A method for connecting a foundation jacket of an offshore booster station to an upper assembly
By using equipment such as guide rails, guide wheels, and airbags in offshore wind farm construction, along with traction equipment and a real-time monitoring system, the stability and safety issues during offshore hoisting were resolved, achieving efficient and safe connection between the upper components and the jacket.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- HAINAN SHENNENG NEW ENERGY CO LTD
- Filing Date
- 2025-01-17
- Publication Date
- 2026-05-15
AI Technical Summary
During the construction of offshore wind farms, the stability of the upper components is difficult to maintain due to the influence of the marine environment, resulting in low construction efficiency and high safety risks.
Guide rails and guide wheels are installed on the transport ship. By using the traction equipment and guide wheels, the upper components are brought close to the jacket structure at the bow of the transport ship. The components are then hoisted by a crane ship and moved in a straight line to the jacket structure. Combined with airbag anti-collision and real-time monitoring by acceleration sensors and inclinometers, stability and safety are ensured.
It improved the wind resistance of the upper components during hoisting, shortened the hoisting path, enhanced the safety and stability of construction, reduced risks, and improved construction efficiency.
Smart Images
Figure CN119929074B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of offshore wind farm construction, and in particular to a construction method for connecting the foundation jacket and upper components of an offshore substation. Background Technology
[0002] Currently, in the construction of offshore wind farms, the booster station plays a crucial role as a key node in power transmission. The foundation jacket is the main supporting structure of the offshore booster station. The superstructure mainly includes a steel frame and inter-level equipment rooms. The inter-level equipment rooms are used to install and house various electrical equipment of the booster station. To meet the operation and maintenance needs of offshore wind farms, the superstructure typically also includes a helicopter platform. This platform allows for helicopter take-off and landing, facilitating rapid access for maintenance personnel to the booster station for on-site operations. The steel frame is mainly used to support and fix the inter-level equipment rooms and the helicopter platform.
[0003] In related technologies, the common practice is to use a whole-unit hoisting method. A crane vessel lifts the upper components from the transport ship and transfers them to the top of the foundation jacket, then slowly lowers them, and finally connects the upper components and the jacket. During the connection process, it is necessary to ensure that the main support column at the bottom of the upper components can accurately align with the main leg at the top of the jacket. However, in actual offshore hoisting, due to the objective factors of the open terrain, the hoisting process is greatly affected by natural environmental factors such as strong winds, monsoons, swells, and fog, making it difficult to maintain the stability of the upper components during hoisting. This results in reduced construction efficiency, higher construction risks, and difficulty in ensuring safety. Therefore, there is still room for improvement. Summary of the Invention
[0004] To improve construction efficiency and safety, this application provides a construction method for connecting the foundation jacket and upper components of an offshore substation.
[0005] This application provides a construction method for connecting the foundation jacket and upper components of an offshore substation, which adopts the following technical solution:
[0006] A construction method for connecting the foundation jacket and superstructure of an offshore substation includes the following steps:
[0007] Transportation preparation: Install two guide rails on the transport ship, which are symmetrically distributed on both sides of the transport ship and extend along the length of the transport ship. Install sliding frames on the guide rails, and then place the upper component frame on the sliding frames; install traction equipment at the stern of the transport ship.
[0008] Lifting preparation: The transport ship and the crane ship travel to the front and rear sides of the jacket structure respectively, and install guide wheels on the jacket structure. Then, pull the connecting end of the traction rope of the traction equipment to the bow of the transport ship. Next, wrap the connecting end of the traction rope around the guide wheel on the side of the jacket structure and then wrap it back to the transport ship. Then, connect the connecting end of the traction rope to the upper component. Then start the traction equipment. The upper component moves to the bow of the transport ship under the action of the traction rope and the guide wheel.
[0009] Lifting operation: Connect the lifting equipment of the crane vessel to the upper component, lift the upper component by the crane vessel, and at the same time start the traction equipment to keep the traction rope taut until the upper component is lifted onto the jacket, and complete the connection operation between the jacket and the upper component.
[0010] By adopting the above technical solution, guide rails are installed on the transport ship, and the transport ship and crane ship are moored on both sides of the jacket structure, so that the sliding trajectories of the transport ship, jacket structure, crane ship, and upper component are aligned in a straight line. Then, the traction rope of the traction equipment is wound around the guide wheel of the jacket structure, then around the rear of the transport ship, and connected to the upper component. Utilizing the pulling action of the traction equipment and the guiding action of the guide wheel, the upper component can be moved to the bow position of the transport ship, thus approaching the jacket structure. Then, the crane ship lifts the upper component and moves it in a straight line towards the guide structure, thereby minimizing the hoisting path of the upper component in the air. At this time, the traction equipment continues to rewind, keeping the traction rope taut at all times, which improves the wind resistance of the upper component during the hoisting and transfer process, until the upper component is hoisted onto the jacket structure. Finally, the connection operation between the jacket structure and the upper component is completed, which helps to improve construction efficiency and safety.
[0011] Preferably, the bow of the transport vessel is provided with an airbag, and when the transport vessel moves to one side of the jacket, the airbag comes into contact with the jacket.
[0012] By adopting the above technical solution, the airbag plays a collision prevention role, enabling the transport ship to get as close as possible to the jacket structure and maintain a safe distance between the transport ship and the jacket structure, which helps to improve construction safety.
[0013] Preferably, during the hoisting preparation step, as the transport vessel approaches the jacket, it gradually slows down and simultaneously inflates the airbag. The airbag expands and its bottom sinks into the water. When the airbag comes into contact with the side of the jacket, it forms an installation platform between the jacket and the transport vessel. Then, the guide wheel installation step and the traction rope winding step of the traction equipment are completed on the airbag.
[0014] By adopting the above technical solution, the airbag not only plays a role in buffering and preventing collisions during the docking of the transport ship, but also serves as an installation platform to facilitate the installation of guide wheels and the winding of traction ropes for the traction equipment by construction personnel. This is conducive to the smooth progress of the upper component pulling work. In addition, since the transport ship tends to tilt forward under the heavy pressure of the upper component when the upper component moves from the middle to the bow of the transport ship, the buoyancy of the bow position of the transport ship is increased by setting the airbag to the bottom, which helps to reduce the risk of the transport ship tilting forward and allows the transport ship to reach a balanced state.
[0015] Preferably, there are two traction devices and two guide wheels. The two guide wheels correspond to the traction ropes of the two traction devices respectively. The two guide wheels are placed on the left and right sides of the jacket frame. The distance between the two traction devices is equal to the distance between the left and right sides of the jacket frame. When the crane vessel lifts the upper component directly above the jacket frame, the connecting end of the traction rope is set vertically.
[0016] By adopting the above technical solution, two traction devices and two guide wheels are set up, with each guide wheel corresponding to the traction rope of one traction device. The two guide wheels are located on the left and right sides of the guide frame, respectively, to ensure that the traction rope remains vertical during the hoisting process. This effectively balances the force on the upper components during the hoisting process and avoids tilting or swaying problems caused by uneven force at a single point, thereby significantly improving the safety and stability of the construction.
[0017] Preferably, an acceleration sensor is installed below each of the several support columns of the upper component. The acceleration sensor is used to detect the vertical and horizontal acceleration of the upper component during transportation and hoisting.
[0018] By adopting the above technical solution, the acceleration sensor can monitor the vertical and horizontal acceleration of the upper components in real time during transportation and hoisting, which helps to detect and deal with possible abnormalities in a timely manner and improve the safety and reliability of construction.
[0019] Preferably, an inclinometer is installed at the top of each of the several support columns of the upper component. The inclinometer is used to detect the lateral and longitudinal tilt values of the upper component during transportation and hoisting.
[0020] By adopting the above technical solution, the installation of the inclinometer can monitor the lateral and longitudinal tilt of the upper components in real time during transportation and hoisting. This helps to promptly detect and correct deviations that may be caused by factors such as wind and waves, ensuring the safety and accuracy of the construction process, and effectively preventing equipment damage or safety accidents caused by excessive tilting.
[0021] Preferably, when the crane vessel lifts the upper component, the horizontal distance between the upper component and the crane vessel's lifting equipment is 7m, and the distance from the bottom of the upper component to the sea level is 15m.
[0022] By adopting the above technical solution, the horizontal distance between the upper component and the lifting equipment of the crane vessel is 7m, effectively avoiding safety hazards and operational inconveniences caused by excessively close or far distances during the lifting process, and improving the safety and accuracy of the lifting. The distance from the bottom of the upper component to the sea level is 15m, ensuring sufficient height margin during the lifting process, preventing collision risks caused by waves and other factors, and further enhancing the safety of construction.
[0023] Preferably, after the upper module's several support columns are accurately placed in the corresponding main leg holes of the guide frame, the welding work between the upper module and the guide frame is completed. Then, the crane vessel is unhooked and removed, and then the upper module and the guide frame are welded and fixed.
[0024] By adopting the above technical solution, the four columns of the upper module are correctly placed on the lower structure, and the welding work between the upper module and the lower structure is completed before the crane vessel can be unhooked and withdrawn. All bevel welds are first-class welds and should use full penetration technology, with smooth connection between both sides of the weld and the base material surface; after welding, magnetic particle testing of the weld is carried out to ensure welding quality.
[0025] In summary, this application includes at least one of the following beneficial technical effects:
[0026] 1. By installing guide rails on the transport ship and mooring the transport ship and crane ship on both sides of the jacket structure, the sliding trajectories of the transport ship, jacket structure, crane ship, and upper component are aligned in a straight line. Then, the traction rope of the traction equipment is wound around the guide wheel of the jacket structure, then around the rear of the transport ship, and connected to the upper component. Utilizing the pulling action of the traction equipment and the guiding action of the guide wheel, the upper component can be moved to the bow position of the transport ship, thus approaching the jacket structure. Then, the crane ship lifts the upper component and moves it in a straight line towards the guide structure, thereby minimizing the hoisting path of the upper component in the air. At this time, the traction equipment continues to rewind, keeping the traction rope taut at all times, which improves the wind resistance of the upper component during the hoisting and transfer process, until the upper component is hoisted onto the jacket structure. Finally, the connection operation between the jacket structure and the upper component is completed, which helps to improve construction efficiency and safety.
[0027] 2. By installing an airbag at the bow of the transport vessel, when the transport vessel moves to one side of the jacket structure, the airbag comes into contact with the jacket structure, and the airbag plays a collision prevention role, allowing the transport vessel to get as close to the jacket structure as possible and maintaining a safe distance between the transport vessel and the jacket structure, which helps to improve construction safety.
[0028] 3. During the hoisting preparation phase, as the transport vessel approaches the jacket structure, its speed is gradually reduced while the airbags are inflated. The airbags expand and their bottoms sink into the water. When the airbags come into contact with the side of the jacket structure, they form an installation platform between the jacket structure and the transport vessel. This facilitates the installation of guide wheels and the winding of traction ropes for the traction equipment by the construction personnel, which is beneficial for the smooth pulling of the upper components. In addition, as the upper components move from the middle to the bow of the transport vessel, the vessel tends to tilt forward under the weight of the upper components. By setting the airbags to the bottom, the buoyancy at the bow of the transport vessel is increased, which helps to reduce the risk of the vessel tilting forward and allows the transport vessel to reach a balanced state. Attached Figure Description
[0029] Figure 1 This is a schematic diagram showing the state of the upper component when it is located at the bow of a transport ship in a construction method for connecting the foundation jacket and upper component of an offshore substation according to an embodiment of this application.
[0030] Figure 2 yes Figure 1 Enlarged diagram of point A in the middle.
[0031] Figure 3 This is a schematic diagram showing the state of the upper component being lifted above the jacket in a construction method for connecting the foundation jacket and upper component of an offshore substation according to an embodiment of this application.
[0032] Explanation of reference numerals in the attached drawings: 1. Crane vessel; 2. Transport vessel; 3. Guide rail; 4. Traction equipment; 41. Traction rope; 5. Sliding frame; 6. Upper component; 61. Support column; 7. Jacket; 71. Guide wheel; 8. Airbag. Detailed Implementation
[0033] The following is in conjunction with the appendix Figure 1-3 This application will be described in further detail.
[0034] This application discloses a construction method for connecting the foundation jacket and superstructure of an offshore substation, referring to... Figure 1 and Figure 2 This includes the following steps:
[0035] S1: Transportation Preparation: Install two guide rails 3 on the transport ship 2. These two guide rails 3 are symmetrically distributed on both sides of the transport ship 2 and extend along the length of the transport ship 2. Install a sliding frame 5 on each guide rail 3, then place the upper component 6 on the sliding frame 5, and temporarily lock the upper component 6 and the sliding frame 5. The guide rails 3 are made of high-strength steel, which has good corrosion resistance and wear resistance. The sliding frame 5 is made of stainless steel and has ball bearings inside to reduce friction and improve sliding efficiency.
[0036] In addition, a towing device 4 is installed at the stern of the transport vessel 2. The towing device 4 is a winch, mainly composed of an electric motor, a winding drum, and a towing rope 41. The electric motor has a power of 50kW, which can provide sufficient traction force. The wire rope is a 20mm diameter galvanized steel wire rope, which is high in strength and corrosion-resistant, and suitable for offshore operations.
[0037] To increase the stability of transport ship 2, counterweights, such as water tanks or other heavy objects, can be added to maintain the ship's stability. Additionally, a support rod can be installed in the middle of transport ship 2 to secure the upper component 6 and prevent it from swaying during movement.
[0038] S2: Lifting Preparation: The transport vessel 2 and the crane vessel 1 travel to the front and rear sides of the jacket frame 7 respectively, and install guide wheels 71 on the jacket frame 7. The guide wheels 71 are made of aluminum alloy, which is lightweight and durable, and the surface is specially treated to reduce wear. The guide wheels 71 are installed on the side of the jacket frame 7 at a moderate height to facilitate the winding of the traction rope 41. Then, the connecting end of the traction rope 41 of the traction device 4 is pulled to the head of the transport vessel 2. Next, the connecting end of the traction rope 41 is wound around the guide wheel 71 on the side of the jacket frame 7 and then wound back to the transport vessel 2. Then, the connecting end of the traction rope 41 is connected to the bottom of the upper component 6. Then, the traction device 4 is started, and the upper component 6 moves along the guide rail 3 to the head of the transport vessel 2 under the combined action of the traction rope 41 and the guide wheel 71.
[0039] During this process, to prevent the transport vessel 2 from tilting due to excessive load, the aforementioned balancing measures can be taken. Additionally, to ensure the safe approach of the transport vessel 2 to the jacket support 7, an airbag 8 can be installed at the bow of the transport vessel 2. The airbag 8 is made of multiple layers of nylon fabric, filled with an inert gas such as nitrogen or helium to ensure it remains elastic under high pressure. The airbag 8 is 1 meter high, 2 meters wide, and its length can be adjusted according to actual conditions. As the transport vessel 2 approaches the jacket support 7, its speed is gradually reduced while the airbag 8 is inflated. The airbag 8 inflates and its bottom sinks into the water. When the transport vessel 2 moves to one side of the jacket support 7, the airbag 8 comes into contact with the jacket support 7, forming an installation platform between the jacket support 7 and the transport vessel 2. This allows workers to complete the installation of the guide wheel 71 and the winding of the traction rope 41 of the traction equipment 4 on the airbag 8. As the upper component 6 moves from the middle of the transport ship 2 to the bow of the transport ship 2, the transport ship 2 tends to tilt forward under the heavy pressure of the upper component 6. By setting the airbag 8 to the bottom, the buoyancy of the bow position of the transport ship 2 is increased, which helps to reduce the risk of the transport ship 2 tilting forward and allows the transport ship 2 to reach a balanced state.
[0040] In this embodiment, two traction devices 4 and two guide wheels 71 are provided. The two guide wheels 71 correspond to the traction ropes 41 of the two traction devices 4 respectively. The two guide wheels 71 are placed on the left and right sides of the jacket frame 7, and the distance between the two traction devices 4 is equal to the distance between the left and right sides of the jacket frame 7. When the crane vessel 1 lifts the upper component 6 directly above the jacket frame 7, the connecting end of the traction rope 41 is set vertically, which can effectively balance the force on the upper component 6 during the lifting process and avoid tilting or swaying problems caused by uneven force at a single point, thereby significantly improving the safety and stability of construction.
[0041] S3: Lifting and Installation: Refer to... Figure 1 and Figure 3 The lifting device of the crane vessel 1 is connected to the upper component 6. Then, the temporary locking of the sliding frame 5 and the upper component 6 is released. The upper component 6 is lifted by the crane vessel 1. During this process, the transport vessel 2 moves away from the jacket 7 to provide sufficient installation space for the upper component 6. At the same time, the traction device 4 is started to keep the traction rope 41 taut. Then, the crane vessel 1 slowly lowers the jacket 7 until the support column at the bottom of the upper component 6 is inserted and fixed to the hole at the top of the support leg of the jacket 7.
[0042] After the upper module's support columns are accurately placed in the corresponding main leg holes of the jacket 7, the welding work between the upper module and the jacket 7 is completed. Then, the crane vessel 1 is unhooked and removed, and the upper component 6 and the jacket 7 are welded and fixed. All bevel welds are first-class welds, using a full penetration process, with smooth connection between both sides of the weld and the base material surface. After welding, magnetic particle testing of the weld is performed to ensure welding quality.
[0043] It is important to emphasize that, during transportation and hoisting, to monitor the status of the upper component 6 in real time and ensure the safety and stability of the process, accelerometers can be installed below several support columns of the upper component. These accelerometers detect the vertical and horizontal acceleration of the upper component during transportation and hoisting. Inclinometers are installed at the top of several support columns of the upper component to detect the lateral and longitudinal tilt angles of the upper component during transportation and hoisting. Furthermore, when the crane vessel 1 lifts the upper component 6, the horizontal distance between the upper component 6 and the lifting equipment of the crane vessel 1 is 7 meters, effectively avoiding safety hazards and operational inconveniences caused by excessively close or far distances during hoisting, thus improving the safety and accuracy of the hoisting. The distance from the bottom of the upper component 6 to the sea level is 15 meters, ensuring sufficient height margin during hoisting and preventing collision risks caused by waves and other factors, further enhancing construction safety.
[0044] In this embodiment, by installing guide rails 3 and sliding frames 5 on the transport vessel 2, and utilizing the coordination of traction equipment 4 and guide wheels 71, the upper component 6 is moved smoothly. Compared with the traditional overall hoisting method, this method greatly shortens the hoisting path of the upper component 6 in the air, reduces the impact of wind and waves on the hoisting process, and improves construction efficiency and safety. In particular, the use of airbags 8 not only provides collision protection but also serves as a temporary platform, facilitating the operation of construction personnel. Furthermore, the monitoring by accelerometers and inclinometers further enhances the safety of the construction process, ensuring the stability and accuracy of the upper component 6 during hoisting.
[0045] The design of dual guide wheels 71 and dual traction devices 4 effectively solves the skewing problem that may be caused by single-point traction, ensuring the horizontal and vertical attitude of the upper component 6 during the hoisting process. This design not only improves the accuracy of hoisting but also significantly enhances the safety of construction. The synergistic effect of dual guide wheels 71 and dual traction devices 4 is particularly important in complex marine environments.
[0046] Real-time monitoring via accelerometers and inclinometers allows for a comprehensive understanding of the dynamic changes of the upper component 6 throughout the entire hoisting process. If any abnormalities are detected, such as a sudden increase in acceleration or a deviation in incline from the predetermined range, the system will immediately issue an alarm, alerting construction personnel to take appropriate measures. This real-time monitoring mechanism not only improves construction safety but also enables timely detection of problems, preventing potential risks.
[0047] Optimization of the welding process ensured a robust connection between the upper component 6 and the jacket 7. The selection of full penetration welding technology and high-performance welding materials gave the weld high mechanical properties, enabling it to withstand the harsh marine environment. Magnetic particle testing, as a reliable non-destructive testing method, ensured weld quality, eliminated potential safety hazards, and improved the reliability and service life of the entire system.
[0048] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
[0049] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
Claims
1. A construction method for connecting the foundation jacket and superstructure of an offshore substation, characterized in that, Includes the following steps: Transportation preparation: Install two guide rails (3) on the transport ship (2). The two guide rails (3) are symmetrically distributed on both sides of the transport ship (2) and extend along the length of the transport ship (2). Install a sliding frame (5) on the guide rails (3). Then place the upper component (6) on the sliding frame (5). Install a traction device (4) at the stern of the transport ship (2). Lifting preparation: The transport ship (2) and the crane ship (1) travel to the front and rear sides of the jacket (7) respectively, and install guide wheels (71) on the jacket (7). Then, the connecting end of the traction rope (41) of the traction device (4) is pulled to the head of the transport ship (2). Then, the connecting end of the traction rope (41) is wrapped around the guide wheel (71) on the side of the jacket (7) and then wrapped back to the transport ship (2). Then, the connecting end of the traction rope (41) is connected to the upper component (6). Then, the traction device (4) is started. The upper component (6) moves to the head of the transport ship (2) under the combined action of the traction rope (41) and the guide wheel (71). Lifting operation: Connect the lifting equipment of the crane vessel (1) to the upper component (6), lift the upper component (6) by the crane vessel (1), and start the traction equipment (4) at the same time to keep the traction rope (41) taut until the upper component (6) is lifted onto the guide frame (7) and the connection operation between the guide frame (7) and the upper component (6) is completed. The head of the transport vessel (2) is provided with an airbag (8). When the transport vessel (2) moves to the side of the guide frame (7), the airbag (8) and the guide frame (7) come into contact. During the hoisting preparation step, as the transport ship (2) approaches the jacket (7), it gradually slows down and simultaneously inflates the airbag (8). The airbag (8) expands and its bottom sinks into the water. When the airbag (8) comes into contact with the side of the jacket (7), the airbag (8) forms an installation platform between the jacket (7) and the transport ship (2). Then, the guide wheel (71) installation step and the towing rope (41) winding step of the towing equipment (4) are completed on the airbag (8). An acceleration sensor is installed below several support columns (61) of the upper component (6). The acceleration sensor is used to detect the vertical acceleration and horizontal acceleration of the upper component (6) during transportation and hoisting.
2. The construction method for connecting the foundation jacket and upper components of an offshore substation according to claim 1, characterized in that: There are two traction devices (4) and two guide wheels (71). The two guide wheels (71) correspond to the traction ropes (41) of the two traction devices (4) respectively. The two guide wheels (71) are placed on the left and right sides of the jacket frame (7). The distance between the two traction devices (4) is equal to the distance between the left and right sides of the jacket frame (7). When the crane ship (1) lifts the upper component (6) directly above the jacket frame (7), the connecting end of the traction rope (41) is set vertically.
3. The construction method for connecting the foundation jacket and upper components of an offshore substation according to claim 1, characterized in that: Inclinometers are installed at the top of several support columns (61) of the upper component (6). The inclinometers are used to detect the lateral and longitudinal inclination values of the upper component (6) during transportation and hoisting.
4. The construction method for connecting the foundation jacket and upper components of an offshore substation according to claim 1, characterized in that: When the crane vessel (1) lifts the upper component (6), the horizontal distance between the upper component (6) and the lifting equipment of the crane vessel (1) is 7m, and the distance from the bottom of the upper component (6) to the sea level is 15m.
5. The construction method for connecting the foundation jacket and upper components of an offshore substation according to claim 1, characterized in that: After the upper component (6) and several support columns (61) are accurately placed in the corresponding main leg holes of the guide frame (7), the welding work between the upper component (6) and the guide frame (7) is completed. Then the crane ship (1) is unhooked and removed, and then the upper component (6) and the guide frame (7) are welded and fixed.