Conformal tooling for FPSO moon pool section construction and its manufacturing and usage methods

Abstract

This invention belongs to the field of shipbuilding technology and discloses a conformal fixture for the construction of FPSO moon pool section hulls, as well as its manufacturing and usage methods. The conformal fixture includes scaffolding, a star-shaped conformal fixture, and an anti-tilting component. The star-shaped conformal fixture consists of a main structure composed of multiple conformal pipe supports, each uniformly welded to the outer ring of a central circular ring, with adjacent conformal pipe supports connected by connecting pipe supports. A transverse slot is cut at the top of each conformal pipe support. An arc-shaped plate is fixedly installed on the anti-tilting component's frame. Lifting lugs III and IV are installed at the top of the arc-shaped plate. Lifting lugs I and II are fixed to the ground. An anti-tilting bracket is installed between lifting lugs I and III, and a guy rope is installed between lifting lugs II and IV. A plumb line is suspended from lifting lug IV. This invention ensures the construction accuracy and quality of each hull section, effectively reduces deformation caused by subsequent lifting and installation forces, improves the overall construction quality and accuracy of the hull, reduces construction costs, and increases production efficiency.

Description

Technical Field

[0001] This invention belongs to the field of shipbuilding technology, specifically to conformal tooling for the construction of FPSO moon pool section cylinders and its manufacturing and usage methods. Background Technology

[0002] Currently, in the manufacturing of FPSO moon pool sections, due to their large size and weight limitations, the moon pool section often needs to be constructed segment by segment, which facilitates processing and installation. However, during the segment-by-segment construction process, the moon pool section may deform due to stress during processing or welding, which could affect the overall quality and precision of the section.

[0003] Traditional methods of constructing cylindrical structures typically involve rolling a single piece of material into a cylindrical shape and then connecting the two ends by welding or fixing to form a complete cylinder. This method has several drawbacks. Because the material is subjected to deformation and stress during processing and welding, the cylinder may deform, and the degree of deformation is uncontrollable. This leads to increased construction costs, material waste, and reduced production efficiency.

[0004] CN115419252A discloses a method for pre-erecting scaffolding for pipe piles. It uses a welded triangular base frame to erect scaffolding to reduce construction costs. However, this scaffolding is not suitable for the construction of FPSO moon pool segmented cylinders and cannot save on the construction costs of the cylinder segments.

[0005] Therefore, a new technical solution is needed to solve the above-mentioned technical problems. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a conformal tooling for the construction of FPSO moon pool segment cylinders, and its manufacturing and usage method, which ensures the construction accuracy and quality of each cylinder segment, effectively reduces deformation caused by external forces during subsequent hoisting and installation, improves the construction quality and accuracy of the entire cylinder, reduces construction costs, saves materials, and improves production efficiency.

[0007] To address the aforementioned technical problems, this invention provides conformal fixtures for constructing segmented cylinder bodies of an FPSO moon pool, including scaffolding, a star-shaped conformal fixture, and anti-tilting components. The star-shaped conformal fixture consists of a main structure composed of multiple conformal pipe supports, each uniformly welded to the outer ring of a central circle. Adjacent conformal pipe supports are connected by connecting pipe supports, forming a regular polygonal frame. A transverse slot is cut at the top of each conformal pipe support. The anti-tilting components include anti-tilting brackets, guy ropes, a plumb line, a frame, and lifting lugs I, II, III, and IV. A circular arc plate is fixedly installed on the frame. Lifting lugs III and IV are located at the top of the circular arc plate. Lifting lugs I and II are fixed to the ground. An anti-tilting bracket is installed between lifting lugs I and III. Guy ropes are installed between lifting lugs II and IV. A plumb line is suspended from lifting lug IV. The scaffolding includes scaffold planks and tie-down steel pipes.

[0008] By adopting the above technical solutions, the use of anti-tilting components reduces the longitudinal and lateral deformation of the arc-shaped panels during construction, which helps improve construction accuracy. The use of a built-in conformal fixture with a star-shaped structure ensures the construction accuracy and quality of each section of the cylinder, effectively reducing deformation caused by external forces during subsequent hoisting and installation. This optimizes the construction process, improves the overall construction quality and accuracy of the cylinder, reduces construction costs, saves materials, and increases production efficiency. Installing scaffolding above the conformal fixture significantly reduces the cost of erecting scaffolding, makes reasonable use of limited working space, optimizes the working methods of construction personnel, and improves operational safety.

[0009] Preferably, a column is installed on the connecting pipe support of the cross-shaped conformal tooling, and a crossbeam is installed on the top of the column. Scaffolding planks are laid on the conformal pipe support. Pulling lugs are welded on the conformal pipe support, and the conformal pipe support is connected to the pulling and fixing steel pipe near the central ring through the pulling and fixing lugs. The pulling and fixing steel pipe near the column is fixedly connected to the column and the crossbeam. The two pulling and fixing steel pipes are connected by a pulling connecting pipe.

[0010] By adopting the above technical solution, the traction and fixing steel pipes increase the stability of the overall scaffold structure by connecting the uprights and beams of the scaffold, fix the main supporting parts of the scaffold, provide more solid support, and reduce the risk of swaying and movement of the scaffold and the overall structure of the cross-shaped conformal fixture during hoisting and dismantling operations.

[0011] The manufacturing method of conformal tooling for constructing the segmented cylinder of an FPSO moon pool includes the following steps:

[0012] Step 1: Manufacture the anti-tilt components;

[0013] After the arc plate is manufactured in sections, the segmented conformal channel steel is welded to the top or bottom of the inner side of the arc plate.

[0014] Step 2: Manufacture a cross-shaped conformal fixture;

[0015] Step 3: Construct scaffolding.

[0016] By adopting the above technical solution, the complex conformal fixture is divided into three parts: anti-tilting components, cross-shaped conformal fixture, and scaffolding. This helps to reduce the manufacturing difficulty of the overall fixture and ensure manufacturing quality.

[0017] Preferably, the manufacturing method of the anti-tilt component is as follows:

[0018] Step 1: Draw lines;

[0019] Mark the positions of the jig frame and lifting lugs I and II on the work site.

[0020] Step 2: Positioning the tire frame;

[0021] Hoist the 404 jig to the marked position;

[0022] Step 3: Welding the lifting lugs;

[0023] Weld lifting lugs III and IV to the top of the arc-shaped plate, with the two lugs welded symmetrically.

[0024] Step 4: Hoisting of the arc-shaped panel;

[0025] Hoist the curved plate above the jig;

[0026] Step 5: Install the anti-tilt bracket;

[0027] Weld lifting lugs I and II to the marked locations on the ground. Lifting lugs I and II are symmetrically distributed around the arc-shaped plate. Connect and secure the anti-tilt bracket to lifting lugs I and III. Connect and secure the guy ropes to lifting lugs II and IV. Attach a plumb line to lifting lug IV.

[0028] By adopting the above technical solution, lifting lugs I and II are symmetrically distributed on both sides of the arc-shaped plate, ensuring that the arc-shaped plate is subjected to a uniform anti-tilting force. A plumb line is attached to lifting lug IV to detect the longitudinal deformation of the arc-shaped plate, facilitating subsequent construction adjustments.

[0029] The preferred method for manufacturing the cross-shaped conformal tooling is as follows:

[0030] Step 1: Welding of conformal tube supports;

[0031] S11: Cut the required length of the conformal tube support according to the diameter of the segmented cylinder and machine the cut.

[0032] S12: Divide the central ring into multiple equal regions with the same height and width, and the included angle between each region is equal.

[0033] S13: Weld conformal tube supports to the divided area. Use symmetrical welding to ensure that the two opposite conformal tube supports are in a straight line.

[0034] Step 2: Welding of connecting pipe supports;

[0035] S21: Based on the width of the scaffolding plank, reserve an appropriate length at the top of the conformal pipe support to determine the welding position of the connecting pipe support. After the reserved position is determined, mark it with a line.

[0036] S22: Measure the distance between the marked positions of two adjacent conformal tube supports, and cut the corresponding connecting tube support length according to the measured length.

[0037] S23: Connecting tubes are used to connect the conformal tube supports to construct a regular polygonal frame.

[0038] Step 3: Welding of supporting steel plates;

[0039] S31: Cut a horizontal groove at the top of the conformal tube support. The groove is slightly wider than the width of the support steel plate so that the support steel plate can be inserted into the groove. The openings are at the same height.

[0040] S32: Mark the welding position of the support steel plate inside the cylinder, and weld the cut support steel plate 202 to the marked position on the inside of the cylinder.

[0041] By adopting the above technical solution, the required length of the conformal pipe support is cut according to the diameter of the segmented cylinder. First, the conformal pipe support is welded, then the connecting pipe support is welded, and finally the supporting steel plate is welded. The size of the star-shaped conformal fixture can be flexibly adjusted according to the inner diameter of the cylinder, increasing or decreasing the number of conformal pipe supports required, thus reducing production costs. By welding the connecting pipe support to the conformal pipe support, a regular polygonal structure is formed, increasing the horizontal stability of the star-shaped conformal fixture and providing greater support capacity. The supporting steel plate is welded to the inner side of the cylinder, and then the supporting steel plate is inserted into the groove at the top of the conformal pipe support by rotation, reducing the installation difficulty of the star-shaped conformal fixture.

[0042] The preferred method for manufacturing scaffolding is as follows:

[0043] S32: Column installation. Install the columns one by one onto the connecting pipe supports of the cross-shaped conformal fixture.

[0044] S33: Horizontal Beam Installation. After the uprights are installed, install the horizontal beams one by one to the top connection points of the uprights. Ensure that the lateral distance between all uprights is consistent during horizontal beam installation.

[0045] S34: Scaffolding plank installation. Lay the scaffolding planks on the conformal pipe supports of the cross-shaped conformal fixture to build the first layer.

[0046] S35: Install the columns and beams in the same way, and then gradually install the scaffolding planks, laying them in a ring structure along the inner wall of the cylinder. Starting from the second floor, reserve space on the scaffolding planks to place the stairs leading to the next floor.

[0047] By adopting the above technical solution, the columns are installed on the connecting pipe supports, which provide stable support and fixed points. There is no need to erect scaffolding from the bottom of the cylinder, improving work efficiency and reducing costs. Using a cross-shaped conformal scaffolding system, including scaffold planks and tensioning steel pipes, a stable working platform is provided, allowing the scaffolding to be closer to the cylinder wall. This facilitates painting, installation, and other operations on the cylinder wall, improving both safety and efficiency.

[0048] The method for using conformal tooling for constructing FPSO moon pool sectional shells includes the following steps:

[0049] Step 1: Process the arc-shaped plate using anti-tilt components.

[0050] After the anti-tilt brackets, guy ropes, and each lifting lug are connected and tightened, symmetrical tension is applied to both ends of the arc-shaped plate. The verticality of the assembled arc-shaped plate is checked and adjusted using a plumb line.

[0051] Step 2: Use a cross-shaped conformal tool to support and maintain the shape of the inner wall of the moon pool cylinder.

[0052] Step 3: Based on the cross-shaped conformal fixture, erect a circular scaffold above the cross-shaped conformal fixture, and carry out 360° all-round operation on the moon pool cylinder through the scaffold.

[0053] By adopting the above technical solutions, the anti-tilting components stabilize the verticality of the arc-shaped panels during splicing, reducing the longitudinal and lateral deformation of the arc-shaped panels during construction. This helps improve the construction accuracy of the arc-shaped panels and the overall cylinder, thus reducing production costs. The star-shaped conformal fixture protects the cylinder's shape after construction, optimizing the construction process, further improving the cylinder's construction accuracy, saving construction costs, reducing construction difficulty and risk, and increasing production efficiency. Based on the star-shaped conformal fixture, a circular scaffold is erected above it, reducing the difficulty of scaffold erection and allowing workers easier access to the inner wall of the moon pool cylinder, facilitating subsequent painting and installation operations, and improving operational safety and flexibility.

[0054] Preferably, the cross-shaped conformal fixture is hoisted into the segmented cylinder. After reaching the predetermined position, the cross-shaped conformal fixture is rotated to insert the supporting steel plate into the groove at the top of the conformal pipe support. The cross-shaped conformal fixture is then leveled, and the supporting steel plate is welded and fixed to the groove.

[0055] By adopting the above technical solution, the cross-shaped conformal tooling is connected and fixed to the supporting steel plate through the groove at the top of the conformal tube support, thereby achieving the function of supporting and conforming the inner wall of the moon pool cylinder.

[0056] Preferably, when dismantling the scaffolding after the work is completed, it should be hoisted and dismantled as a whole along with the star-shaped conformal fixtures. The dismantling method is as follows.

[0057] S41: Welding of traction lugs.

[0058] Weld traction lugs onto the conformal tube support.

[0059] S42: Install and fix the steel pipe.

[0060] Tie-and-fix steel pipes are erected between the conformal pipe supports and the scaffolding planks to fix the scaffolding and the star-shaped conformal fixtures.

[0061] S43: Cutting the support steel plate.

[0062] The supporting steel plate welded to the inner side of the segmented cylinder is cut off to separate it from the inner wall of the cylinder.

[0063] S44: Lifting and dismantling.

[0064] Secure the hook to the lifting lug for dismantling and hoisting.

[0065] By adopting the above technical solution, the scaffolding and the cross-shaped conformal fixtures are hoisted and dismantled together by applying tension to the traction lugs through the crane hook, ensuring that the overall structure of the scaffolding is subjected to stable tension and preventing dangerous conditions such as swaying and falling off when cutting the supporting steel plates.

[0066] Compared with the prior art, the present invention has the following advantages:

[0067] 1. The conformal fitting of this invention employs anti-tilting components to reduce the longitudinal and lateral deformation of the arc-shaped plates during construction, thus improving construction accuracy. The built-in conformal fitting with a star-shaped structure ensures the construction accuracy and quality of each cylinder segment, effectively reducing deformation caused by subsequent hoisting and installation forces. This optimizes the construction process, improves the overall construction quality and accuracy of the cylinder, reduces construction costs, saves materials, and increases production efficiency. Installing scaffolding above the conformal fitting significantly reduces the cost of erecting scaffolding, makes reasonable use of limited working space, optimizes the working methods of construction personnel, and improves operational safety.

[0068] 2. In manufacturing the star-shaped conformal tooling of this invention, the required length of the conformal tube support is cut according to the diameter of the segmented cylinder. First, the conformal tube support is welded, then the connecting tube support is welded, and finally, the supporting steel plate is welded. The size of the star-shaped conformal tooling can be flexibly adjusted according to the inner diameter of the cylinder, increasing or decreasing the number of conformal tube supports required, thereby reducing production costs. By welding the connecting tube support to the conformal tube support, a regular polygonal structure is formed, increasing the horizontal stability of the star-shaped conformal tooling and providing greater support capacity. The supporting steel plate is welded to the inner side of the cylinder, and then the supporting steel plate is inserted into the groove at the top slot of the conformal tube support by rotation, reducing the installation difficulty of the star-shaped conformal tooling.

[0069] 3. In the manufacturing of scaffolding, this invention installs the uprights on connecting pipe supports, which provide stable support and fixed points. There is no need to erect scaffolding from the bottom of the cylinder, improving work efficiency and reducing costs. The scaffolding, including scaffold planks and tensioning steel pipes, is erected using a cross-shaped conformal fixture, providing a stable working platform. This allows the scaffolding to be closer to the cylinder wall, facilitating painting, installation, and other operations, thus improving work safety and efficiency. Attached Figure Description

[0070] Figure 1 This is a schematic diagram of the anti-tilt component of the present invention;

[0071] Figure 2 This is a schematic diagram of the cross-shaped conformal tooling of the present invention;

[0072] Figure 3 This is a schematic diagram of the segmented conformal channel steel portion of the present invention;

[0073] Figure 4 This is a schematic diagram of the segmented conformal channel steel of the present invention;

[0074] Figure 5 This is a schematic diagram of the scaffolding of the present invention.

[0075] Figure 6 This is a schematic diagram showing the groove at the top of the conformal tube support of the present invention.

[0076] In the attached image: Figures 1-5 In the middle, 100-rice-shaped conformal tooling, 201-conformal pipe support, 202-supporting steel plate, 203-segmented conformal channel steel, 301-connecting pipe support, 302-central ring, 303-tensioning lug, 401-anti-tilting bracket, 402-wind rope, 403-plumb line, 404-frame, 405-lifting lug I, 406-lifting lug II, 407-lifting lug III, 408-lifting lug IV, 501-scaffolding plank, 503-tensioning and fixing steel pipe. Detailed Implementation

[0077] like Figure 1-3 As shown, the conformal fittings used for constructing the segmented cylinder of an FPSO moon pool include a star-shaped conformal fitting 100, an anti-tilting assembly 400, and scaffolding 500. It also includes a conformal fitting assembly 200 and a connecting assembly 300. The conformal fitting assembly 200 includes conformal pipe supports 201, supporting steel plates 202, and segmented conformal channel steel 203. The connecting assembly 300 includes connecting pipe supports 301, a central ring 302, and tension lugs 303. The anti-tilting assembly 400 includes anti-tilting brackets 401, guy ropes 402, plumb lines 403, a jig 404, and lifting lugs I, II, III, and IV 408. The scaffolding 500 includes scaffold planks 501 and tensioning and fixing steel pipes 503. The star-shaped conformal tooling 100 consists of a main structure composed of multiple conformal tube supports 201. The number of conformal tube supports 201 can be determined according to the inner diameter of the cylinder. Each conformal tube support 201 must be welded evenly spaced to the outer ring of the central circular ring 302. This evenly distributed structure significantly improves the stability and support of the star-shaped conformal tooling 100. Adjacent conformal tube supports 201 are connected by connecting tube supports 301, ultimately constructing a regular polygonal frame. This regular polygonal frame effectively improves the overall stability of the conformal tube supports 201, and also improves the stability and reliability of the star-shaped conformal tooling 100. A transverse slot is cut at the top of each conformal tube support 201, such as... Figure 6The transverse slot is used for welding the support steel plate 202. Welding the support steel plate 202 can increase the support area of ​​the cross-shaped conformal tooling 100 on the inner wall of the segmented cylinder, making the stress on the pipe wall more uniform. The anti-tilting component 400 consists of an anti-tilting bracket 401 and a wind rope 402, which can effectively ensure the longitudinal accuracy of the arc plate during construction and reduce transverse bending deformation. First, the arc plate is hoisted onto the jig 404 and fixed. Then, lifting lugs III 407 and IV 408 are welded to the top of the arc plate, and lifting lugs I 405 and II 406 are welded at the marked positions on the site. The installation positions of the lifting lugs are symmetrically distributed with the arc plate as the center line, and the positions can be adjusted according to the height of the arc plate. Connect the anti-tilt bracket 401 to the lifting lugs I 405 and III 407, and connect the guy rope 402 to the lifting lugs II 406 and IV 408 with a flexible connection. The anti-tilt assembly is now complete. Finally, a plumb line 403 is hung on the lifting lug IV 408 to check the verticality of the arc-shaped plate. After the arc-shaped plate is manufactured in sections, weld the section conformal channel steel 203 to the top or bottom of the inner side of the arc-shaped plate. The section conformal channel steel 203 can reduce segment deformation during the lifting and segmentation process. Scaffolding 500 is laid on the star-shaped conformal fixture 100 after the arc-shaped plate assembly is completed. It is used for subsequent positioning assembly, precision measurement, welding, flaw detection and inspection, sandblasting and painting, and large-scale segmentation assembly, including welding, flaw detection, grinding, and paint touch-up. After all inspections are completed, scaffolding 500 is lifted and dismantled along with the star-shaped conformal fixture 100. The scaffolding is erected in one go and used uniformly throughout the entire process, reducing construction costs.

[0078] This application's conformal fixture includes a star-shaped conformal fixture 100, an anti-tilting component 400, and scaffolding 500. The anti-tilting component reduces the longitudinal and lateral deformation of the curved panels during construction, helping to improve construction accuracy. The built-in star-shaped conformal fixture ensures the construction accuracy and quality of each cylinder segment, effectively reducing deformation caused by external forces during subsequent hoisting and installation, optimizing the construction process, improving the overall construction quality and accuracy of the cylinder, saving materials, reducing construction costs, and increasing production efficiency. Installing the scaffolding above the conformal fixture significantly saves on the cost of erecting scaffolding, makes reasonable use of limited working space, optimizes the working methods of construction personnel, and improves operational safety.

[0079] like Figure 5As shown, the scaffolding 500 includes scaffold planks 501 and tie-down steel pipes 503. Uprights are installed on the connecting pipe supports 301 of the cross-shaped conformal fitting 100, and horizontal beams are installed on the top of the uprights. Scaffold planks 501 are laid on the conformal fitting supports 201. Tie-down lugs 303 are welded to the conformal fitting supports 201, and the conformal fitting supports 201 are connected to the tie-down steel pipes 503 near the central ring 302 through the tie-down lugs 303. The tie-down steel pipes 503 near the uprights are simultaneously fixedly connected to both the uprights and the horizontal beams. The tie-down steel pipes 503 near the central ring 302 and near the uprights are connected together by a central tie-down connecting pipe. The central tie-down connecting pipe forms a 90-degree angle with the upper and lower tie-down steel pipes 503.

[0080] The tie-and-fix steel pipe 503 in this application increases the overall stability of the scaffolding structure by connecting the uprights and beams of the scaffolding 500. It secures the main supporting parts of the scaffolding, providing stronger support and reducing the risk of swaying and movement of the scaffolding and the overall structure of the X-shaped conformal fixtures during hoisting and dismantling operations. Simultaneously, it increases horizontal and vertical stability: the tie-and-fix steel pipe 503 can help adjust the horizontal and vertical position of the scaffolding 500. By strengthening the connections of the scaffolding 500, instability factors and tilting can be reduced, providing a safer and more stable working platform. The tie-and-fix steel pipe 503 and the tie lugs 303 can be adjusted or disassembled relatively easily, allowing the scaffolding 500 to be flexibly adjusted according to work progress or specific requirements, while also facilitating the dismantling and relocation of the scaffolding 500.

[0081] The manufacturing method of the conformal tooling used for constructing the segmented cylinder of the FPSO moon pool is as follows:

[0082] The specific construction process and steps for the anti-tilt assembly are as follows:

[0083] Step 1: Marking. Mark the positions of jig frame 401 and lifting lugs I 405 and II 406 on the work site.

[0084] Step 2: Fixture positioning. Hoist the 404 stainless steel fixture to the marked position;

[0085] Step 3: Welding of lifting lugs. Weld lifting lugs III407 and IV408 to the top of the arc-shaped plate, ensuring the two lugs are welded symmetrically.

[0086] Step 4: Hoisting the curved plate. Hoist the curved plate above the 404 jig;

[0087] Step 5: Install the anti-tilt components.

[0088] S41: Weld lifting lugs I 405 and II 406 to the marked positions on the ground. The positions of the lifting lugs on the ground can be adjusted according to the size of the arc plate. The lifting lugs on both sides are symmetrically distributed with the arc plate as the center line. Symmetrical installation can ensure that the arc plate is subjected to uniform anti-tilting force.

[0089] S42: Connect and fix the anti-tilt bracket 401 to the lifting lug I 405 and lifting lug III 407. The anti-tilt bracket 401 is installed on the outer side of the arc plate.

[0090] S43: Connect and fix the wind rope 402 to the lifting lugs II 406 and IV 408. The wind rope 402 is installed on the inner side of the arc plate.

[0091] S44: Attach a plumb line 403 to the lifting lug Ⅳ408 to detect the longitudinal deformation of the arc plate, which will facilitate subsequent construction adjustments.

[0092] S45: Weld segmented conformal channel steel 203 to the top or bottom of the inner side of the arc plate. The segmented conformal channel steel 203 can reduce segment deformation during the hoisting and segmentation process.

[0093] The specific construction process and steps for the cross-shaped conformal tooling are as follows:

[0094] Step 1: Welding of conformal tube supports with 201 stainless steel;

[0095] S11: Cut the required length of the conformal tube support 201 according to the diameter of the segmented cylinder and machine the cut to facilitate subsequent docking.

[0096] S12: Divide the central ring 302 into multiple equal regions with the same height and width, and the included angle between each region is equal.

[0097] S13: Weld conformal tube supports 201 on the divided area. Use symmetrical welding method to ensure that the two opposite conformal tube supports 201 are on a straight line.

[0098] Step 2: Weld the connecting pipe support using 301 weld;

[0099] S21: Based on the width of the scaffolding board 501, reserve an appropriate length at the top of the conformal pipe support 201 to determine the welding position of the connecting pipe support 301. Mark the reserved position after it is determined.

[0100] S22: Measure the distance between the marked positions of two adjacent conformal tube supports 201, and cut the corresponding connecting tube support 301 according to the measured length.

[0101] S23: The conformal supports 201 are connected by connecting supports 301 to form a regular polygonal frame. The size of the star-shaped conformal fixture can be flexibly adjusted according to the inner diameter of the cylinder. By increasing or decreasing the number of conformal supports 201 required, the production cost can be reduced. By welding connecting supports 301 to the conformal supports 201 to form a regular polygonal structure, the horizontal stability of the star-shaped conformal fixture 100 can be increased, providing greater support capacity.

[0102] Step 3: Welding of the supporting steel plate with 202 stainless steel;

[0103] S31: Cut a horizontal slot at the top of the conformal tube support 201. The slot is slightly wider than the width of the support steel plate 202. In this embodiment, the slot width is 2-5mm wider than the width of the support steel plate 202 so that the support steel plate 202 can be inserted into the slot. The opening position must be at a uniform height.

[0104] S32: Mark the welding positions of the support steel plate 202 inside the cylinder, and weld the cut support steel plate 202 to the marked positions inside the cylinder. One layer of cross-shaped conformal tooling 100 corresponds to one layer of support steel plate 202 being welded.

[0105] Step 4: Use a cross-shaped conformal fixture to hoist and position the object.

[0106] A support steel plate 202 is welded to the inner side of the cylinder. The support steel plate 202 is then inserted into the slot at the top of the conformal pipe support 201 by rotation, reducing the installation difficulty of the star-shaped conformal tooling 100. The support steel plate 202 and the conformal pipe support 201 are connected by welding, providing support to the inner side of the pipe wall. The lateral load-bearing area of ​​the support steel plate 202 is larger than the lateral cross-sectional area of ​​the conformal pipe support 201, providing a more uniform support load to the pipe wall and ensuring its integrity.

[0107] This application's conformal tooling divides the complex conformal tooling into three parts: an anti-tilting component 400, a star-shaped conformal tooling 100, and scaffolding 500. This reduces the overall manufacturing difficulty of the tooling and helps ensure manufacturing quality. The anti-tilting component 400 stabilizes the verticality of the arc-shaped plates during splicing. When the verticality changes, the anti-tilting bracket 401 and the tightening rope 402 can be adjusted in a timely manner to flexibly adjust the situation, improving the construction accuracy of the cylinder. The star-shaped conformal tooling 100 plays a role in maintaining the shape during the hoisting, assembly, and welding processes of the cylinder after its construction is completed. The scaffolding 500 utilizes the conforming stage of the star-shaped conforming fixture 100. Based on the star-shaped conforming fixture 100, the scaffolding 500, including scaffold planks 501 and tie-down steel pipes 503, is erected. This rational use of the star-shaped conforming fixture 100 structure creates a safe and stable working platform. The scaffolding 500 allows workers easier access to the inner wall of the moon pool cylinder, facilitating subsequent painting and installation work. Erecting the scaffolding 500 on the star-shaped conforming fixture 100 avoids direct contact between the scaffolding 500 and the inner wall of the moon pool, reducing scratches, damage, or other physical harm to the inner wall during construction and helping to maintain the integrity and structural stability of the moon pool cylinder.

[0108] The conformal tooling used for constructing the segmented cylinder of an FPSO moon pool includes the following steps:

[0109] Step 1: Specific instructions for using the anti-tilt assembly;

[0110] S11: The anti-tilt assembly 400 applies symmetrical tension to both ends of the arc-shaped plate after being tightened by the anti-tilt bracket 401 and the wind rope 402 connected to the lifting lug, thereby reducing the deformation of the arc-shaped plate under stress during manufacturing. At the same time, the tension of the anti-tilt bracket 401 and the wind rope 402 facilitates subsequent adjustment of the arc-shaped plate's posture.

[0111] S12: Connect the lifting lug Ⅳ408 to the plumb line 403. Use the plumb line to check and adjust the verticality of the assembled arc plate, ensuring that the verticality deviation is within 1mm. After the adjustment and positioning are completed, fix the anti-tilt bracket 401 and tighten the wind rope 402.

[0112] S13: After the arc-shaped plate is manufactured in segments, weld segmented conformal channel steel 203 to the top or bottom of each segment, such as... Figure 4 The use of segmented conformal channel steel 203 solves the problem of deformation that easily occurs during the hoisting of the main assembly, effectively improving the construction and assembly accuracy of the moon pool segment assembly. Multiple segmented conformal channel steels can be welded according to the dimensions of the segments, or they can be welded simultaneously at the top and bottom. After the arc plate segments are welded and assembled, the segmented conformal channel steel 203 needs to be cut off to facilitate the subsequent hoisting of the cross-shaped conformal fixture 100.

[0113] The anti-tilting component 400 stabilizes the verticality of the arc-shaped plates during splicing. When the verticality changes, the anti-tilting bracket 401 and the tightening rope 402 can be adjusted in time to make flexible adjustments, thereby improving the construction accuracy of the cylinder.

[0114] Step 2: How to use the cross-shaped conformal fixture;

[0115] After the construction of the cylindrical body is completed, the star-shaped conformal fixture 100 plays a role in maintaining the shape of the cylindrical body during hoisting, assembly, and welding, thereby improving the construction accuracy of the cylindrical body. The constructed star-shaped conformal fixture 100 is hoisted into the segmented cylindrical body. After reaching the predetermined position, the star-shaped conformal fixture 100 is rotated to engage the support steel plate 202 with the top groove of the conformal tube support 201. The overall levelness of the star-shaped conformal fixture 100 is measured and adjusted. Then, the support steel plate 202 is welded to the groove. Thus, the star-shaped conformal fixture 100 fulfills its function of supporting and maintaining the shape of the inner wall of the moon pool cylindrical body.

[0116] Step 3: How to use scaffolding;

[0117] After the moon pool section is hoisted into the hull, scaffolding 500 needs to be erected for subsequent positioning and assembly, precision measurement, welding, flaw detection and inspection, sandblasting and painting, and large-scale assembly of sections, including welding, flaw detection, grinding, and paint touch-up. Utilizing the structure of the X-shaped conformal fixture 100, a circular scaffolding 500 is erected above it, solving the problem of limited working space inside the moon pool section making it difficult to erect traditional scaffolding, and increasing the working area and efficiency. It allows for 360° all-around operation, reducing the difficulty of grinding, sandblasting, and painting.

[0118] The scaffolding 500 utilizes the conformal stage of the star-shaped conformal fixture 100 as a base platform, making reasonable use of the structure of the star-shaped conformal fixture 100 to create a safe and stable working platform. The scaffolding 500 allows workers easier access to the inner wall of the moon pool cylinder, facilitating subsequent painting and installation operations. Erecting the scaffolding 500 on the star-shaped conformal fixture 100 avoids direct contact between the scaffolding 500 and the inner wall of the moon pool, reducing scratches, damage, or other physical harm to the inner wall during construction, and helping to maintain the integrity and structural stability of the moon pool cylinder.

[0119] This application employs an anti-tilting component 400 to stabilize the verticality of the arc-shaped plates during splicing, reducing longitudinal and lateral deformation during construction. This improves the construction accuracy of the arc-shaped plates and the overall cylinder, while reducing production costs. The cross-shaped conformal fixture 100 protects the cylinder's shape after construction, optimizing the construction process, further improving construction accuracy, saving costs, reducing construction difficulty and risk, and increasing production efficiency. Based on the cross-shaped conformal fixture 100, a circular scaffolding 500 is erected above it, reducing the difficulty of erecting the scaffolding 500 and allowing workers easier access to the inner wall of the moon pool cylinder. This facilitates subsequent 360° all-around painting and installation operations, improving operational safety and flexibility.

[0120] The specific steps for erecting scaffolding are as follows:

[0121] S31: Begin constructing the scaffolding using the bottom star-shaped conformal fixture 100 as a base. Using the star-shaped conformal fixture 100 to erect the scaffolding provides a stable working platform, allowing the scaffolding to be closer to the cylinder wall, facilitating painting, installation, and other operations on the cylinder wall, thus improving work safety and efficiency.

[0122] S32: Column Installation. Install each column onto the connecting pipe support 301 of the cross-shaped conformal tool 100, and secure it firmly. The connecting pipe support 301 provides stable support and a stable fixing point. This eliminates the need for scaffolding from the bottom of the cylinder, improving work efficiency and reducing costs.

[0123] S33: Horizontal Beam Installation. After the uprights are installed, the horizontal beams need to be installed one by one at the top connection points of the uprights. When installing the horizontal beams, it is necessary to ensure that the lateral distance between each upright is consistent, so that the scaffolding has the characteristics of stable support.

[0124] S34: Installation of scaffold planks. Lay the scaffold planks 501 on the conformal support pipes 201 of the cross-shaped conformal fixture 100 to construct the first layer. One cross-shaped conformal fixture 100 is used for each layer. The scaffolding 500 is constructed starting from the bottom layer, with all the scaffold planks 501 on the first layer laid. Starting from the second layer, staircase space will be reserved on the scaffold planks 501 for access to and from the first layer, as well as for access to the third layer.

[0125] S35: Install the columns and beams in the same way, and then gradually install the scaffolding planks 501, laying them in a ring structure along the inner wall of the cylinder, and leaving space for the staircase leading to the next floor.

[0126] Step 4: Instructions for dismantling scaffolding;

[0127] Installing scaffolding 500 onto the star-shaped conforming fixture 100 facilitates subsequent dismantling, eliminating the need for individual layer-by-layer dismantling as with traditional scaffolding. Scaffolding 500 and the star-shaped conforming fixture 100 can be dismantled as a whole, shortening the dismantling period and reducing costs. After all inspection work is completed, scaffolding 500 is dismantled as a whole along with the star-shaped conforming fixture 100. The specific dismantling steps are as follows:

[0128] S41: Welding of tension lugs. Weld tension lugs 303 onto the conformal tube support 201.

[0129] S42: Install tie-down steel pipes. Tie-down steel pipes 503 are erected between the conformal support 201 and the scaffold plank 501 to secure the scaffold 500 and the star-shaped conformal fixture 100. One tie-down steel pipe 503 near the central ring 302 is connected to the conformal support 201 via a tie-down lug 303. The tie-down steel pipe 503 near the uprights is fixedly connected to the uprights and beams for easy subsequent hoisting and dismantling. One tie-down steel pipe 503 near the central ring 302 and another tie-down steel pipe 503 near the uprights are connected together via a central tie-down connecting pipe. The central tie-down connecting pipe forms a 90-degree angle with the upper and lower tie-down steel pipes 503.

[0130] S43: Cut the support steel plate. Cut off the support steel plate 202 that is welded to the inner side of the segmented cylinder to separate it from the inner wall of the cylinder.

[0131] S44: Lifting and dismantling. Secure the hook to the lifting lug 303 for dismantling and lifting. Apply tension to the lifting lug 303 using the crane hook to ensure that the overall scaffold structure is under stable tension, preventing dangerous situations such as swaying or falling off when cutting the support steel plate 202.

[0132] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing conformal tooling for constructing segmented cylinder bodies of an FPSO moon pool, characterized in that: The conformal fixture includes scaffolding, a star-shaped conformal fixture, and an anti-tilting component. The star-shaped conformal fixture consists of a main structure composed of multiple conformal pipe supports, each of which is evenly welded to the outer ring of a central circle. Adjacent conformal pipe supports are connected by connecting pipe supports to form a regular polygonal frame. A horizontal slot is cut at the top of each conformal pipe support. The anti-tilting component includes an anti-tilting bracket, guy ropes, a plumb line, a frame, and lifting lugs I, II, III, and IV. A circular arc plate is fixedly installed on the frame. Lifting lugs III and IV are set at the top of the circular arc plate. Lifting lugs I and II are fixed to the ground. An anti-tilting bracket is set between lifting lugs I and III. Guy ropes are set between lifting lugs II and IV. A plumb line is suspended from lifting lug IV. The scaffolding includes scaffold planks and tie-down steel pipes. A column is installed on the connecting pipe support of the cross-shaped conformal tooling, and a crossbeam is installed on the top of the column; scaffolding planks are laid on the conformal pipe support; traction lugs are welded on the conformal pipe support, and the conformal pipe support is connected to the traction fixing steel pipe near the central ring through the traction lugs. The traction fixing steel pipe near the column is fixedly connected to the column and the crossbeam, and the two traction fixing steel pipes are connected by a traction connecting pipe. The manufacturing method includes the following steps: Step 1: Manufacture the anti-tilt components; After the arc plate is manufactured in sections, the segmented conformal channel steel is welded to the top or bottom of the inner side of the arc plate. Step 2: Manufacture a cross-shaped conformal fixture; Step 3: Construct scaffolding; The manufacturing method of the rice-shaped conformal tooling is as follows: Step 1: Welding of conformal tube supports; S11: Cut the required length of the conformal tube support according to the diameter of the segmented cylinder and machine the cut. S12: Divide the central ring into multiple equal regions with the same height and width, and the included angle between each region is equal; S13: Weld conformal tube supports to the divided area. Use symmetrical welding to ensure that the two opposite conformal tube supports are in a straight line. Step 2: Welding of connecting pipe supports; S21: Based on the width of the scaffolding plank, reserve an appropriate length at the top of the conformal pipe support to determine the welding position of the connecting pipe support. Mark the reserved position after it is determined. S22: Measure the distance between the marked positions of two adjacent conformal tube supports, and cut the corresponding connecting tube support length according to the measured length; S23: Connecting tube supports are used between conformal tube supports to construct a regular polygonal frame; Step 3: Welding of supporting steel plates; S31: Cut a horizontal groove at the top of the conformal tube support. The groove is slightly wider than the width of the support steel plate so that the support steel plate can be inserted into the groove. The openings are at the same height. S32: Mark the welding positions of the support steel plates inside the cylinder, and weld the cut support steel plates to the marked positions on the inside of the cylinder.

2. The method for manufacturing the conformal tooling for constructing the FPSO moon pool segmented cylinder according to claim 1, characterized in that: The manufacturing method of the anti-tilt component is as follows. Step 1: Draw lines; Mark the positions of the jig frame and lifting lugs I and II on the work site. Step 2: Positioning the tire frame; Hoist the jig to the marked position; Step 3: Welding the lifting lugs; Weld lifting lugs III and IV to the top of the arc-shaped plate, with the two lugs welded symmetrically. Step 4: Hoisting of the arc-shaped panel; Hoist the curved plate above the jig; Step 5: Install the anti-tilt bracket; Weld lifting lugs I and II to the marked positions on the ground; lifting lugs I and II are symmetrically distributed with the arc plate as the center; connect and fix the anti-tilt bracket to lifting lugs I and III; connect and fix the wind rope to lifting lugs II and IV; tie a plumb line to lifting lug IV.

3. The method for manufacturing the conformal tooling for constructing the segmented cylinder of an FPSO moon pool according to claim 1, characterized in that: The manufacturing method of scaffolding is as follows: S32: Column installation; Install the columns one by one onto the connecting pipe supports of the cross-shaped conformal fixture; S33: Horizontal beam installation; After the columns are installed, install the horizontal beams one by one to the top connection of the columns; When installing the horizontal beams, ensure that the lateral distance between each column is consistent; S34: Scaffolding plank installation; Lay the scaffolding planks on the conformal pipe supports of the cross-shaped conformal fixture to build the first layer; S35: Install the columns and beams in the same way, and then gradually install the scaffolding planks, laying them in a ring structure along the inner wall of the cylinder. Starting from the second floor, reserve space on the scaffolding planks to place the stairs leading to the next floor.

4. The method of using the conformal tooling manufactured according to the manufacturing method of the conformal tooling for FPSO moon pool segmented cylinder construction according to claim 2, characterized in that: Includes the following steps: Step 1: Process the arc-shaped plate using the anti-tilt assembly; After the anti-tilt brackets, wind ropes, and each lifting lug are connected and tightened, symmetrical tension is applied to both ends of the arc plate; the verticality of the assembled arc plate is checked and adjusted by plumb line. Step 2: Use a cross-shaped conformal fixture to support and maintain the shape of the inner wall of the moon pool cylinder; Step 3: Based on the cross-shaped conformal fixture, erect a circular scaffold above the cross-shaped conformal fixture, and carry out 360° all-round operation on the moon pool cylinder through the scaffold.

5. The method of using the conformal tooling for constructing the FPSO moon pool segmented cylinder according to claim 4, characterized in that, The cross-shaped conformal fixture is hoisted into the segmented cylinder. After reaching the predetermined position, the cross-shaped conformal fixture is rotated to insert the supporting steel plate into the groove at the top of the conformal pipe support. The cross-shaped conformal fixture is then leveled, and the supporting steel plate is welded and fixed to the groove.

6. The method of using the conformal tooling for constructing the FPSO moon pool segmented cylinder according to claim 4, characterized in that, When the scaffolding work is completed and it is dismantled, it shall be hoisted and dismantled as a whole together with the star-shaped conforming fixture. The dismantling method is as follows. S41: Welding of lifting lugs; Weld tension lugs onto the conformal tube support; S42: Install and fix the steel pipe; Tie-and-fix steel pipes are erected between the conformal pipe supports and the scaffolding planks to fix the scaffolding and the star-shaped conformal fixtures; S43: Cutting the supporting steel plate; Cut off the supporting steel plate welded to the inside of the segmented cylinder to separate it from the inner wall of the cylinder. S44: Lifting and dismantling; Secure the hook to the lifting lug for dismantling and hoisting.

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