Technological construction method for building ultra-large single pile

Abstract

The invention relates to the technical field of offshore wind power single pile manufacturing methods, in particular to an ultra-large type single pile construction process method which comprises the following steps: (a) plate blanking; (b) splicing the jointed plates, hoisting the jointed plates to a feeding platform of a plate rolling machine by using a jointed plate horizontal hoisting scheme, turning over the jointed plates by using a jointed plate turning scheme, and splicing and welding the jointed plates before rolling; (c) prefabricating a single-section cylinder body; (d) segmental lengthening is carried out; (e) the whole pile is lengthened; (f) flange installation and machining; (g) sanding, paint spraying and waterline marking; according to the method, a new technological method is researched and designed from all procedures and all links, various difficulties in the ultra-large type single pile construction process are solved, streamlined production lines are achieved, and practicability is high; manufacturing and welding are completed step by step from single section to segmentation to integration, the manufacturing process is simple, the construction period can be effectively shortened, and the machining time is shortened.

Description

Technical Field

[0001] The present invention relates to the technical field of offshore wind power monopile manufacturing methods, and in particular to a process for constructing a super-large monopile. Background Art

[0002] With the trend of large-scale offshore wind turbines, the diameter and weight of monopile products are getting larger and larger, and the construction difficulty and requirements are getting higher and higher, and the requirements for equipment and plant areas are also getting higher and higher. The diameter of traditional offshore monopiles is usually ≤11m, the length of a single pile is about 100m, and the weight of a single pile is ≤2000T. In the future, the diameter and weight of offshore monopiles will be larger and larger. The diameter of super-large monopiles will reach 12m~15m, the length will be ≥110m, and the weight will be about ≥3500t. Limited by factors such as equipment capacity and workshop size, super-large monopiles are difficult to build and the processing period is long. To meet the requirements for super-large monopiles, it is necessary to study and design reasonable construction processes, processes and methods, and consider various aspects such as equipment processing capacity, size control, hoisting and transportation, and reasonable planning. For these aspects, a process and method for the construction of super-large monopiles is now provided. Summary of the invention

[0003] In order to solve the problems existing in the prior art, the present invention provides a process for constructing a super-large single pile, which is used to solve the problems of difficulty in constructing a super-large single pile and a long processing period.

[0004] To solve the above problems, the technical solution of the present invention is as follows: A process for constructing a super large single pile comprises the following steps:

[0005] (a) Cutting the sheets into required sizes using a CNC cutting machine to obtain panels;

[0006] (b) Panel splicing: Use the panel horizontal lifting solution to lift the panel to the feeding platform of the plate rolling machine, use the panel turning solution to turn the panel over, and weld each panel before rolling;

[0007] (c) Prefabrication of single-section cylinder. After the welding of each panel, longitudinal seam welding, rounding and circumferential seam beveling are performed to obtain a single-section cylinder;

[0008] (d) Segmented extension, splicing and welding adjacent cylinders to obtain segmented cylinders;

[0009] (e) Extend the entire pile and weld each segmented cylinder;

[0010] (f). Flange installation and machining;

[0011] (g) Sandblasting and painting, waterline marking, using transport tools and SPMT transport vehicles to transport single piles, and sandblasting and painting;

[0012] (h) Complete the work and ship out.

[0013] Furthermore, the panel lifting scheme in (b) includes two sets of lifting devices, and the lifting devices include two flappers, bolts, struts, and steel ropes.

[0014] Furthermore, the lifting method of the plan for horizontal lifting of the panels in (b) is to lay the panels flat, put on two flappers, tighten the flappers with bolts, connect the two flappers to the support rods through a steel wire rope, and hang the steel wire rope hooks on the ear holes at both ends of the flappers. The other group is operated in the same way, and the steel wire ropes of the two overhead cranes are passed through the support rod lifting points to synchronously lift the panels, and synchronously move and lift them to the feeding platform of the plate rolling machine.

[0015] Furthermore, the panel turning solution in (b) includes two sets of turning and lifting devices, and the turning and lifting devices include a panel flipper, bolts, struts, and steel wire ropes.

[0016] Furthermore, the lifting method of the panel turning solution in (b) includes:

[0017] Step 1: Lay the panels flat, put on two flappers, fasten the flappers with bolts, connect one end of the flapper to the support rod through a wire rope, and hang the wire rope hook on the ear hole at one end of the flapper. Repeat the same operation for the other set.

[0018] Step 2: Use the wire ropes of two cranes to pass through the support rod lifting points and slowly lift one end of the panel to ensure that the other end always touches the ground during the lifting process. After turning to 90°, the crane hook head continues to move forward to flip the panel to the opposite direction of > 90°, and slowly release the hook until the panel is completely flat, then open and remove the wire rope to complete the flip.

[0019] Furthermore, in step (g), the transport tooling includes section A and section B, and sections A and B are fixedly connected by bolts.

[0020] Furthermore, in step (g), when transporting a monopile, section A tooling is fixed on the SPMT transport vehicle. After entering the vehicle, section B tooling is inserted into the monopile and the bottom of the SPMT transport vehicle by a forklift, and after docking with section A, it is fixed with bolts. When unloading the vehicle, the bolts are loosened and section A and section B tooling are removed separately by a forklift.

[0021] Compared with the prior art, the present invention has the following beneficial effects: new processes and methods are studied and designed from each process and each link, various difficulties in the construction process of super-large single piles are solved, and the production line is streamlined, which is highly practical; from a single section to a segment and finally to the whole, the production and welding are completed step by step, the production process is simple, and it can effectively save construction period and shorten processing time. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of a single pile structure of the present invention;

[0023] Figure 2 It is the overall construction flow chart of the present invention;

[0024] Figure 3 It is a regional division diagram of the present invention;

[0025] Figure 4 Design a flow chart for the process of the present invention;

[0026] Figure 5 This is a schematic diagram of the horizontal hanging of the hoisting assembly of the present invention;

[0027] Figure 6 Schematic diagram of the present invention for hoisting and turning over the panel

[0028] Figure 7 It is a schematic diagram of the structure of the transport tooling of the present invention. DETAILED DESCRIPTION

[0029] like Figure 1 As shown, the total length of the super-large single pile is 119.1m, the weight is 3576t, the diameter is 8m to 12.5m, the wall thickness is 87mm to 148mm, and it is divided into 6 sections ((S1)\(S2)\(S3)\(S4)\(S5)\(S6)), a total of 32 cylinder sections) and 1 flange.

[0030] Construction process Figure 2 As shown:

[0031] (a) Cutting the sheets into required sizes using a CNC cutting machine to obtain panels;

[0032] (b) Panel splicing: Use the panel horizontal lifting solution to lift the panel to the feeding platform of the plate rolling machine, use the panel turning solution to turn the panel over, and weld each panel before rolling;

[0033] (c) Prefabrication of single-section cylinder. After the welding of each panel, longitudinal seam welding, rounding and circumferential seam beveling are performed to obtain a single-section cylinder;

[0034] (d) Segmented extension, splicing and welding adjacent cylinders to obtain segmented cylinders;

[0035] (e) Extend the entire pile and weld each segmented cylinder;

[0036] (f). Flange installation and machining;

[0037] (g) Sandblasting and painting, waterline marking, using transport tools and SPMT transport vehicles to transport single piles, and sandblasting and painting;

[0038] (h) Complete the work and ship out.

[0039] Construction area such as Figure 3 As shown, it can be steel plate stacking area, material unloading area, groove area, steel plate splicing area, pipe coiling area, longitudinal seam welding area, single-section cylinder storage area, segment assembly area, segment welding area, whole pile closure area, sandblasting workshop, and paint spraying workshop.

[0040] The area division diagram is divided based on the overall construction process and plant equipment and facilities. The steel plate storage area is for storing steel plate raw materials using vehicles and cranes. The unloading area is for hoisting steel plates to the work station using cranes, and then unloading the plates using CNC cutting machines; the steel plate splicing area is for hoisting steel plates to the paneling platform using cranes for steel plate pairing and then welding; the pipe rolling area is for hoisting the spliced ​​steel plates to the pipe rolling machine using cranes for rolling and subsequent rounding; the longitudinal seam welding area is for hoisting single-section cylinders to the roller racks using cranes, and welding is performed on the longitudinal seam welding platform using roller racks and welding machines; the single-section cylinder storage area is for inspection and storage of single-section cylinders after welding. The segment assembly area uses a crane to lift a single-section cylinder to the work station, and then uses a roller frame to assemble it, completing the segment ((S1)\(S2)\(S3)\(S4)\(S5)\(S6)) assembly process; the segment welding area uses a roller frame to rotate the segment welding platform after the segment is assembled, and performs circumferential welding on the circumferential welding platform; the whole pile closing area uses a crane to lift each segment to the final assembly roller frame for assembly, and performs circumferential welding on the circumferential welding platform. At the same time, when the segment (S5) (cone tube segment) is prefabricated, it is also assembled and welded in the whole pile closing area to solve the problem that the S5 segment pile body needs to be lifted; the sandblasting workshop uses SPMT to transport the whole pile to the sandblasting workshop roller frame, rotate the roller frame, and use a sandblasting gun to perform sandblasting operations; the paint shop uses the sandblasting roller frame to transport it to the paint shop, and then rotates the roller frame to use paint spraying equipment to perform paint spraying operations.

[0041] like Figure 4As shown, the process design flow and the equipment used in this process are as follows: 1. For plate cutting, CNC gas cutting machine and semi-automatic cutting machine can be used; 2. For plate splicing before rolling, plate turning device and submerged arc automatic welding machine can be used; 3. For single-section cylinder rolling, plate rolling machine and C-type sling can be used; 4. For longitudinal seam welding, roller frame, submerged arc automatic welding machine and longitudinal seam welding platform can be used; 5. For rounding, plate rolling machine and C-type sling can be used; 6. For circumferential seam beveling, roller frame and semi-automatic cutting machine can be used; 7. For segmented prefabrication, it can be divided into (S1)\(S2)\(S3)\(S4)\(S5)\(S6) segments, which can be made of paired walking roller frame, submerged arc automatic welding machine, Circumferential welding platform and circular heating torch; 8. Segmental extension, (S1) and (S2), (S3) and (S4), (S5) and (S6); 9. Overall extension, using roller rack, submerged arc automatic welding machine, circumferential welding platform and circular heating torch; 10. Flange installation, using roller rack, submerged arc automatic welding machine, circumferential welding platform and circular heating torch; 11. Flange machining, using roller rack, machining equipment and machining platform; 12. Sandblasting and painting, using explosion-proof roller rack, sandblasting equipment, paint spraying equipment, baking equipment and dust collector; 13. Waterline marking, using roller rack for secondary use; 14. Completion and elimination of items; 15. Shipping and shipment.

[0042] like Figure 5 As shown, in the plan for horizontal lifting of the panel, the horizontal lifting device includes two flappers, bolts, struts, and wire ropes, and the horizontal lifting method is: the panel 5 is placed horizontally, and four flappers are put on, and the flappers are fastened with bolts. The flappers 1 and 2 are connected to the strut 1 respectively through a wire rope, and the wire rope hooks are hung on the ear holes at both ends of the flappers. Similarly, the flappers 3 and 4 are connected to the strut 2 respectively through a wire rope, and the wire rope hooks are hung on the ear holes at both ends of the flappers. The wire ropes of two overhead cranes are passed through the strut lifting points, and the panel is lifted synchronously, and then moved and lifted to the feeding platform of the plate rolling machine synchronously.

[0043] like Figure 6 As shown, in the panel turning scheme, the turning device includes a panel flipper, bolts, struts, and wire ropes. The turning method includes: the panel is laid flat, 4 panel flippers are put on, the panel flippers are fastened with bolts, one end of the panel flipper is connected to the strut through a wire rope, the wire rope hook is hung on the ear hole at one end of the panel flipper, and the wire ropes of two cranes are passed through the strut lifting points to slowly lift one end of the panel, ensuring that the other end touches the ground during the lifting process, and after turning to 90° (the panel is vertical), the crane hook head continues to move forward to flip the steel plate in the opposite direction of >90°, and slowly release the hook until the panel is completely laid flat. Then open and disassemble the wire rope to complete the turning.

[0044] like Figure 7As shown, the transport tooling includes section A and section B. Sections A and B are connected by bolts. Section A is fixed on the SPMT transport vehicle. After entering the vehicle, section B is inserted into the monopile and the bottom of the SPMT transport vehicle by a forklift. After docking with section A, it is fixed with bolts. When unloading, the bolts are loosened and section A and section B are removed separately by a forklift.

[0045] The above specific implementation methods are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to examples, a person skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the scope of the technical solution of the present invention, which should be included in the scope of the claims of the present invention.

Claims

1. A process for constructing a super-large single pile, characterized by: The following steps are included: (a) Cutting the sheets into required sizes using a CNC cutting machine to obtain panels; (b) Panel splicing: Use the panel horizontal lifting solution to lift the panel to the feeding platform of the plate rolling machine, use the panel turning solution to turn the panel over, and weld each panel before rolling; (c) Prefabrication of single-section cylinder. After the welding of each panel, longitudinal seam welding, rounding and circumferential seam beveling are performed to obtain a single-section cylinder; (d) Segmented extension, splicing and welding adjacent cylinders to obtain segmented cylinders; (e) Extend the entire pile and weld each segmented cylinder together; (f). Flange installation and machining; (g) Sandblasting and painting, waterline marking, using transport tooling and SPMT transport vehicles to transport single piles, and sandblasting and painting; (h) Complete the work and ship out.

2. The process for constructing a super-large single pile according to claim 1, characterized in that: The panel horizontal lifting scheme in (b) includes two sets of horizontal lifting devices, and the horizontal lifting devices include two flappers, bolts, struts, and steel ropes.

3. The process for constructing a super-large single pile according to claim 2, characterized in that: The lifting method of the horizontal lifting scheme of the panel in (b) is to lay the panel flat, put on two flappers, and fasten the flappers with bolts. The two flappers are connected to the support rods respectively through a steel wire rope, and the steel wire rope hooks are hung on the ear holes at both ends of the flappers. The other group is operated in the same way, and the steel wire ropes of the two overhead cranes are passed through the lifting points of the support rods to simultaneously lift the panel, and simultaneously move and lift it to the feeding platform of the plate rolling machine.

4. The process for constructing a super-large single pile according to claim 3 is characterized by: The panel turning solution in (b) includes two sets of turning and lifting devices, and the turning and lifting devices include a panel turner, bolts, struts, and wire ropes.

5. The process for constructing a super-large single pile according to claim 4 is characterized in that: The lifting method of the panel turning solution in (b) includes: Step 1: Lay the panels flat, put on two flappers, fasten the flappers with bolts, connect one end of the flapper to the support rod through a wire rope, and hang the wire rope hook on the ear hole at one end of the flapper. Repeat the same operation for the other set. Step 2: Use the wire ropes of two cranes to pass through the support rod lifting points and slowly lift one end of the panel to ensure that the other end always touches the ground during the lifting process. After turning to 90°, the crane hook head continues to move forward to flip the panel to the opposite direction of > 90°, and slowly release the hook until the panel is completely flat, then open and remove the wire rope to complete the flip.

6. The process for constructing a super-large monopile according to claim 5, characterized in that: In step (g), the transport tooling includes section A and section B, and sections A and B are fixedly connected by bolts.

7. The process for constructing a super-large monopile according to claim 6, characterized in that: In step (g), when transporting a monopile, section A tooling is fixed on the SPMT transport vehicle. After entering the vehicle, section B tooling is inserted into the monopile and the bottom of the SPMT transport vehicle by a forklift, and after docking with section A, it is fixed with bolts. When unloading the vehicle, the bolts are loosened and section A and section B tooling are removed separately by a forklift.

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