks and interfering obstacles at the assembly site must be cleared in advance, and the entire pre-assembly site fully meets the operation requirements; S3: Check whether the equipment tooling and slings are intact and undamaged, and conduct trial operation of the lifting equipment to avoid safety accidents such as the fan equipment being unable to be used during the turning and buckling process, causing it to be suspended in the air; S4: The work in the construction preparation stage is complicated and tedious, but it is crucial. Any inadequate inspection of any link will affect the smooth implementation of the turning and fastening operation, causing delays in the fastening operation; Step 2: Transformer module assembly Prepare the frame type tooling of the bottom tower (8) in the installation area. The placement area is required to be flat and solid. Remove the waterproof cloth of the transformer unit (2) before lifting. Then remove the tooling connection bolts between the transformer unit (2) and the transport tooling. Then lift the transformer unit (2) onto the frame type tooling of the bottom tower (8), tighten the tooling connection bolts, and remove the lifting equipment. Step 3: Inverter module assembly S1: After the transformer unit (2) is hoisted onto the frame-type fixture of the bottom tower (8) and the connecting bolts are tightened as required, the converter unit is hoisted; S2: Open the four small covers on the top platform of the converter and hoist it in the same way as when unloading; remove the connecting bolts between the unit and the transport tooling, tie the wind ropes at the two legs of the converter unit, hoist the converter unit above the transformer unit (2), observe the location of the converter cooling pipeline or the elevator guardrail, pull the wind ropes to make the cooling pipelines of the converter and the transformer unit (2) on the same side. When hoisting, be careful to avoid collision between the pipelines of the two units, then connect the bolt installation holes of the four side columns. After the installation holes are aligned, insert the connecting bolts from the bottom to the top from one side of the transformer and tighten them as required; Step 4: Turn over the bottom tower S1: Use the tower lifting sling (4) to lift the tower and turn it vertically, and install tower hanging brackets on the upper and lower flanges of the bottom tower (8) respectively. Before installing the hanging brackets, the installation holes can be marked in advance. Four hanging brackets are installed on the upper flange, with hanging points at 7:30, 10:30, 1:30, and 4:

30. Two hanging brackets are installed on the lower flange, with hanging points at 10:30 and 1:30, and the included angle is less than or equal to 90°. S2: After the installation of the suspension seat is completed, the wire rope, the single-wheel block, the shackle and the ring sling are assembled, and two single-wheel blocks are hung on the No. 1 hook (5) of the 800t gantry crane to connect with the four suspension seats on the upper flange, and two tail suspension seats are hung on the No. 2 hook (6) and the No. 3 hook (7) respectively; S3: Use the No. 1 hook (5), No. 2 hook (6) and No. 3 hook (7) of the walking 800t gantry crane to use the "three-point lifting" method to turn the bottom tower section (8) over and stand it up at the assembly site. After the bottom tower section (8) is turned over and upright, remove the two tail suspension seats on the lower flange and tie two guy ropes of no less than 15 meters in a 180° direction on the bottom flange of the tower; Step 5: Install the bottom tower S1: Two cables and wind ropes are tied to the lower flange of the bottom tower at 180°. The turned-over bottom tower is lifted and moved to the top of the bottom frame. The direction of the bottom tower is adjusted using the cables and wind ropes to make the tower door direction consistent with the tower door direction of the bottom tower buckle tooling. The ladder is aligned with the elevator hole and slowly dropped. The hoisting commander in the tower observes and directs the crane to avoid scraping and collision between the inner wall accessories of the tower and the edge of the bottom frame. During the falling process, attention should be paid to protecting the two-unit platform beams, enclosures, adjustment supports, etc., with emphasis on protecting the transformer platform arc protection box; S2: Before the bottom flange of the bottom tower is fastened to the bottom tower fixture, use a guy rope or a lever hoist to fine-tune the circumferential direction so that the connection point of the transformer unit (2) is aligned with the connection point of the bottom tower inner wall. Before the bottom flange surface of the tower contacts the flange surface of the bottom frame fixture, fine-tune the circumferential direction so that the connection point of the converter unit is aligned with the connection point of the bottom tower inner wall. The tower continues to fall so that the flange holes of the tower flange fixture are aligned. After completing the precise alignment, lower the tower and connect the fixture and the bottom flange of the tower with 12 M64 fixture bolts. Tighten them with an electric wrench of not less than 1000Nm. Step 6: Installation of the platform system outside the tower The installation of the tower door outer platform and cooling system is divided into three parts: the door outer platform frame, cooler, and cooling pipeline installation. Use a 25t truck crane, two 6-meter-long slings and a lever hoist to install the two frames of the door outer platform on the tower wall and fasten them with bolts; install the connecting beam between the two frames and tighten the bolts with an electric wrench or torque wrench; Step 7: Acceptance and erection of the whole machine After the bottom tower section (8) is turned over and fastened, the electrical installation work inside the tower and the installation of the platform system outside the tower are carried out. After the installation is completed, the whole machine is inspected and accepted. After the acceptance is qualified, it is hoisted and transported to the transport barge by an 800t walking gantry crane, loaded on board, and shipped at sea.

2. A wind turbine bottom section tower yard assembly method according to claim 1, characterized in that: The transformer module comprises a transformer unit (2), which is arranged on top of a base ring layer (1).

3. A wind turbine bottom section tower yard assembly method according to claim 2, characterized in that: The transformer unit (2) comprises: A tower base control cabinet (21) is arranged at the right end of the surface of the transformer unit (2); A ring main unit (22) is arranged at the rear end of the tower base control cabinet (21); The transformer (23) is arranged at the left end of the tower base control cabinet (21).

4. A wind turbine bottom section tower yard assembly method according to claim 1, characterized in that: The converter module comprises an AC unit (3), and the AC unit (3) is arranged at the upper end of the transformer unit (2).

5. A wind turbine bottom section tower yard assembly method according to claim 4, characterized in that: The AC unit (3) comprises: A communication cabinet (31) is arranged at the front left side of the surface of the communicator unit (3); An auxiliary transformer (32) is arranged at the rear end of the communication cabinet (31); A salt mist dehumidifier (33) is arranged at the rear end of the auxiliary transformer (32); A converter (34) disposed at the right end of the auxiliary transformer (32); An automatic fire fighting system (35) is arranged at the rear end of the converter (34).

6. A wind turbine bottom section tower yard assembly method according to claim 1, characterized in that: A No. 1 hook (5), a No. 2 hook (6) and a No. 3 hook (7) are installed at the bottom of the tower hanging sling (4).

7. A wind turbine bottom section tower yard assembly method according to claim 6, characterized in that: The No. 1 hook (5) is hung with two single-wheel pulleys and connected to four suspension seats on the upper flange at the right end of the bottom tower (8).

8. A wind turbine bottom section tower stacking method according to claim 6, characterized in that: The No. 2 hook (6) and the No. 3 hook (7) are respectively hung on two tail suspension seats at the left end of the bottom tower (8).

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