A wind power tower flange welding method

Abstract

The application discloses a wind power tower drum flange welding method, which comprises the following steps: segment drum section and flange group pairing, girth welding, adjusting the groove gap of the first and second drum sections at two ends, segment remaining girth welding, and monitoring the flange during the welding process. The basic installation and manufacturing process of the flange, the segment drum section and the whole flange group pairing mode provided by the application reduce the process flow and improve the pairing efficiency. The girth welding provided by the application adopts a multi-head simultaneous welding mode, one welding machine position is used for each welding seam, all the welding seams are welded at the same time, and the welding efficiency of the drum section welding seam is significantly improved. After the girth welding, the groove gap of the first and second drum sections at two ends is adjusted to the parallelism and coaxiality of the flange to meet the requirements, which not only ensures the uniformity of the welding seam gap between the flange and the drum section, but also adjusts the parallelism and coaxiality of the flanges at two ends of the whole drum section until the design requirements are met. The application improves the installation and welding efficiency of the offshore wind power tower drum flange, and reduces the construction cost of the offshore wind power tower drum installation.

Description

TECHNICAL FIELD

[0001] The present application relates to the offshore wind tower cylinder technical field, and particularly to a wind tower cylinder flange welding method. BACKGROUND

[0002] China has abundant offshore wind energy resources. According to the national survey results, the offshore wind power development potential of China is about 200 million kilowatts at a water depth of 5-25 meters and a height of 50 meters; the offshore wind power development potential is about 500 million kilowatts at a water depth of 5-50 meters and a height of 70 meters, and the industry development prospect is broad.

[0003] The booming development of offshore wind power drives the boom of offshore tower cylinder and wind turbine installation. The tower cylinder is a connecting component between the wind turbine generator and the foundation ring, and transmits the hundreds of tons of wind turbine load on the upper part, and is an important part required for realizing the functions of wind turbine generator maintenance, power transmission and transformation, etc. With the continuous expansion of the scale of China's offshore wind power and the development of deep-sea wind farms, the offshore wind turbine power is becoming large, and the power of the off-line research prototype has reached the 20MW level. The tower cylinder also develops in the direction of super-high, super-heavy and super-large. The flange diameter of the tower cylinder reaches 9 meters, and deformation is prone to occur in the flange assembly, welding and other links. The flatness, roundness and inclination of the flange do not meet the design requirements, thereby affecting the use function of the tower cylinder and reducing the service life. In the past, the tower cylinder flange adopts the ground horizontal assembly mode, and is horizontally assembled with the first cylinder segment, then is turned over and erected, and then is assembled with other cylinder segments. The process is relatively complex and the cycle is long. SUMMARY

[0004] In view of the problems in the prior art method, the purpose of the present application is to provide a wind tower cylinder flange welding method, which reduces the time required for offshore wind tower cylinder flange installation and welding, improves the efficiency, and ensures that the installation precision of the flange meets the design and specification requirements.

[0005] The present application is realized by the following technical solutions:

[0006] A wind tower cylinder flange welding method, comprising the following steps:

[0007] Step S1, segment cylinder and flange assembly:

[0008] Step S11, mark the four equal division lines on the inner side of the rounded cylinder segment;

[0009] Step S12, hoist the segment bottom flange and the adjacent pipe segment that have passed the incoming inspection to the assembly roller frame, uniformly arrange the girth gap offset through the circumference difference of the cylinder segment and the flange butt joint, and adjust the relative position of the four division points of the cylinder segment corresponding to the flange bolt holes according to the pipe segment processing drawing and the four equal division lines;

[0010] Step S13, after the segmented bottom flange and the cylinder segment group are matched, the cylinder segment and the segmented top flange are matched according to steps S11 to S12. The girth seam misalignment and straightness are strictly controlled during the matching process, and attention should be paid to that the girth seam is welded after the two girth seams are matched.

[0011] Step S14, if the flange is not supplied in time, the cylinder segment can be matched first, and then the top and bottom flanges are matched after the cylinder segment is matched.

[0012] Step S2, girth seam welding. After the precision detection before welding is qualified, the girth seam welding is performed according to the tower cylinder welding process requirements. First, the inside bevel welding is performed. The inside girth seam of a single segment can be welded by multiple welds at the same time. The welding station is arranged with the middle girth seam as the midpoint and one girth seam in between. After the inside welding is completed, the outside root cleaning and outside welding are performed.

[0013] Step S3, adjust the gap of the bevel of the first and second cylinder segments at both ends. After the girth seam welding of the middle cylinder segment is completed and the non-destructive testing is qualified, the parallelism and coaxiality of the top and bottom flange end faces are detected by a total station instrument. The parallelism and coaxiality are measured according to the four-part line. If one of them is out of tolerance by 3 mm, the out-of-tolerance position is located according to the measurement points, and the girth seam of the first and second cylinder segments at the top and bottom ends is planed to open. The relative gap is controlled to make the precision meet the requirements.

[0014] Step S4, welding of the remaining girth seams of the segments: after the parallelism, coaxiality and other precision of the segments are adjusted, the welding of the girth seams of the flanges and the cylinder segments and the first and second cylinder segments is performed. Attention should be paid to that the welding methods are different according to the different thicknesses of the flange welds, including the following steps:

[0015] Step S41, top flange: ① outside gas shielded welding backing; ② inside submerged arc welding filling, after 2-3 layers of submerged arc welding filling, outside gas planing; ③ after the outside is polished clean, perform submerged arc welding filling to leave only one cover weld; ④ turn to the inside to perform submerged arc welding filling to leave only one cover weld; ⑤ after the outside cover is completed, perform the inside cover;

[0016] Step S42, third connecting flange: ① inside gas shielded welding backing; ② after the outside submerged arc welding filling cover is completed, inside gas planing; ③ after the inside is polished clean, perform submerged arc welding filling cover;

[0017] Step S43, first and second connecting flanges: ① outside gas shielded welding backing; ② inside submerged arc welding filling, after 2-3 layers of submerged arc welding filling, outside gas planing; ③ after the outside is polished clean, perform submerged arc welding filling cover; ④ turn to the inside to perform submerged arc welding filling cover;

[0018] Step S44, bottom T-shaped flange: ① air-arc welding on the outer side; ② inner side arc welding, after 2-3 layers of arc welding, air planing on the outer side; ③ after polishing the outer side, arc welding is performed to leave only one layer of cover; ④ turning to the inner side, arc welding is performed to leave only one layer of cover; ⑤ after the outer side cover is completed, the inner side cover is performed;

[0019] Step S5, the flange needs to be monitored during the welding process to prevent excessive inward inclination or outward turning.

[0020] Further improvement of the technical scheme of the application, in step S12, the gap between the flange and the first cylinder segment is close to 0, the single positioning welding length is not less than 100 mm, and the welding thickness is not less than 8 mm.

[0021] Further improvement of the technical scheme of the application, in step S13, the flange and the cylinder segment ring seam and the first and second cylinder segment ring seam are only treated by positioning welding.

[0022] Further improvement of the technical scheme of the application, in step S41, the thickness T of the top flange is 52 mm, the inward inclination is ≤0.5 mm, and the flatness is ≤0.5 mm.

[0023] Further improvement of the technical scheme of the application, in step S42, the thickness T of the third connecting flange is 28 mm, the inward inclination is ≤1.5 mm, and the flatness is ≤1.5 mm.

[0024] Further improvement of the technical scheme of the application, in step S43, the thickness T of the first and second connecting flanges is 39 / 32 mm, the inward inclination is ≤1.5 mm, and the flatness is ≤1.5 mm.

[0025] Further improvement of the technical scheme of the application, in step S44, the thickness T of the bottom T-shaped flange is 58 mm, the inward inclination is ≤1.5 mm, and the flatness is ≤1.5 mm.

[0026] The application has the following beneficial effects:

[0027] The basic installation and manufacturing process of the flange provided by the application, the segmented cylinder segment and the overall assembly of the flange, reduces the process flow and improves the assembly efficiency; the ring seam welding (except for the ring seam of the two end flanges and the ring seam of the first and second cylinder segments at both ends) adopts a multi-head simultaneous welding method, one welding machine is used for each weld, and all welds are welded simultaneously, which significantly improves the welding efficiency of the cylinder segment welds; after the ring seam welding, the gap between the first and second cylinder segments at both ends is adjusted to the parallelism and coaxiality of the flanges to meet the requirements, which not only ensures the uniformity of the weld gap between the flanges and the cylinder segments, but also adjusts the parallelism and coaxiality of the flanges at both ends of the entire cylinder segment until the design requirements are met.

[0028] The flange and the barrel joint connecting weld provided by the application have different welding trace arrangement sequences according to different plate thicknesses, so that the flange weld after welding is not outwardly turned, and flatness and parallelism meet design requirements.

[0029] The application reduces the time required for offshore wind tower barrel flange installation and welding, improves efficiency, reduces the construction cost of offshore wind tower barrel installation, ensures the installation accuracy of the flange to meet the design and specification requirements, and reduces unnecessary rework. BRIEF DESCRIPTION OF DRAWINGS

[0030] Fig. 1 A segmented barrel joint and flange assembly diagram of an embodiment of the application is shown in the figure.

[0031] Fig. 2 An adjustment gap between the first and second barrel joints at two ends of an embodiment of the application is shown in the figure.

[0032] Fig. 3 A flange inner inclination measurement diagram of an embodiment of the application is shown in the figure. DETAILED DESCRIPTION

[0033] The application will be described in detail below with reference to the accompanying drawings and specific embodiments, which are used to explain the application but not to limit the application.

[0034] It should be noted that all directional indications (such as up, down, left, right, front, back, upper end, lower end, top, bottom, etc.) in the embodiments of the application are only used to explain the relative positional relationship and movement condition between components in a certain specific posture (as shown in the drawings), and if the specific posture changes, the directional indications also change accordingly.

[0035] In the application, unless otherwise explicitly specified and limited, the term "connection" should be understood broadly, for example, "connection" can be fixed connection, can be detachable connection, or can be integrated; can be mechanical connection, can be electrical connection; can be directly connected, can be indirectly connected through an intermediate medium, can be internal communication of two elements or interaction relationship between two elements, unless otherwise explicitly limited. For ordinary skilled in the art, the specific meaning of the above-mentioned term in the application can be understood according to the specific situation.

[0036] In addition, the description such as "first", "second" and the like in the present application is only for the purpose of description and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined as "first", "second" can be explicitly or implicitly included at least one of the features; in addition, the technical solutions of various embodiments can be combined with each other, but it must be based on the realization of the ordinary skilled in the art, when the combination of technical solutions appears contradictory or cannot be realized, it should be considered that the combination of technical solutions does not exist, nor within the protection scope required by the present application.

[0037] The following will be described in detail in combination with the accompanying drawings Figs. 1-3 The present application will be further described in detail.

[0038] The present application relates to a kind of wind power tower flange welding method:

[0039] Flange basic installation manufacturing process:

[0040] Segmented cylinder section and flange group are matched → ring seam welding (except the ring seam of two end flanges and the ring seam of two end first, second cylinder section) → adjust the gap of the bevel of two end first, second cylinder section to the parallelism and coaxiality of flange to meet the requirements → remaining weld ring seam welding → complete.

[0041] Manufacturing method and control points of each process:

[0042] 1. Segment cylinder section and flange group are matched

[0043] 1) The cylinder section that is well rounded is marked with four equal division lines (i.e. 0°, 90°, 180°, 270° positions) on the inside of the cylinder wall.

[0044] 2) The segmented bottom flange and adjacent pipe section that pass the incoming inspection are hoisted to the group matching roller frame, the ring seam misalignment is evenly arranged through the circumference difference of the cylinder section and the flange butt joint, and the relative position of the four division points of the cylinder section corresponding to the flange bolt hole is adjusted according to the pipe section processing drawing and the four equal division lines. Note that the group matching gap between the flange and the first cylinder section should tend to 0, the single positioning weld length should be not less than 100 mm, and the weld thickness should be not less than 8 mm.

[0045] 3) After the segmented bottom flange and cylinder section are matched, the cylinder section and segmented top flange are matched in the above manner. During the matching process, the ring seam misalignment and straightness are strictly controlled, and attention should be paid to that when two ring seams are matched, ring seam backing welding should be performed in time (the flange and cylinder ring seam and the first and second cylinder ring seam are only treated with positioning welding).

[0046] 4) If the flange is not supplied in time, the cylinder section can be matched first, and then the top and bottom flanges are matched after the cylinder section is matched.

[0047] 2. Ring seam welding (except the ring seam of two end flanges and the ring seam of two end first, second cylinder section)

[0048] After the pre-welding accuracy detection is qualified, the girth welding is performed according to the tower drum welding process requirements. First, the inner side bevel welding is performed, and multiple welds can be welded simultaneously for the single segmented inner side girth. The welding station is arranged with the middle girth as the midpoint and one girth in between. After the inner welding is completed, the outer side root cleaning and outer side welding are performed.

[0049] 3. Adjust the gap of the bevels of the first and second cylinder sections at both ends

[0050] After the girth welding of the middle cylinder section is completed and the non-destructive testing is qualified, the parallelism and coaxiality of the top and bottom flange end faces are detected by a total station instrument. The parallelism and coaxiality are measured according to the four-part line. If one of them is out of tolerance by 3 mm, the out-of-tolerance position is located according to the measurement points, and the girths of the first and second cylinder sections at the top and bottom ends are planed open for positioning, and the relative gap is controlled to meet the accuracy requirements.

[0051] 4. Welding of the remaining girths in sections

[0052] After the accuracy adjustments such as parallelism and coaxiality of the sections are completed, the welding of the flange and cylinder section girths and the first and second cylinder section girths is performed. Note that the welding method is different according to the thickness of the flange weld. Details are as follows.

[0053] 1) Top flange (T = 52 mm, inner inclination ≤0.5 mm, flatness ≤0.5 mm): ① Perform gas shielded welding on the outside for backing; ② Perform submerged arc welding on the inside for filling, and after 2-3 layers of submerged arc welding, perform outside gas planing; ③ After the outside is polished clean, perform submerged arc welding for filling and leave only a cover for welding; ④ Turn to the inside and perform submerged arc welding for filling and leave only a cover for welding; ⑤ After the outside cover is completed, perform the inside cover.

[0054] 2) Third connecting flange (T = 28 mm, inner inclination ≤1.5 mm, flatness ≤1.5 mm): ① Perform gas shielded welding on the inside for backing; ② After the outside cover is completed by submerged arc welding, perform inside gas planing; ③ After the inside is polished clean, perform submerged arc welding for cover.

[0055] 3) First and second connecting flanges (T = 39 / 32 mm, inner inclination ≤1.5 mm, flatness ≤1.5 mm): ① Perform gas shielded welding on the outside for backing; ② Perform submerged arc welding on the inside for filling, and after 2-3 layers of submerged arc welding, perform outside gas planing; ③ After the outside is polished clean, perform submerged arc welding for cover; ④ Turn to the inside and perform submerged arc welding for cover.

[0056] 4) Bottom T-shaped flange (T=58mm, inner inclination ≤1.5mm, flatness ≤1.5mm): ① Outside is gas shielded welding; ② Inside is submerged arc welding, after 2-3 layers of submerged arc welding, the outside is gas planished; ③ After the outside is polished, the submerged arc welding is performed to leave only a cover surface; ④ The inside is turned to and the submerged arc welding is performed to leave only a cover surface; ⑤ After the outside cover surface is finished, the inside cover surface is finished.

[0057] 5) Note: The flange should be monitored during welding to prevent the inner inclination or the outer turning from exceeding the standard.

[0058] Compared with the prior art, the present application has the following beneficial effects:

[0059] The basic installation and manufacturing process of the flange, the segmented cylinder segment and the overall assembly mode of the flange provided by the present application reduce the process flow and improve the assembly efficiency; the girth welding (except for the girth welding of the two end flanges and the girth welding of the first and second cylinder segments at the two ends) adopts a multi-head simultaneous welding mode, one welding position is used for each weld, and all the welds are welded simultaneously, which significantly improves the welding efficiency of the cylinder segment welds; after the girth welding, the gap of the bevel of the first and second cylinder segments at the two ends is adjusted to the parallelism and coaxiality of the flange to meet the requirements, which not only ensures the uniformity of the weld gap between the flange and the cylinder segment, but also adjusts the parallelism and coaxiality of the flanges at the two ends of the entire cylinder segment until the design requirements are met.

[0060] The welding process of the flange and the cylinder segment connection weld provided by the present application is different for different plate thicknesses, and different welding pass arrangement sequences are explored to ensure that the flange weld after welding does not turn outward, and the flatness, parallelism, etc. meet the design requirements.

[0061] The present application reduces the time required for offshore wind turbine tower flange installation and welding, improves efficiency, reduces the construction cost of offshore wind turbine tower installation, ensures that the installation accuracy of the flange meets the design and specification requirements, and reduces unnecessary rework.

[0062] The above describes the technical solutions provided by the embodiments of the present application in detail, and the principles and implementation modes of the embodiments of the present application are described by applying specific examples; the above description of the embodiments is only applicable to help understand the principles of the embodiments of the present application; at the same time, for those skilled in the art, according to the embodiments of the present application, the specific implementation modes and application ranges will be changed, and the above description of the present application should not be understood as a limitation of the present application.

Claims

1. A method of welding a flange of a wind turbine tower section, characterized in that, It comprises the following steps: Step S1, segment cylinder section and flange group pair: Step S11, the cylinder section is marked with four equal division lines on the inner side of the cylinder wall after being rounded; Step S12, the segment bottom end flange and the adjacent pipe section that have passed the incoming inspection are hoisted to the group pair roller frame, the girth weld misalignment is uniformly arranged through the circumference difference of the cylinder section and the flange joint, and the relative position of the cylinder section four-point corresponding flange bolt hole is adjusted according to the pipe section processing drawing and the four equal division lines; Step S13, after the segment bottom end flange and the cylinder section are well paired, the cylinder section and the segment top end flange are paired according to steps S11 to S12, the girth weld misalignment and straightness are strictly controlled during the pairing process, and attention should be paid to that the girth weld back welding should be performed in time after two girth welds are paired; If the flange supply is not timely, the cylinder section can be paired first, and then the top and bottom end flanges are paired after the cylinder section is paired; Step S2, girth weld, after the precision detection before welding is qualified, the girth weld is welded according to the tower cylinder welding process requirement, first the inner side bevel welding is performed, the inner side girth weld of a single segment can be welded by multiple welds at the same time, the welding station is arranged with the middle girth weld as the midpoint and one girth weld as the interval; after the inner welding is completed, the outer side root cleaning and outer side welding are performed; Step S3, the bevel gap of the first and second cylinder sections at both ends is adjusted, and after the girth weld of the middle cylinder section is welded and the non-destructive testing is qualified, the parallelism and coaxiality of the top and bottom flange end faces are detected by a total station instrument; the parallelism and coaxiality are measured according to the four equal division lines, if one of them is out of tolerance by 3mm, the out-of-tolerance position is located according to the measurement point, the girth weld of the first and second cylinder sections at the top and bottom ends is planed, and the relative gap is controlled to make the precision meet the requirements; Step S4, remaining girth weld of segment: after the precision adjustment of the parallelism and coaxiality of the segment, the girth weld of the flange and the cylinder section and the girth weld of the first and second cylinder sections are welded; attention should be paid to that according to the different thicknesses of the flange welds, the welding methods are different, which comprise the following steps: Step S41, top flange: ① outer side gas shielded welding back welding is performed; ② inner side submerged arc welding filling is performed, after 2-3 layers of submerged arc welding filling, outer side gas planing is performed; ③ after the outer side is polished clean, submerged arc welding filling is performed to leave only one cover surface weld; ④ turn to the inner side to perform submerged arc welding filling to leave only one cover surface weld; ⑤ after the outer side cover surface is completed, inner side cover surface is performed; Step S42, third connecting flange: ① inner side gas shielded welding back welding is performed; ② after the outer side submerged arc welding filling cover surface is completed, inner side gas planing is performed; ③ after the inner side is polished clean, submerged arc welding filling cover surface is performed; Step S43, first and second connecting flange: ① outer side gas shielded welding back welding is performed; ② inner side submerged arc welding filling is performed, after 2-3 layers of submerged arc welding filling, outer side gas planing is performed; ③ after the outer side is polished clean, submerged arc welding filling cover surface is performed; ④ turn to the inner side to perform submerged arc welding filling cover surface; Step S44, bottom T-shaped flange: ① outer side gas shielded welding back welding is performed; ② inner side submerged arc welding filling is performed, after 2-3 layers of submerged arc welding filling, outer side gas planing is performed; ③ after the outer side is polished clean, submerged arc welding filling is performed to leave only one cover surface weld; ④ turn to the inner side to perform submerged arc welding filling to leave only one cover surface weld; ⑤ after the outer side cover surface is completed, inner side cover surface is performed; Step S5, the flange should be monitored during the welding process to prevent the inner inclination or the outward turning from exceeding the standard.

2. The method of claim 1, wherein: In the step S12, the gap between the flange and the first cylinder segment tends to be 0, the single-position welding length is not less than 100 mm, and the welding thickness is not less than 8 mm.

3. The method of claim 1, wherein: In the step S13, the flange and the cylinder segment ring seam and the first and second cylinder segment ring seams are only subjected to positioning welding treatment.

4. The method of claim 1, wherein: In the step S41, the thickness T of the top flange is 52 mm, the internal inclination is less than or equal to 0.5 mm, and the flatness is less than or equal to 0.5 mm.

5. The method of claim 1, wherein: In the step S42, the thickness T of the third connecting flange is 28 mm, the internal inclination is less than or equal to 1.5 mm, and the flatness is less than or equal to 1.5 mm.

6. The method of claim 1, wherein: In the step S43, the thickness T of the first and second connecting flanges is 39 / 32 mm, the internal inclination is less than or equal to 1.5 mm, and the flatness is less than or equal to 1.5 mm.

7. The method of claim 1, wherein: In the step S44, the thickness T of the bottom T-shaped flange is 58 mm, the internal inclination is less than or equal to 1.5 mm, and the flatness is less than or equal to 1.5 mm.

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