A method for manufacturing an offshore wind power jacket

Abstract

The application relates to the component manufacturing field, in particular to a method for manufacturing an offshore wind power guide pipe rack, S1, erecting a total assembly jig frame at a total assembly site, then performing column and diagonal bracing pipe assembly on the total assembly jig frame by taking one side face as a reference; S2, hoisting the column and diagonal bracing pipes of the other three side faces on the total assembly jig frame respectively to perform folding; S3, performing column piece prefabrication, diagonal bracing piece prefabrication and top segment prefabrication on the total assembly jig frame; S4, folding the prefabricated column piece, diagonal bracing piece and top segment prefabrication jig on the guide pipe rack; S5, installing functional and protective components on the guide pipe rack; and S6, performing safety measurement on the assembled guide pipe rack. The offshore wind power guide pipe rack manufacturing method disclosed by the application takes one side face as a reference, and hoists the column and diagonal bracing pipes of the other three side faces respectively to perform folding, effectively shortens the prefabrication period, reduces the construction difficulty and cost, and guarantees the manufacturing precision.

Description

Technical Field

[0001] This invention relates to the field of component manufacturing, and more specifically, to a method for manufacturing offshore wind turbine jackets. Background Technology

[0002] The offshore wind power market has extremely promising prospects, so in recent years, my country's wind power companies have increasingly attached importance to the development of the offshore wind power industry.

[0003] The development of the offshore wind power industry is inseparable from the fabrication of offshore wind turbine jackets. Currently, the fabrication process of offshore wind turbine jackets involves large components that need to be installed and connected, which makes construction difficult and production costs high. It also makes it difficult to guarantee the manufacturing precision, resulting in long prefabrication cycles and affecting the construction progress.

[0004] Therefore, it is necessary to propose a method for manufacturing offshore wind turbine jackets to solve the above problems. Summary of the Invention

[0005] To overcome at least one of the defects (deficiencies) of the prior art, the present invention provides a method for manufacturing offshore wind turbine jackets.

[0006] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows: A method for manufacturing offshore wind turbine jackets, comprising the following steps:

[0007] S1. Erect the main assembly frame at the main assembly site, and then use one of its sides as a reference to assemble the columns and diagonal bracing tubes on the main assembly frame.

[0008] S2, hoist the other three side columns and diagonal bracing tubes onto the main assembly frame and assemble them;

[0009] S3, Prefabricate the column pieces, diagonal brace pieces and top sections on the main assembly frame;

[0010] S4, assemble the prefabricated column pieces, diagonal brace pieces and top segment prefabricated form onto the guide frame;

[0011] S5, Install functional and protective components on the jacket support;

[0012] S6, Perform safety measurements on the assembled guide frame;

[0013] Furthermore, step S1 includes the following steps:

[0014] S11. When assembling the columns and diagonal braces on the main assembly frame, add a 20mm allowance at the top of the column. The allowance will be trimmed on-site when the transition section structure at the top of the guide frame is installed.

[0015] S12, when assembling the diagonal bracing tube, if there is a large precision error at the intersection, the intersection should be trimmed according to the actual size of the allowance. If there is no precision error or the error is small and only local trimming is needed to meet the assembly requirements, the straight end of the thin tube should be trimmed according to the actual size of the allowance.

[0016] Furthermore, step S2 includes the following steps:

[0017] S21, process the columns on the other three sides in sections, and then connect the three sections with the reference column using round tubes.

[0018] S22, after the other three sides of the diagonal bracing tubes are processed, the diagonal bracing tubes are joined together.

[0019] Furthermore, step S3 includes the following steps:

[0020] S31, For the two uprights and the diagonal bracing tubes between the uprights on the main frame, the upright sheet body is prefabricated on the main frame of the guide frame.

[0021] S32, the inclined support tubes between the left and right side columns of the main frame are prefabricated on the special frame, and three inclined support pieces are prefabricated on each side.

[0022] S33, prefabricate the bottom plate of the top section.

[0023] Furthermore, step S4 includes the following steps:

[0024] S41, the upper, middle and lower three sections of the round pipe of each column are hoisted onto the main assembly frame for splicing;

[0025] S42. After the columns are spliced, use a total station to check the straightness and positioning accuracy of the columns. If there is any deviation, make adjustments. When the accuracy is qualified, install the diagonal bracing tubes that intersect with the columns between the two columns according to the ground line by using a plumb bob and string line.

[0026] S43, set up the work frame and erect temporary supports, and then hoist the two side diagonal bracing round tubes on the main assembly frame respectively. After the diagonal bracing round tubes are assembled, perform precision inspection. If there is any deviation, make adjustments. When the precision is qualified, weld the joint of the diagonal bracing round tubes and the fillet weld between the diagonal bracing round tubes and the column.

[0027] S44, Install the top segment prefabricated tire onto the main tire frame.

[0028] Furthermore, in step S5, the functional and protective components are installed as ladders and guardrails, or anti-collision components, or sacrificial anode protection components.

[0029] Furthermore, in step S6, the safety measurement of the assembled jacket includes precision measurement, weld inspection measurement, and flaw detection measurement of the assembled jacket.

[0030] Compared with the prior art, the beneficial effects of the technical solution of the present invention are:

[0031] The offshore wind turbine jacket fabrication method disclosed in this invention involves erecting a general assembly frame at the assembly site, then assembling the columns and diagonal bracing tubes on the general assembly frame using one side as a reference, and then hoisting the columns and diagonal bracing tubes on the other three sides onto the general assembly frame for assembly. By prefabricating the column sections, diagonal bracing sections, and top sections separately before assembling, the prefabrication cycle is shortened, the construction difficulty and cost are reduced, and the fabrication accuracy is guaranteed. Attached Figure Description

[0032] Figure 1 This is a flowchart of the offshore wind power jacket fabrication method in this invention.

[0033] Figure 2 This is a schematic diagram of the overall structure of the catheter frame in this invention.

[0034] Figure 3 This is a schematic diagram of the structure when the column tube is closed in this invention.

[0035] Figure 4 This is a schematic diagram of the structure when the inclined support tubes of this invention are joined together.

[0036] Figure 5 This is a schematic diagram of the structure during the prefabrication of the column sheet in this invention.

[0037] Figure 6 This is a structural diagram of the column prefabrication in the first step of the prefabrication process in this invention.

[0038] Figure 7 This is a structural schematic diagram of the column prefabrication in the second step of the present invention.

[0039] Figure 8 This is a structural schematic diagram of the column prefabrication in the third step of the present invention.

[0040] Figure 9 This is a schematic diagram of the structure of the diagonal bracing circular tube during the prefabrication process in this invention.

[0041] Figure 10 This is a schematic diagram of the structure when the base plate is installed in this invention.

[0042] Figure 11 This is a schematic diagram of the structure during the installation of the deck in this invention.

[0043] Figure 12This is a structural diagram of the main cylinder during installation in this invention.

[0044] In the diagram, 1 is the column, 2 is the diagonal bracing tube, 3 is the top section, 4 is the bottom plate, 5 is the deck, and 6 is the main cylinder. Detailed Implementation

[0045] The accompanying drawings are for illustrative purposes only and should not be construed as limiting the scope of this patent. To better illustrate this embodiment, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0046] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. The technical solution of this invention will be further described below with reference to the accompanying drawings and embodiments.

[0047] like Figure 1 As shown, a method for manufacturing offshore wind turbine jackets includes the following steps:

[0048] S1. Erect the main assembly frame at the main assembly site, and then use one of its sides as a reference to assemble the columns and diagonal bracing tubes on the main assembly frame.

[0049] S2, hoist the other three side columns and diagonal bracing tubes onto the main assembly frame and assemble them;

[0050] S3, Prefabricate the column pieces, diagonal brace pieces and top sections on the main assembly frame;

[0051] S4, assemble the prefabricated column pieces, diagonal brace pieces and top segment prefabricated form onto the guide frame;

[0052] S5, Install functional and protective components on the jacket support;

[0053] S6, Perform safety measurements on the assembled guide frame;

[0054] In this invention, step S1 includes the following steps:

[0055] S11. When assembling the columns and diagonal braces on the main assembly frame, add a 20mm allowance at the top of the column. The allowance will be trimmed on-site when the transition section structure at the top of the guide frame is installed.

[0056] S12, when assembling the diagonal bracing tube, if there is a large precision error at the intersection, the intersection should be trimmed according to the actual size of the allowance. If there is no precision error or the error is small and only local trimming is needed to meet the assembly requirements, the straight end of the thin tube should be trimmed according to the actual size of the allowance.

[0057] Step S2 includes the following steps:

[0058] S21, process the columns on the other three sides in sections, and then connect the three sections with the reference column using round tubes.

[0059] S22, after the other three sides of the diagonal bracing tubes are processed, the diagonal bracing tubes are joined together.

[0060] Step S3 includes the following steps:

[0061] S31, For the two uprights and the diagonal bracing tubes between the uprights on the main frame, the upright sheet body is prefabricated on the main frame of the guide frame.

[0062] S32, the inclined support tubes between the left and right side columns of the main frame are prefabricated on the special frame, and three inclined support pieces are prefabricated on each side.

[0063] S33, prefabricate the bottom plate of the top section.

[0064] Step S4 includes the following steps:

[0065] S41, the upper, middle and lower three sections of the round pipe of each column are hoisted onto the main assembly frame for splicing;

[0066] S42. After the columns are spliced, use a total station to check the straightness and positioning accuracy of the columns. If there is any deviation, make adjustments. When the accuracy is qualified, install the diagonal bracing tubes that intersect with the columns between the two columns according to the ground line by using a plumb bob and string line.

[0067] S43, set up the work frame and erect temporary supports, and then hoist the two side diagonal bracing round tubes on the main assembly frame respectively. After the diagonal bracing round tubes are assembled, perform precision inspection. If there is any deviation, make adjustments. When the precision is qualified, weld the joint of the diagonal bracing round tubes and the fillet weld between the diagonal bracing round tubes and the column.

[0068] S44, Install the top segment prefabricated tire onto the main tire frame.

[0069] In step S5 of the present invention, the functional and protective components are installed as ladders and guardrails or anti-collision components or sacrificial anode protection components. In step S6, the safety measurement of the assembled jacket includes the accuracy measurement, weld inspection measurement and flaw detection measurement of the assembled jacket.

[0070] Example

[0071] like Figure 2 As shown, in this embodiment, the jacket is constructed on the side of the main assembly frame. During construction, the main assembly frame is first erected at the main assembly site. Then, using one side as a reference, the column 1 is erected on the main assembly frame, and the diagonal bracing tube 2 is assembled. Then, the columns and diagonal bracing tubes on the other three sides are hoisted onto the main assembly frame and joined together. Finally, the top section 3 is installed to form a complete jacket steel structure.

[0072] like Figure 3 As shown, the main construction instructions for the cutting and processing of the inclined support round tube are as follows: First, when cutting the inclined support round tube and cutting the intersection, considering that there will be certain precision errors in the cutting and assembly of the intersection line at the tube end, an allowance can be added to the intersection end of the inclined support round tube (Note: the allowance at the intersection end must be retained when the intersection is cut for the first time). The principle for trimming the allowance is as follows: If there is a large precision error at the intersection when the inclined support round tube is assembled, the intersection is trimmed according to the actual size of the allowance. If there is no precision error or the error is small and only local trimming is needed to meet the assembly requirements when the inclined support round tube is assembled, the straight end of the thin tube is trimmed according to the actual size of the allowance. The straight end of the thin tube does not need to be cut in the thickness difference transition between the inner and outer plates, and the trimming amount is relatively small. When the round tube of column 1 is cut, a 20mm allowance is added to the top of the column. The allowance is reserved for on-site trimming when the transition section structure at the top of the guide frame is installed.

[0073] like Figure 4-5 As shown, when the round tubes of the upright and the diagonal bracing are joined together, after the round tubes of the upright are processed, they will be joined in three sections, while the round tubes of the diagonal bracing will be joined in one section.

[0074] like Figure 6-9As shown, during the prefabrication of the column segments, the two columns on the jig surface and the diagonal braces between the columns are prefabricated on the overall jig of the guide frame. A total of two column segments are prefabricated. The first step in the prefabrication process is to hoist the upper, middle, and lower three sections of the circular pipe for each column onto the overall jig for splicing. During column splicing, a total station is used to mark the center lines of the guide frame, the columns, the column closure joints, the column ends, and the diagonal braces on the jig and the ground. A plumb line is required during column splicing to align with the ground line, and a plumb line is used... The first step is to use a total station to perform accuracy checks to ensure the accuracy requirements of the column splicing. The second step is to use a total station to check the straightness and positioning accuracy of the columns after the columns are spliced. If there is any deviation, adjustments are made. Once the accuracy is qualified, install the diagonal bracing between the two columns according to the ground line using a plumb bob and string line. The third step is to install other diagonal bracing between the two columns. The fourth step is to perform accuracy checks after the column panels are assembled. If there is any deviation, adjustments are made. Once the accuracy is qualified, weld the joints of the diagonal bracing and the fillet weld between the diagonal bracing and the column.

[0075] like Figure 10-12 As shown, the inclined support tubes between the left and right side columns of the guide frame are prefabricated on a special jig. The main tube at the intersection of the inclined support tubes uses a temporary tool tube with a plate thickness ≥14mm. Three inclined support tubes are prefabricated on each side.

[0076] During the prefabrication of the top section, the bottom plate 4, the deck 5, and the main cylinder 6 of the top section are prefabricated in sections first, and then the jacket frame is assembled. The assembly steps of the jacket frame are as follows: First step: The two columns on the jig surface and the diagonal bracing tubes between the columns are all welded. Second step: The work frame is erected and temporary supports are set up. Then, the diagonal bracing tube sections on the two sides are hoisted on the main jig. Third step: The upper column sections and the diagonal bracing sections between the columns are hoisted. Fourth step: The top section is installed. The installation sequence of the top section is as follows: First, the bottom plate sections are installed. Then, the deck sections are installed and the four reinforcing elbow plates under the main cylinder are installed. After the reinforcing elbow plates are installed, the main cylinder sections are installed and the platform plates are installed. Fifth step: Ladders, guardrails, anti-collision components, sacrificial anode protection components, etc. are installed. Finally, sixth step: After the jacket frame is completed, precision measurement, weld inspection and flaw detection are carried out.

[0077] The positional relationships described in the figures are for illustrative purposes only and should not be construed as limiting this patent. Clearly, the above embodiments of the present invention are merely examples to clearly illustrate the invention and are not intended to limit the implementation of the invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of this invention.

Claims

1. A method for manufacturing offshore wind turbine jackets, characterized in that: Includes the following steps: S1. Erect the main assembly frame at the main assembly site, and then use one of its sides as a reference to assemble the columns and diagonal bracing tubes on the main assembly frame. S2, hoist the other three side columns and diagonal bracing tubes onto the main assembly frame and assemble them; S3, Prefabricate the column pieces, diagonal brace pieces and top sections on the main assembly frame; S4, assemble the prefabricated column pieces, diagonal brace pieces and top segment prefabricated form onto the guide frame; S5, Install functional and protective components on the jacket support; S6, Perform safety measurements on the assembled guide frame; Step S1 includes the following steps: S11. When assembling the columns and diagonal braces on the main assembly frame, add a 20mm allowance at the top of the column. The allowance will be trimmed on-site when the transition section structure at the top of the guide frame is installed. S12. When assembling the diagonal bracing tube, if there is a large precision error at the intersection, the intersection should be trimmed according to the actual size of the allowance. If there is no precision error or the error is small and only local trimming is needed to meet the assembly requirements, the straight end of the thin tube should be trimmed according to the actual size of the allowance. Step S2 includes the following steps: S21, process the columns on the other three sides in sections, and then connect the three sections with the reference column using round tubes. S22, After the other three sides of the diagonal bracing tubes are processed, the diagonal bracing tubes are joined together; Step S3 includes the following steps: S31, For the two uprights and the diagonal bracing tubes between the uprights on the main frame, the upright sheet body is prefabricated on the main frame of the guide frame. S32, the inclined support tubes between the left and right side columns of the main frame are prefabricated on the special frame, and three inclined support pieces are prefabricated on each side. S33, prefabricate the bottom plate of the top section; Step S4 includes the following steps: S41, the upper, middle and lower three sections of the round pipe of each column are hoisted onto the main assembly frame for splicing; S42. After the columns are spliced, use a total station to check the straightness and positioning accuracy of the columns. If there is any deviation, make adjustments. When the accuracy is qualified, install the diagonal bracing tubes that intersect with the columns between the two columns according to the ground line by using a plumb bob and string line. S43, set up the work frame and erect temporary supports, and then hoist the two side diagonal bracing round tubes on the main assembly frame respectively. After the diagonal bracing round tubes are assembled, perform precision inspection. If there is any deviation, make adjustments. When the precision is qualified, weld the joint of the diagonal bracing round tubes and the fillet weld between the diagonal bracing round tubes and the column. S44, Install the top segment prefabricated tire onto the main tire frame.

2. The method for manufacturing offshore wind turbine jackets according to claim 1, characterized in that: In step S5, the functional and protective components are installed as ladders and guardrails, or anti-collision components, or sacrificial anode protection components.

3. The method for manufacturing offshore wind turbine jackets according to claim 1, characterized in that: In step S6, the safety measurement of the assembled jacket includes the accuracy measurement, weld inspection measurement, and flaw detection measurement of the assembled jacket.

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