All-welded large-diameter sea binding flange

Abstract

The invention discloses a large-diameter sea binding flange in an all-welded mode, and belongs to the field of new energy offshore wind power manufacturing. A large-diameter Haibang flange is mainly composed of six arc-shaped plates and is achieved in a welding mode. In the welding process, fixing is conducted through the portal and the inclined iron, and deformation in the welding process is prevented; designing a splicing seam groove into a 1 / 3-2 / 3 form, and firstly welding a large groove side; an even number of welders are adopted for welding symmetrically; and after welding, the weld reinforcement is polished in a polishing manner to be flush with the surface of the steel plate. By adopting the manufacturing scheme, the cost is saved, the efficiency is high, and the environment is protected; the process is simple and the production period is short; on the premise that customer requirements are met, forging is changed into welding manufacturing, efficiency is high, and quality is good.

Description

Technical Field

[0001] The invention relates to the technical field of offshore wind power generation pipe pile manufacturing, in particular to a large-diameter sea-bound flange in a fully welded manner. Background Art

[0002] At present, offshore wind power is developing rapidly, the megawatt is getting bigger and bigger, and the size and weight of towers and monopiles are getting bigger and bigger. As an important component connecting towers and monopiles, the transition section is particularly important. The sea-bound flange is an important component in the transition section, which plays an important role in connection and rigid fixed support, so it puts forward higher requirements on the production, quality and transportation of the flange.

[0003] In the transition section project, the material of the sea-bound flange is EN 10025-3S355NL, with a size of more than φ8000mm and a thickness of more than 120mm. If forgings are used, such a large size will be very difficult to make and transport, and the cost is quite high. Therefore, under the requirements of customer drawings and specifications, it is necessary to develop a welded sea-bound flange, which uses steel plates for splicing to make sea-bound flanges, which can save a lot of cost and efficiency. Summary of the invention

[0004] In order to overcome the shortcomings of the existing process technology, the present invention provides a large-diameter sea-bound flange in a fully welded manner. Through a reasonable manufacturing process, a large-diameter and large-thickness welded sea-bound flange can be realized, which saves costs, improves production efficiency, reduces labor intensity, and improves welding quality.

[0005] The technical solution adopted by the present invention to solve its technical problem is:

[0006] A large-diameter sea-bound flange with full welding method comprises: manufacturing the large-diameter sea-bound flange according to the following steps: A. preparation of a tire frame and tooling; B. marking of the tire frame; C. assembly of panels; D. welding; E. hoisting; F. grinding and sandblasting; G. flaw detection; and H. painting for corrosion protection.

[0007] Further preparation of the tire frame and tooling includes: a. designing and manufacturing corresponding tire frames and tooling according to the structural characteristics of the large-diameter sea-bound flange; b. placing the tire frame and tooling on a flat ground, checking their levelness, and ensuring that the tire frame and tooling are stably and firmly set on the ground.

[0008] The further marking of the tire frame includes: c. marking on the tire frame for positioning the arc plate for welding the sea-bound flange as a reference line for the sea-bound flange assembly.

[0009] The further described paneling includes: d. Assembling the sea-binding flange in sequence according to the drawn paneling reference line, and positioning the paneling seam at the node position of the tire frame tooling; e. Fixing the paneling seam position with a triangular plate to prevent dimensional deviation caused by welding shrinkage; f. Installing the gantry tooling in the middle position of the flange part, and using it in conjunction with a wedge and square steel bar; requiring a 10±0.01mm steel plate to be placed between the wedge and the sea-binding flange to prevent the wedge from damaging the surface of the sea-binding flange.

[0010] Further welding includes: g. Flat welding position, 4 or 6 welders symmetrically weld, each welder is responsible for the welding of two adjacent welds; h. The minimum preheating temperature during welding is 73°C, and the maximum interlayer temperature is 200°C. The temperature during welding must not be lower than the minimum preheating temperature, and it is also prohibited to be higher than the maximum interlayer temperature; i. The welding process is strictly in accordance with the WPS parameter requirements, and it is prohibited to use welding parameters that exceed the WPS; j. First weld the large groove side until the welding filling cover is completed. The welding groove angle is 45° / 50°, and the groove depth is 2 / 3~1 / 3; k. Turn over the flange, and clean the small groove on the back with air planing. The groove depth after cleaning is 50mm; l. Weld the small groove side until the welding is filled.

[0011] The further hoisting includes: m. After the welding on one side of the large groove is completed, the sea-binding flange is hoisted by a magnetic crane and raised with soft materials such as wood; n. Rubber protection is installed at the lifting point; o. Hoisting and turning operations are performed using a sling with a specification of 10 tons or more.

[0012] Furthermore, at least one side surface of the large-diameter sea-bound flange is composed of more than two plates.

[0013] Furthermore, the two side surfaces of the large-diameter sea-bound flange are composed of three plates.

[0014] Furthermore, each plate is in a circular ring shape, the outer diameter of the large-diameter sea-binding flange is equal to the sum of the inner diameters of all the plates, and the inner diameter of the large-diameter sea-binding flange is equal to the outer diameter of any plate.

[0015] The beneficial effects of the present invention are as follows: adopting this production scheme saves costs, is highly efficient, and is green and environmentally friendly; the process is simple and the production cycle is short; on the premise of meeting customer requirements, the forging is changed to welding production, which is highly efficient and of excellent quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of a tire frame of the present invention;

[0017] Figure 2 This is a schematic diagram of the panel reference line of the present invention;

[0018] Figure 3 It is a node schematic diagram of the present invention;

[0019] Figure 4 This is the assembly diagram of the sea-bound flange of the present invention;

[0020] Figure 5 for Figure 4 Middle AA schematic diagram;

[0021] Figure 6 It is a schematic diagram of the portal frame tooling of the present invention;

[0022] Figure 7 for Figure 6 Side view;

[0023] Figure 8 This is a schematic diagram of the sea-bound flange hoisting of the present invention;

[0024] Fig. 9 It is a schematic diagram of welding of the present invention.

[0025] Among them: 1. Panel reference line; 2. Node; 3. Sea-binding flange; 4. Triangle plate; 5. Tire frame; 6. Square steel bar; 7. Wedge; 8. Steel pad protection flange; 9. Door frame tooling; 10. Pads; 11. Sling; 12. Rubber protection; 13. Large bevel; 14. Small bevel. DETAILED DESCRIPTION

[0026] It should be noted that in the description of the embodiments of the present application, the terms "front, rear", "left, right", "up, down", etc. indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present application. The terms "install", "connect", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be a connection between the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.

[0027] The present application is further described in detail below through drawings and examples.

[0028] Tire frame 5. Tooling preparation: First Figure 1 Make an H-shaped steel frame structure frame 5 by splicing the frame 5, and then use the plate thickness of 30mm and above to cut the door frame tooling 9 and wedge iron 7, use 50-60mm steel plates to cut and make square steel bars 6 that match the door frame tooling 9, use scraps to cut triangular plates 4 with a thickness of 15mm or more, arrange the frame 5 tooling on a hard and flat ground, and adjust the level to within ±3mm.

[0029] Marking of tire frame 5: With the center point of tire frame 5 as the center of the circle, use a drawing ruler to draw a circle with an inner diameter of Φ7590mm, and mark it on the I-beam panel as the reference line 1 for the sea-binding flange 3;

[0030] Paneling: Assemble the sea-binding flange 3 in sequence according to the paneling reference line 1. It is necessary to position the paneling seam at the node 2 of the tire frame 5, and fix it with a triangle plate 4 at the paneling seam position to prevent dimensional deviation caused by welding shrinkage. Install the door frame tooling 9 in the middle position of the flange part, and use it in conjunction with the wedge iron 7 and the square steel bar 6. It is required that a 10±0.01mm steel plate is placed between the wedge iron 7 and the sea-binding flange 3 to prevent the wedge iron 7 from damaging the surface of the sea-binding flange 3. A steel pad must be used between the wedge iron 7 and the flange. It is strictly forbidden to damage the flange due to the wedge iron 7.

[0031] Welding: Flat welding position, 6 welders perform symmetrical welding, each welder is responsible for welding two adjacent welds. The minimum preheating temperature during welding is 73℃, and the maximum interlayer temperature is 200℃. The temperature during welding must not be lower than the minimum preheating temperature, nor higher than the maximum interlayer temperature.

[0032] The welding process must be strictly in accordance with the WPS parameter requirements. It is prohibited to use welding parameters that exceed the WPS. First weld the large groove 13 side until the welding filling cover is completed. Turn the flange over, and gouge the small groove 14 on the back to clean the root. The groove depth after cleaning is 50mm. Weld the small groove 14 side until the welding is completed.

[0033] Lifting and turning over: After the welding of one side of the large groove 13 is completed, the sea-binding flange 3 is lifted by a magnetic crane and padded with soft materials such as wood. Rubber protection 12 is installed at the lifting point, and a lifting belt 11 of 10 tons or more is used for lifting and turning over.

[0034] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0035] Although the embodiments of the present application have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present application, and that the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A fully welded large diameter sea-bound flange, characterized in that: include: The large-diameter sea-bound flange (3) is manufactured according to the following steps: A. tire frame (5), tooling preparation; B. tire frame (5) marking; C. plate assembly; D. welding; E. hoisting.

2. The large-diameter sea-bound flange of the fully welded method according to claim 1 is characterized in that: Also includes: F. Grinding and sandblasting; G. NDT; H. Painting for corrosion protection.

3. The large-diameter sea-bound flange (3) of all-welded method according to claim 1 is characterized in that: The tire frame (5) and tooling preparation include: a. designing and manufacturing corresponding tire frame (5) and tooling according to the structural characteristics of the large-diameter sea-binding flange (3); b. placing the tire frame (5) and tooling on a flat ground, checking its levelness, and ensuring that the tire frame (5) and tooling are stably and firmly placed on the ground.

4. The large-diameter sea-bound flange of the all-welded method according to claim 1 is characterized in that: The marking of the tire frame (5) includes: c. marking a line on the tire frame (5) for positioning the arc plate for welding the sea-bound flange (3) as a reference line (1) for the sea-bound flange (3) assembly.

5. The large-diameter sea-bound flange of the all-welded method according to claim 1 is characterized in that: The panel assembly includes: d. assembling the sea-binding flange (3) in sequence according to the drawn panel assembly reference line (1), and positioning the panel assembly seam at the position of the tire frame (5) tooling node (2); e. fixing the panel assembly seam position with a triangle plate (4) to prevent dimensional deviation caused by welding shrinkage; f. installing the door frame tooling (9) in the middle position of the flange part, and using it in conjunction with the wedge iron (7) and the square steel bar (6); it is required that a 10±0.01mm steel plate is padded between the wedge iron (7) and the sea-binding flange (3) to prevent the wedge iron (7) from damaging the surface of the sea-binding flange (3).

6. The large-diameter sea-bound flange of the all-welded method according to claim 1 is characterized in that: The welding includes: g. Flat welding position, 4 or 6 welders symmetrically weld, each welder is responsible for the welding of two adjacent welds; h. The minimum preheating temperature during welding is 73°C, and the maximum interlayer temperature is 200°C. The temperature during welding shall not be lower than the minimum preheating temperature, and it is also forbidden to be higher than the maximum interlayer temperature; i. The welding process is strictly in accordance with the WPS parameter requirements, and it is forbidden to use welding parameters exceeding the WPS; j. First weld the side of the large groove (13) until the welding filling cover is completed. The welding groove angle is 45° / 50°, and the groove depth is 2 / 3 to 1 / 3; k. Turn over the flange, and clean the small groove (14) on the back with air planing. The groove depth after cleaning is 50mm; l. Weld the side of the small groove (14) until the welding is completed.

7. The large-diameter sea-bound flange of all-welded type according to claim 1 is characterized in that: The hoisting comprises: m. After the welding of one side of the large groove (13) is completed, the sea-binding flange (3) is hoisted by a magnetic jack and is raised by soft materials such as wood; n. A rubber protection (12) is installed at the hoisting point; o. A hoisting and turning operation is performed using a sling (11) of 10 tons or more.

8. The all-welded large-diameter sea-bound flange according to claim 1, characterized in that: At least one side surface of the large-diameter sea-binding flange (3) is composed of more than two plates.

9. The large-diameter sea-bound flange of all-welded type according to claim 8, characterized in that: The two side surfaces of the large-diameter sea-binding flange (3) are composed of three plates.

10. The all-welded large-diameter sea-bound flange according to claim 9, characterized in that: Each plate is in the shape of a ring, the outer diameter of the large-diameter sea-binding flange (3) is equal to the sum of the inner diameters of all the plates, and the inner diameter of the large-diameter sea-binding flange (3) is equal to the outer diameter of any plate.

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