A segmented construction process for a lattice leg of a jack-up wind turbine service platform

Abstract

The present application relates to the technical field of steel structure manufacturing in ocean engineering, in particular to a kind of self-elevating wind power operation platform truss type pile leg segmented construction process, comprising the following steps: one, main chord tube quality inspection;Two, support tube quality inspection;Three, support tube cutting;Four, main chord tube lengthening;Five, main chord tube and support tube single piece prefabrication;Six, pile leg segmented large group, by combining large equipment assembly, in the process of pile leg construction, in data form, strict control is carried out, the quality of raw material of pile leg is tracked and traced, and its process step is set with scientific and reasonable process parameters, effectively improve production efficiency and production quality, manual arc welding is used for the welding of semicircular plate and window plate, four welders can be used to symmetrically weld four butt joints during welding, after welding, weld flaw detection is carried out, size monitoring is carried out uninterruptedly during welding, to ensure that welding receives heat evenly, weld forming is beautiful, and the overall welding quality is guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of steel structure manufacturing in ocean engineering, in particular to a segmented construction process of a truss type pile leg of a self-elevating wind power operation platform. BACKGROUND

[0002] Ocean engineering refers to a new, reconstruction or expansion project whose main body is located on the sea side of the coastline for the purpose of developing, utilizing, protecting and restoring marine resources. Specifically, it includes reclamation, offshore dam engineering, artificial island, offshore and submarine material storage facilities, cross-sea bridge, submarine tunnel engineering, submarine pipeline, submarine electric (optical) cable engineering, marine mineral resource exploration and development and its auxiliary engineering, offshore tidal power station, wave power station, temperature difference power station and other marine energy development and utilization engineering, large-scale mariculture farm, artificial reef engineering, salt field, seawater desalination and other seawater comprehensive utilization engineering, offshore entertainment and sports, landscape development engineering.

[0003] A large number of pile legs are used in the structural arrangement of an offshore wind turbine installation ship. The large pile leg is an important guarantee for the stability of the offshore wind turbine installation ship. However, due to the large size of the pile leg, it can only be constructed in segments. The segments are then assembled. In the assembly process, the imperfect assembly process can easily cause the structural strength of the pile leg to be much smaller than the theoretical value, and affect the production efficiency. SUMMARY

[0004] The purpose of the present application is to solve the above problems of the prior art and provide a segmented construction process of a truss type pile leg of a self-elevating wind power operation platform. In the construction process of the pile leg, the quality of the raw materials of the pile leg is tracked and traced in the form of data, and the process steps are set with scientific and reasonable process parameters, thereby effectively improving the production efficiency and production quality.

[0005] In order to achieve the above purpose, the present application adopts the following technical scheme:

[0006] A segmented construction process of a truss type pile leg of a self-elevating wind power operation platform comprises the following steps:

[0007] I. Main chord pipe quality inspection: The main chord pipe surface is not allowed to have defects such as splashing and welding slag; in the welding process of the rack and semicircular plate and the welding process of the rack and rack, the same welding position is only allowed to have one unqualified welding, and the unqualified position must have corresponding marks and records; the number, inspection line and various marks on the main chord pipe should be clear and complete, so as to facilitate construction and material tracking; the main dimension, deflection, levelness, tooth spacing and weight of the main chord pipe are inspected, and the main chord pipe is coated after inspection.

[0008] II. Support tube quality inspection: The surface of the support tube is not allowed to have defects such as splashing and welding slag; the length and straightness of the support tube are inspected; the support tube is coated after passing the inspection;

[0009] III. Support tube cutting: The process flow of support tube cutting is divided into four stages of workshop primer, marking, cutting and inspection; the support tube cutting sequence is: tube end sample plate marking - key point punching - cutting machine test - cutting one end after no error - cutting the other end after inspection;

[0010] IV. Main chord tube lengthening:

[0011] a. Manufacture of special jig for main chord tube, when supporting the jig, the distance between the jig and the butt joint should be about 1 meter;

[0012] b. Positioning on the jig, the left and right and horizontal positioning should be performed with the center line of the thickness of the rack plate and the longitudinal center line, and the rack plate should be perpendicular to the tread, after the left and right and horizontal positioning, the main chord tube needs to be fixed to the jig on site with reinforcing materials;

[0013] c. Welding of rack plate, the welding method is manual arc welding, and special welding rods should be used, and the arc plate should be positioned before welding; two welders should be used to symmetrically weld, 2-3 passes of welding should be performed on one side of the weld by one welder, and after the back is polished, two welders should be used to symmetrically weld;

[0014] d. During the welding of the rack plate, size inspection should be performed at any time, mainly the straightness, levelness and pitch distance; the flatness and camber inspection method can be performed by combining laser theodolite and on-site steel wire drawing, the flatness inspection reference is the PITCH LINE line, and the camber inspection reference is the tooth top or PITCH LINE line;

[0015] e. After the welding of the rack plate is completed, the arc plate should be removed, the welding residue at both ends should be polished, and then the inspection should be performed;

[0016] f. The rack plate is perpendicular to the tread, manual arc welding is used for the welding of the semicircular plate and the window plate, four welders can be used to symmetrically weld the four butt joints during the welding, and then the weld inspection is performed after the welding;

[0017] g. In order to prevent cracks and reduce residual stress, preheating should be performed before welding, the preheating temperature is 150℃, the preheating range is 76mm around the weld, the preheating method can be performed by using electric heater, the interlayer temperature should be controlled during the welding, the interlayer temperature should not be lower than the preheating temperature and not exceed 250℃, and the cooling speed should be controlled after the welding, which should not exceed 50℃ per hour;

[0018] h. To facilitate dimensional inspection and segmented assembly, for all main chord tubes, the longitudinal center line, plate thickness center line, and outer PITCH LINE of the rack plate should be marked at the main chord tube splicing site. The longitudinal center line of the rack plate should be on the semicircular plate, and the plate thickness center line should be on the tooth tip, and a punch mark should be made.

[0019] i. After the main chord tubes are connected, the rack weld is cleaned and then the dimensions are inspected.

[0020] V. Prefabrication of Main Chord Pipes and Support Pipes: The main chord pipes and support pipes are prefabricated in single pieces on a special jig with a height of 1200mm. According to the welding shrinkage, a 2mm anti-deformation allowance needs to be left when aligning the support pipes. Before assembling the main chord pipes, the incoming materials need to be optimized to ensure that the tolerances of the three main chord pipes in each segment are as consistent as possible during single-piece assembly and after segment assembly, and to meet the tolerance requirements.

[0021] VI. Segmented Assembly of Pile Legs: The segmented assembly includes the welding of three prefabricated single pieces of main chord tubes and the welding of some loose support tubes. The process sequence of the segmented assembly is as follows: marking and inspecting the ground line—supporting the jig—positioning and inspecting the jig frame—installing the single piece of the horizontal main chord tube on the jig—installing the single piece of the right main chord tube on the jig—installing the single piece of the left main chord tube on the jig—installing the external support tube—installing the internal support tube—pre-welding dimensional inspection and pre-welding inspection report—welding.

[0022] As a preferred technical solution of the present invention, the scribing in step three needs to be done with a scribing needle, including the inner diameter line of the support pipe and the bevel line for cutting the bevel, and the center transverse inspection line and the end inspection line for checking the dimensions, and determining the inspection point and the cutting point. All inspection lines and key points need to be marked with a punch so that they can be used for alignment during the dimension inspection and assembly stages.

[0023] Compared with the prior art, the beneficial effects of the present invention are:

[0024] This invention combines large-scale equipment assembly with strict data-driven control during the pile leg construction process, enabling traceability of the quality of raw materials for the pile legs and setting scientific and reasonable process parameters for the process steps, thereby effectively improving production efficiency and quality.

[0025] Manual arc welding is used to weld the semi-circular plate and window panel. During welding, four welders can symmetrically weld the four butt joints. After welding, weld flaw detection is performed. Dimensions are continuously monitored during the welding process to ensure uniform heating, aesthetically pleasing weld formation, and overall welding quality. Detailed Implementation

[0026] The advantages and features of the present application will be more clearly understood from the following detailed description of the preferred embodiments of the present application, so as to make the scope of protection of the present application more clearly defined.

[0027] Embodiment

[0028] A segmental construction process of a truss type pile leg of a self-elevating wind power work platform, comprising the following steps:

[0029] I. Quality inspection of the main chord pipe: the surface of the main chord pipe is not allowed to have defects such as spatter and slag; in the welding processes of the rack and the half-round plate and the rack and the rack, only one welding failure is allowed at the same welding position, and the failure position must be marked and recorded accordingly; the number, the inspection line and various marks on the main chord pipe should be clear and complete, so as to facilitate the tracking of construction and materials; the main dimension, deflection, levelness, tooth spacing and weight of the main chord pipe are inspected, and the main chord pipe is painted after the inspection is passed; before sandblasting and painting, the marks and lines on the main chord pipe need to be effectively protected.

[0030] II. Quality inspection of the support pipe: the surface of the support pipe is not allowed to have defects such as spatter and slag; the length and straightness of the support pipe are spot-checked; the support pipe is painted after the inspection is passed.

[0031] III. Cutting of the support pipe: the process flow of the cutting of the support pipe is divided into four stages of workshop primer, line marking, cutting and inspection; in order to ensure the accuracy of the cutting of the support pipe, the line marking with the pipe end template and the test running of the cutting machine are combined during the cutting; the cutting sequence of the support pipe is: pipe end template line marking, key point punch marking, test running of the cutting machine, cutting of one end after no error, cutting of the other end after inspection.

[0032] The line marking in step III needs to be performed using a marking needle, including the support pipe inner diameter line and the bevel line for cutting bevel, the center transverse inspection line and the end inspection line for detecting the size, and the detection point and the cutting point are determined, and marks are punched on all the inspection lines and key points, so as to be used during the positioning in the size detection and assembly stages.

[0033] The length size inspection and the bevel shape inspection are performed after the cutting of the support pipe, the length size inspection is performed along the generatrix direction at 0 degree, 90 degree, 180 degree and 270 degree with the pipe inner skin as the reference, and the tolerance requirement is 0 to -2 mm.

[0034] IV. Lengthening of the main chord pipe:

[0035] a. A special jig for the main chord pipe is manufactured, and when the jig is supported, the distance between the jig and the butt joint should be about 1 meter;

[0036] b. Positioning on the tire, the left and right and horizontal positioning should be done with the center line of the plate thickness and the longitudinal center line of the rack plate, and the rack plate should be perpendicular to the tread. After the left and right and horizontal positioning, the main chord tube should be fixed to the tire stand with reinforcing materials on site;

[0037] c. Welding of the rack plate, the welding method is manual arc welding, and special electrodes should be used. The arc plate should be positioned before welding. Two welders should be used to weld symmetrically. First, one welder welds 2-3 passes on one side, and then two welders weld symmetrically after grinding the back;

[0038] d. During the welding of the rack plate, size inspection should be carried out at any time, mainly straightness, levelness and pitch; flatness and arch height inspection method can be combined with laser theodolite and on-site steel wire, the inspection reference of flatness is PITCH LINE line, and the inspection reference of arch height is tooth top or PITCH LINE line;

[0039] e. After the welding of the rack plate, the arc plate should be removed, the weld at both ends should be ground, and then it should be inspected;

[0040] f. The rack plate is perpendicular to the tread, and manual arc welding is used for the welding of the semicircular plate and the window plate. Four welders can be used to weld symmetrically on four butt joints. Welding is followed by weld inspection;

[0041] g. In order to prevent cracks and reduce residual stress, preheating should be carried out before welding, the preheating temperature is 150℃, the preheating range is 76mm around the weld, the preheating method can be carried out by electric heater, the interlayer temperature should be controlled during welding, the interlayer temperature should not be lower than the preheating temperature and not exceed 250℃, and the cooling speed should be controlled after welding, not more than 50℃ per hour;

[0042] h. In order to facilitate size detection and segmented assembly, the longitudinal center line of the rack plate, the center line of the plate thickness and the PITCH LINE line outside the rack plate should be marked on all main chord tubes in the main chord tube lengthening field. The longitudinal center line of the rack plate should be marked on the semicircular plate, and the center line of the plate thickness should be marked on the tooth top, and the Chinese character mark should be marked;

[0043] i. After the butt joint of the main chord tube, the rack weld is cleaned, and then size inspection is carried out;

[0044] Five, single piece prefabrication of main chord tube and support tube: the main chord tube and the support tube are single piece prefabricated on the special tire stand, the height of the tire stand is 1200mm; according to the welding shrinkage, 2mm of reverse deformation should be left when the support tube is aligned; before the assembly of the main chord tube, the incoming materials should be optimized to ensure that the tolerances of the three main chord tubes of each segment after single piece assembly and segmented assembly are as consistent as possible and meet the tolerance requirements;

[0045] The single-piece prefabrication process size detection is divided into several stages, such as ground sample line size inspection, cradle size inspection, assembly positioning (before welding) size inspection, welding process size inspection, and post-welding size inspection, and the precision requirements are as follows:

[0046]

[0047] Six, segmented large group of legs: segmented large group assembly includes the welding of three main chord pipe prefabricated single-piece and the welding of part of the scattered supporting pipe. The process sequence of the segmented large group is as follows: ground sample line marking and inspection - supporting cradle - cradle positioning and inspection - horizontal main chord pipe single-piece cradle - right side main chord pipe single-piece cradle - left side main chord pipe single-piece cradle - external supporting pipe installation - internal supporting pipe installation - pre-welding size inspection and pre-welding inspection - welding.

[0048] It should be noted that when marking the ground sample line, the center line of the main chord pipe, the center line of the cradle, and the position line and alignment line of various components on the ground projection line need to be marked. At the same time, considering the welding shrinkage, the amount of reverse deformation needs to be considered when marking the ground sample line. The size of the reverse deformation must be measured by pre-assembled welding.

[0049] The segmented large group of legs needs to be performed on a special cradle. The cradle template needs to be processed and marked (including the width and thickness of the center line of the rack plate used for alignment, as well as the main chord pipe center horizontal line and vertical line used for template positioning) to meet the assembly needs.

[0050] Among them, the segmented ground sample line marking and cradle precision requirements are as follows:

[0051]

[0052]

[0053] Among them, the welding requirements are as follows:

[0054] a. Welding sequence: first weld the welds of the supporting inclined pipe and the main chord pipe, and then weld the segmented scattered pipe and the internal supporting pipe.

[0055] b. Size detection should be performed at any time during the welding process. If a size deviation is found, it should be corrected at any time. When a size deviation is found, one end can be corrected using a sling or a pull rod, and at the same time, the reverse welding method can be used for adjustment.

[0056] c. To prevent cracks and reduce residual stress, preheating is required before re-welding. The preheating temperature is 150°C, the preheating range is 76mm around the weld, and the preheating method can be performed using an electric heater. The interlayer temperature should be controlled during welding to ensure that the interlayer temperature is not lower than the preheating temperature and not higher than 250°C. After welding, the cooling speed should be controlled to not exceed 50°C per hour.

[0057] After the sectional welding construction is completed, 100% nondestructive detection of the weld is required, the detection should be carried out 72 hours after the welding construction is completed and cooled to normal temperature, and a detection report is provided.

[0058] The present application effectively improves production efficiency and production quality by combining large equipment assembly, strictly controlling in data form during the construction of the pile leg, tracking the quality of the pile leg raw materials, and setting scientific and reasonable process parameters for the process steps.

[0059] Manual electric arc welding is used for welding of the semicircular plate and the window plate, four welders can be used to symmetrically weld four butt seams, weld detection is carried out after welding, size monitoring is continuously carried out during welding, uniform heat absorption of the weld is ensured, the weld is formed to be beautiful, and the overall welding quality is ensured.

[0060] The above-described embodiments only express several embodiments of the present application, and the description is relatively specific and detailed, but it should not be understood as a limitation on the scope of the patent. It should be pointed out that for ordinary skilled persons in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which are all within the protection scope of the present application.

Claims

1. A segmented construction process for truss-type pile legs of a self-elevating wind power operation platform, characterized in that: Includes the following steps: I. Quality Inspection of Main Chord Pipe: The surface of the main chord pipe must not have spatter or weld slag defects; during the welding of the rack and semi-circular plate and the welding of the rack and pinion, only one welding failure is allowed at the same welding position, and the failure must be marked and recorded accordingly; the numbering, inspection lines and various markings on the main chord pipe should be clear and complete to facilitate construction and material tracking. The main dimensions, deflection, levelness, tooth spacing, and weight of the main chord tube are inspected. If the inspection is qualified, the main chord tube is painted. II. Quality Inspection of Support Pipes: The surface of the support pipes must be free of spatter and welding slag defects; the length and straightness of the support pipes shall be randomly checked; the support pipes that pass the inspection shall be coated. III. Support tube cutting: The process of support tube cutting is divided into four stages: workshop primer - marking - cutting - inspection; the cutting sequence of support tube is: marking the end template - marking key points - test running the cutting machine - cutting one end after confirming that there are no errors - cutting the other end after inspection. IV. Main chord extension: a. When manufacturing a special jig for the main chord tube, the distance between the jig and the joint should be about 1 meter. b. Tire positioning should be performed on the left and right sides and horizontally using the center line of the toothed plate thickness and the longitudinal center line. The toothed plate should be perpendicular to the tire surface. After the left and right and horizontal positioning is completed, the main chord tube needs to be fixed to the tire frame on site with reinforcement. c. Welding of the rack plate: The welding method is manual arc welding vertical welding. Special welding rods must be used. Before welding, the arc-starting plate should be positioned first. During welding, two welders should weld symmetrically. First, one welder should weld 2-3 times on one side of the weld. After grinding the back side, the two welders should weld symmetrically. d. During the welding process of the rack plate, dimensional inspections should be carried out at any time, including straightness, levelness and tooth pitch; the flatness and camber height inspection methods are carried out by combining laser theodolite and on-site steel wire pulling. The inspection benchmark for flatness is the PITCH LINE line, and the inspection benchmark for camber height is the tooth tip or PITCH LINE line. e. After the rack plate is welded, the arc-starting plate should be removed, the weld at both ends should be ground, and then it should be handed over for inspection. f. The rack plate is perpendicular to the tire tread. The semi-circular plate and window plate are welded by manual arc welding. Four welders are used to weld the four butt joints symmetrically. After welding, the weld is inspected. g. To prevent cracks and reduce residual stress, preheating should be performed before welding. The preheating temperature is 150℃ and the preheating range is 76mm around the weld. The preheating method is to use an electric heater. During welding, the interpass temperature should be controlled so that the interpass temperature is not lower than the preheating temperature and does not exceed 250℃. After welding, the cooling rate should be controlled so that it does not exceed 50℃ per hour. h. To facilitate dimensional inspection and segmented assembly, for all main chord tubes, the longitudinal center line, plate thickness center line, and outer PITCH LINE of the rack plate should be marked at the main chord tube splicing site. The longitudinal center line of the rack plate should be on the semicircular plate, and the plate thickness center line should be on the tooth tip, and a punch mark should be made. i. After the main chord tubes are connected, the rack weld is cleaned and then the dimensions are inspected. V. Prefabrication of main chord tubes and support tubes: The main chord tubes and support tubes are prefabricated in single pieces on a special jig with a height of 1200mm. Based on the welding shrinkage, a 2mm anti-deformation allowance needs to be left when aligning the support pipe; Before assembling the main chord tubes, the incoming materials need to be optimized to ensure that the tolerances of the three main chord tubes in each segment are as consistent as possible in both single-piece assembly and segment assembly, and to meet the tolerance requirements. VI. Segmented Assembly of Pile Legs: The segmented assembly includes the welding of three prefabricated single pieces of main chord tubes and the welding of some loose support tubes. The process sequence of the segmented assembly is as follows: marking and inspecting the ground line—supporting the jig—positioning and inspecting the jig frame—installing the single piece of the horizontal main chord tube on the jig—installing the single piece of the right main chord tube on the jig—installing the single piece of the left main chord tube on the jig—installing the external support tube—installing the internal support tube—pre-welding dimensional inspection and pre-welding inspection report—welding.

2. The segmented construction process of the truss-type pile legs for a self-elevating wind power operation platform according to claim 1, characterized in that: The scribing in step three requires the use of a scribing needle, including the inner diameter line of the support tube for cutting the bevel and the bevel line, as well as the center transverse inspection line and end inspection line for checking dimensions. The inspection points and cutting points are also determined. All inspection lines and key points need to be marked with a punch for use during the dimension inspection and assembly stages.

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