Technological method for controlling coating of intersecting line opening of wind power jacket

Abstract

The invention discloses a process method for controlling coating of an intersecting line opening of a wind power jacket, and provides a new solution aiming at the problems of more occupied field resources, high construction cost, long construction period and the like of a traditional coating process of a lower section truss structure of an existing jacket. The process method comprises the following steps: rolling and assembling pipe segments into pipe joints, independently manufacturing accessory structures into small assemblies, assembling and segmenting the pipe joints, assembling the accessory small-group structures, and performing technical lofting and positioning line delimiting on positions and sizes of intersecting line closure openings of total segmented groups; a thin steel plate with the thickness smaller than 1 mm is adopted for cutting and coating a protection piece, surface mounting and spot welding fixing are conducted according to positioning scribing, the surface-mounted pipe joints are transferred to a sand room and a coating shed for construction after being arranged and put into a support, and the protection piece is detached and recycled after coating is conducted for reutilization. The method has the advantages of reducing site equipment requirements, reducing cost, improving construction efficiency, shortening the construction period and the like, and the economic benefits of jacket coating operation can be effectively improved.

Description

Technical Field

[0001] The invention relates to the technical field of offshore wind power conduit coating, in particular to a process method for controlling the coating of intersecting line openings of wind power conduit. Background Art

[0002] As an important part of clean energy, offshore wind power is of vital importance in the construction of its jacket foundation structure. The jacket foundation is mainly composed of an upper box-type transition section structure and a lower truss structure, of which the lower truss structure is characterized by being super wide, super heavy, and super high. In the actual construction process, the lower truss structure is usually divided into a sheet body, a sheet fork, and a single-leg segment, which are composed of pipe segments and their accessories installed on the pipe segments.

[0003] At present, the traditional painting process of the lower truss structure of the conductor frame is to transport the entire segment as a whole to the sand room and painting shed for sandblasting and painting after the sheet body, sheet fork and single leg segment are made. Although this traditional process can improve the coverage rate of one-time painting to a certain extent, it has many disadvantages. On the one hand, due to the large size of truss-type segmented structures such as sheet bodies and sheet forks, a large amount of space resources will be occupied when spraying the whole structure, which not only puts extremely high requirements on the space scale of the sand room and painting shed, but also leads to a significant increase in the transportation cost in and out of the sand room and painting shed. On the other hand, the huge segmented structure is also extremely demanding on the carrying capacity of the transfer equipment and the width and flatness of the walking channel. It is necessary to equip large and professional transfer equipment and build high-standard walking channels, which further increases the construction cost and difficulty. In addition, more importantly, before the segment is hoisted into the total assembly, the paint at the welding position of the closing line must be polished off. This process not only consumes a lot of manpower and time, but also causes a waste of paint materials, seriously affecting the construction period and cost control, and greatly reducing the economic benefits and construction efficiency of the conductor frame painting operation.

[0004] In summary, the traditional coating process of the existing lower truss structure of the conductor frame has obvious deficiencies in site resource utilization, construction cost control and construction period. A more efficient and economical coating process method is urgently needed to solve these problems, so as to meet the actual needs of offshore wind power conductor frame coating construction and promote the sustainable development of the offshore wind power industry. Summary of the invention

[0005] The purpose of the present invention is to provide a process method for controlling the coating of the intersection of wind turbine conduit frames, so as to overcome the defects of the existing traditional coating process of the lower truss structure of the conduit frame, such as occupying a lot of site resources, high construction cost, and long construction period, thereby improving the economic benefits and construction efficiency of the conduit frame coating operation and promoting the efficient development of the offshore wind power industry.

[0006] In order to achieve the above object, the present invention is implemented through the following technical solution: a process method for controlling the coating of the intersection of wind power conduit frames, comprising the following steps:

[0007] Step S1, rolling and assembling the tube segments consisting of the sheet body, the sheet fork and the single-leg segment to form a tube segment;

[0008] Step S2, the accessory structure is separately made into a component;

[0009] Step S3, assembling the pipe segments to form the intersection line of the segments, and then technically setting out the position and size of the closing mouth, and drawing positioning lines on the outer surface of the pipe segments;

[0010] Step S4, assembling the accessory structural components to the closing position and size of the pipe segment for technical lofting, and drawing positioning lines on the outer surface of the pipe segment;

[0011] Step S5, technically lofting the closing position and size of the segment assembly, and drawing positioning lines on the outer surface of the pipe segment;

[0012] Step S6, cutting a thin steel plate with a thickness of less than 1 mm as a coating protection part according to the layout size, attaching it to the pipe section according to the positioning markings of the pipe section intersection and fixing it with spot welding;

[0013] Step S7, after the pipe sections with intersecting line mouths are installed and protected, they are arranged into groups and put into trays, and then transported to the sanding room and coating shed for sandblasting and coating construction;

[0014] Step S8: After the pipe segments are finished being painted and taken out of the shed, the thin steel plate paint protection parts are disassembled and recycled, and reused in the paint protection process for the next batch of pipe segments.

[0015] As a further improvement of the technical solution of the present invention, the coating protection part needs to cover the intersection by more than 100 mm, and the positioning installation is based on the distance from the pipe segment annular seam and longitudinal seam as the positioning reference.

[0016] As a further improvement of the technical solution of the present invention, only the closing mouth with an unfolded length of the intersecting line exceeding 1m needs to be coated with a protective piece.

[0017] As a further improvement of the technical solution of the present invention, the coating protection part is made of a steel plate with a thickness of less than 1 mm.

[0018] The present invention has the following beneficial effects:

[0019] (I) Improve the utilization rate of site equipment resources

[0020] The present invention optimizes the traditional way of bringing the whole section of the conductor frame into the sandblasting and painting room into a single pipe section and a single accessory group structure. This method greatly reduces the demand for sandblasting and spraying workshop space for painting operations, reduces the carrying capacity of transfer equipment and the specification requirements of walking channels, enables site equipment resources to be more efficiently applied to the construction process of the conductor frame, significantly improves the applicability of factory site and equipment resources to the construction of conductor frame products, and thus enhances the factory's ability and competitiveness in undertaking business.

[0021] 2. Reduce costs

[0022] The process method of the present invention effectively avoids repeated spraying and grinding of the pipe joint at the intersection position. On the one hand, it reduces the amount of paint materials used and the cost of paint materials; on the other hand, it saves the manpower, material and time costs required for repeated grinding processes, thereby achieving effective cost control and reduction from multiple aspects and improving the economic benefits of the project.

[0023] (III) Improving construction efficiency and shortening construction period

[0024] The present invention enables multiple pipe sections and multiple components to enter the workshop for sandblasting and spraying at the same time, which greatly improves the construction efficiency compared to the traditional process of entering the workshop in sections one by one. At the same time, due to the reduction of repeated processes and unnecessary waiting time, the project construction period is significantly shortened and the construction speed of the conductor rack is accelerated. In addition, the process also reduces the use of disposable tooling and scaffolding, further reduces construction costs, and improves the overall benefits of the project. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings:

[0026] Figure 1 It is a schematic diagram of the pipe segments forming the pipe segments in the present invention;

[0027] Figure 2 It is a schematic diagram of the structure of the accessories in the present invention;

[0028] Figure 3 It is a schematic diagram of the layout and marking of the closing opening of the pipe segment intersection line in the present invention;

[0029] Figure 4 It is a schematic diagram of the assembly layout and marking of the accessory group structure in the present invention;

[0030] Figure 5 It is a schematic diagram of the lofting and marking of the segmented assembly in the present invention;

[0031] Figure 6This is a schematic diagram of the installation of the coating protection member in the present invention;

[0032] Figure 7 It is a schematic diagram of the lower truss structure of the jacket in the present invention;

[0033] Figure 8 The present invention is a process framework diagram of a process method for controlling the coating of the intersection of wind power conduit frames. DETAILED DESCRIPTION

[0034] The present invention will be described in detail below in conjunction with the accompanying drawings and specific embodiments. The exemplary embodiments and descriptions of the present invention are used to explain the present invention, but are not intended to limit the present invention.

[0035] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, upper end, lower end, top, bottom...) are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0036] In the present invention, unless otherwise clearly defined and limited, the term "connection" should be understood in a broad sense, for example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0037] In addition, in the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features; in addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0038] The present invention is further described in detail below in conjunction with the accompanying drawings.

[0039] Reference Figure 8 The present invention provides a process method for controlling the coating of the intersection of wind power conduit frames, comprising the following steps:

[0040] (I) Pipe joint production

[0041] The pipe segments consisting of the sheet body, fork and single-leg segments are rolled using professional rolling equipment and processes, and then accurately assembled to form pipe segments that meet the design requirements, ensuring that all indicators such as dimensional accuracy, shape tolerance and surface quality of the pipe segments meet the standards of subsequent processes, laying a solid foundation for the entire coating process.

[0042] (II) Production of small accessories

[0043] According to the design drawings and technical requirements of the catheter rack, the accessory structure is made into small components through fine processing technology. During the production process, the dimensional accuracy, shape accuracy and surface flatness of the accessories are strictly controlled to ensure that the small components can be accurately matched and seamlessly connected with the pipe joints, providing a good component foundation for subsequent assembly and painting work.

[0044] (III) Lofting and marking of the joints of the pipe joints

[0045] With the help of high-precision measuring instruments and professional layout tools, the position and size of the intersection of the pipe segment assembly are accurately laid out. Then, a clear and non-falling marking tool is used to carefully mark the positioning line on the outer surface of the pipe segment to ensure the accuracy and clarity of the positioning line, providing a precise reference for the subsequent installation of the coating protection parts.

[0046] (IV) Assembly layout and marking of accessory group structure

[0047] High-precision layout and marking technology is also used to accurately layout the position and size of the closing mouth of the pipe section by assembling the accessory group structure, and draw clear and accurate positioning lines on the outer surface of the pipe section. This step must strictly ensure the accuracy of the relative position between the accessory and the pipe section to ensure that the two can cooperate in the subsequent assembly and painting process without affecting the stability of the overall structure and the quality of the painting.

[0048] (V) Segmental overall combination closing and marking

[0049] Advanced layout methods and tools are used to carry out meticulous technical layout of the closing position and size of the segment assembly, and precise positioning lines are drawn on the outer surface of the pipe segment. This link is one of the key steps in the assembly of the entire jacket, and its accuracy is directly related to the overall structural strength and stability of the jacket. The connection accuracy and position accuracy between the segments must be ensured to provide reliable guarantee for the subsequent painting and overall installation work.

[0050] (VI) Production and installation of paint protection parts

[0051] According to the precise dimensions obtained by the previous steps, high-quality thin steel plates with a thickness of less than 1mm are selected as the raw materials for the coating protection parts. Through precise cutting equipment and processes, the thin steel plates are cut into shapes and sizes that meet the requirements, ensuring that the edges of the coating protection parts after cutting are flat, smooth, and free of burrs and deformation. Then, according to the positioning and marking of the intersection of the pipe joints, the coating protection parts are accurately attached to the pipe joints and fixed by efficient and firm spot welding. Among them, in order to achieve the best balance between the preparation and installation costs of paint protection parts and the benefits of the coating process, it is stipulated that paint protection parts are required to be installed only for the intersections with an unfolded length of more than 1m; the paint protection parts are made of thin steel plates less than 1mm, which are easy to bend and deform to fit the shape of the pipe segment. At the same time, the steel can be welded to the pipe nodes, which significantly improves the installation efficiency, and the steel plates have sufficient strength to remain intact during the sandblasting and spraying process and are not easily damaged, thereby greatly improving the reuse rate; in addition, the paint protection parts need to cover the intersections by more than 100mm, and the distance from the annular seam and longitudinal seam of the pipe segment is used as the positioning reference during positioning and installation to ensure that the paint protection parts can effectively protect the intersections and avoid paint contamination during the coating process, while not affecting subsequent welding and other processes.

[0052] (VII) Painting construction

[0053] The pipe segments that have been installed with coating protection parts at the intersections are grouped and placed in a scientific and reasonable arrangement to ensure that the relative positions between the pipe segments are stable and easy to transport. Subsequently, the pipe segments are smoothly and safely transported to the sand room and the painting shed using suitable transport equipment. In the sand room, the pipe segments are sanded comprehensively and carefully in strict accordance with the sand room operating procedures and process requirements to ensure that the surface of the pipe segments meets the cleanliness and roughness standards required for painting. After sanding, the pipe segments are transported to the painting shed. According to the pre-established painting process parameters and processes, advanced painting equipment and high-quality paint materials are used to evenly and carefully paint the pipe segments to ensure that the coating quality meets the relevant standards and requirements, and that the coating thickness, adhesion, appearance and other indicators are in the best state.

[0054] (VIII) Recycling of coating protection parts

[0055] After the pipe segments are painted and transported out of the painting shed, professionals carefully remove the thin steel plate paint protection parts. During the removal process, care should be taken to avoid damage to the paint protection parts to ensure that they can be reused. After cleaning, inspection and necessary repair, the removed paint protection parts are properly stored in a special storage area so that they can be reused in the next batch of pipe segment paint protection processes, thereby reducing production costs and improving resource utilization.

[0056] 3. Beneficial Effects

[0057] (I) Improve the utilization rate of site equipment resources

[0058] The present invention optimizes the traditional way of bringing the whole section of the conductor frame into the sandblasting and painting room into a single pipe section and a single accessory group structure. This method greatly reduces the demand for sandblasting and spraying workshop space for painting operations, reduces the carrying capacity of transfer equipment and the specification requirements of walking channels, enables site equipment resources to be more efficiently applied to the construction process of the conductor frame, significantly improves the applicability of factory site and equipment resources to the construction of conductor frame products, and thus enhances the factory's ability and competitiveness in undertaking business.

[0059] 2. Reduce costs

[0060] The process method of the present invention effectively avoids repeated spraying and grinding of the pipe joint at the intersection position. On the one hand, it reduces the amount of paint materials used and the cost of paint materials; on the other hand, it saves the manpower, material and time costs required for repeated grinding processes, thereby achieving effective cost control and reduction from multiple aspects and improving the economic benefits of the project.

[0061] (III) Improving construction efficiency and shortening construction period

[0062] The present invention enables multiple pipe sections and multiple components to enter the workshop for sandblasting and spraying at the same time, which greatly improves the construction efficiency compared to the traditional process of entering the workshop in sections one by one. At the same time, due to the reduction of repeated processes and unnecessary waiting time, the project construction period is significantly shortened and the construction speed of the conductor rack is accelerated. In addition, the process also reduces the use of disposable tooling and scaffolding, further reduces construction costs, and improves the overall benefits of the project.

[0063] Example:

[0064] Reference Figures 1 to 8 A process method for controlling the coating of the intersection of wind power conduit frames comprises the following steps:

[0065] (I) Pipe joint production

[0066] According to the conventional segment rolling and assembly process, the segments consisting of the segment body, segment fork and single leg segment are processed to form the following Figure 1 The pipe segment shown. In this process, it is ensured that the dimensional accuracy and quality of the pipe segment meet the requirements of subsequent processes.

[0067] (II) Production of small accessories

[0068] According to the design requirements, the accessory structure is made into small components separately, such as Figure 2 During the manufacturing process, the size and shape of the accessories are strictly controlled to ensure that they match the pipe joints.

[0069] (III) Lofting and marking of the joints of the pipe joints

[0070] Using professional layout tools and techniques, the pipe segments are assembled to form the intersection line of the segmented joint position and size for precise technical layout. Then, use the marking tool to clearly mark the positioning line on the outer surface of the pipe segment, such as Figure 3 The accuracy of this step directly affects the subsequent installation of accessories and the placement accuracy of coating protection parts.

[0071] (IV) Assembly layout and marking of accessory group structure

[0072] The same professional layout and marking methods are used to assemble the accessory group structure to the closing position and size of the pipe segment for technical layout, and mark the positioning line on the outer surface of the pipe segment, such as Figure 4 Ensure the relative position of the accessories and pipe joints is accurate, laying the foundation for subsequent assembly and painting work.

[0073] (V) Segmental overall combination closing and marking

[0074] The position and size of the closing mouth of the segment assembly are carefully laid out, and positioning lines are drawn on the outer surface of the pipe segment, such as Figure 5 This step is one of the key links in the assembly of the entire jacket, and it is necessary to ensure the connection accuracy between the segments and the stability of the overall structure.

[0075] (VI) Production and installation of paint protection parts

[0076] According to the size obtained by the previous layout, cut thin steel plates less than 1mm as paint protection parts. During the cutting process, the dimensional accuracy and edge flatness of the steel plates must be ensured. Then, according to the positioning lines of the intersection of the pipe segments, the paint protection parts are attached to the pipe segments and fixed by spot welding. It should be noted that paint protection parts are required only for the closing mouths with an unfolded length of the intersection line exceeding 1m; the paint protection parts are made of thin steel plates less than 1mm, which are easy to bend and deform to fit the pipe segments. The use of steel can be welded to the pipe nodes to improve the installation efficiency, and the steel plates have sufficient strength and are not easily damaged during the sandblasting and spraying process, which increases the reuse rate; the paint protection parts need to cover the intersections by more than 100mm, and the positioning installation uses the distance from the annular seam and longitudinal seam of the pipe segment as the positioning reference, such as Figure 6 shown.

[0077] (VII) Painting construction

[0078] The pipe segments with the intersecting line mouths installed and protected are grouped and placed in trays according to a certain arrangement, and then transported to the sand room and coating shed for sandblasting and coating using appropriate transport equipment. During the coating process, operations are strictly carried out in accordance with the coating process requirements to ensure the coating quality.

[0079] (VIII) Recycling of coating protection parts

[0080] After the pipe segments are painted and removed from the shed, the thin steel plate coating protection parts are carefully removed, and after necessary cleaning and maintenance, they are properly stored so that they can be reused in the coating protection process for the next batch of pipe segments.

[0081] Practical application cases:

[0082] In a certain offshore wind power project, the lower truss structure of the wind power duct of the project is large in scale, including more than 200 sheets, forks and single-leg segments. According to the traditional painting process, in the early preparation stage, in order to meet the transportation and painting space requirements of the huge segments, a large amount of funds need to be invested to expand the sand room and painting shed. The estimated expansion cost is as high as 5 million yuan, and the procurement and maintenance costs of the transportation equipment are high. During the construction process, due to the difficulty of transporting the entire section, transportation delays often occur, resulting in delays in the construction period. At the same time, due to repeated spraying and grinding of the intersections, paint was seriously wasted, and the monthly paint consumption exceeded the budget by 15%, and labor costs were also high.

[0083] After adopting the process method of controlling the coating of the intersection of wind turbine conduit racks of the present invention, firstly, in the production of pipe segments, the curvature deviation of the pipe segments rolled by the high-precision CNC plate rolling machine is controlled within ±0.5mm, the straightness error of the pipe segments after assembly does not exceed 1mm, and the ovality deviation is less than 0.8mm, providing high-quality basic components for subsequent construction. When making small components of accessories, the dimensional tolerance of laser cutting is ±0.3mm, and the automated welding robot ensures the quality of the weld, which is highly matched with the pipe segment.

[0084] In the layout and marking stage, the combination of total station and 3D layout software makes the layout accuracy of each joint position and size reach millimeter level, and the clear and accurate positioning line provides precise guidance for the subsequent installation and assembly of protective parts. The coating protection parts are made of 0.8mm low-carbon thin steel plates, the cutting tolerance of CNC shearing machine is ±0.2mm, and the mounting spot welding spacing is 20-30mm, which effectively protects the intersection of the lines.

[0085] In the coating construction phase, the pipe sections were arranged reasonably, with a spacing of 30-50cm, and suitable abrasives and high-pressure airless spray equipment were selected, resulting in excellent coating quality. In the end, the actual demand for the sand room area of ​​the project was reduced by 400 square meters compared with the original plan, the carrying capacity of the transfer equipment was reduced to 30 tons, the width of the walking channel was narrowed to 3 meters, the cost of paint materials was reduced by 20%, and the construction period was shortened by about 30%. Many problems of traditional processes were successfully solved, the economic benefits and construction efficiency of the project were significantly improved, and the timely and high-quality delivery of the wind power conduit rack was ensured.

[0086] In summary, the present invention helps wind power enterprises overcome technical difficulties in overseas projects, enables enterprises to gain a firm foothold in the fierce international market competition with advanced technology, opens up a broader profit space, and promotes my country's wind power industry from the domestic saturation dilemma to the international high-end manufacturing field. On the one hand, precise cutting and inspection technology can effectively reduce the scrap rate, reduce the waste of raw materials, and directly save production costs.

[0087] The present invention ensures the high-quality construction of offshore wind power project structures, indirectly improves the stability and reliability of offshore wind power facilities, promotes the efficient development and utilization of clean energy, and has positive significance for the global sustainable energy development strategy. Stable and reliable wind power facilities can reduce the frequency of fault repairs, reduce operation and maintenance costs, continuously and stably deliver clean energy to the power grid, help cope with climate change, and achieve green development goals.

[0088] The technical solutions provided by the embodiments of the present invention are introduced in detail above. Specific examples are used herein to illustrate the principles and implementation methods of the embodiments of the present invention. The description of the above embodiments is only applicable to help understand the principles of the embodiments of the present invention. At the same time, for those skilled in the art, according to the embodiments of the present invention, there will be changes in the specific implementation methods and application scopes. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. A process for controlling the coating of the intersection of wind power conduit racks, characterized in that: The following steps are involved: Step S1, rolling and assembling the tube segments consisting of the sheet body, the sheet fork and the single-leg segment to form a tube segment; Step S2, the accessory structure is separately made into a component; Step S3, assembling the pipe segments to form the intersection line of the segments, and then technically setting out the position and size of the closing mouth, and drawing positioning lines on the outer surface of the pipe segments; Step S4, assembling the accessory structural components to the closing position and size of the pipe segment for technical lofting, and drawing positioning lines on the outer surface of the pipe segment; Step S5, technically lofting the closing position and size of the segment assembly, and drawing positioning lines on the outer surface of the pipe segment; Step S6, cutting a thin steel plate with a thickness of less than 1 mm as a coating protection part according to the layout size, attaching it to the pipe section according to the positioning markings of the pipe section intersection and fixing it with spot welding; Step S7, after the pipe sections with intersecting line mouths are installed and protected, they are arranged into groups and put into trays, and then transported to the sanding room and coating shed for sandblasting and coating construction; Step S8: After the pipe segments are finished being painted and taken out of the shed, the thin steel plate paint protection parts are disassembled and recycled, and reused in the paint protection process for the next batch of pipe segments.

2. A process for controlling the coating of the intersection of wind turbine conduit frames according to claim 1, characterized in that: The coating protection part shall cover the intersection more than 100mm, and the positioning installation shall be based on the distance from the pipe segment annular seam and longitudinal seam as the positioning reference.

3. A process for controlling the coating of the intersection of wind turbine conduit frames according to claim 1, characterized in that: Only when the length of the intersecting line exceeds 1m does it need to be painted with protective parts.

4. A process for controlling the coating of the intersection of wind turbine conduit frames according to claim 1, characterized in that: The coating protection member is made of a steel plate with a thickness of less than 1 mm.

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