High-mountain wind power plant single-blade high-fall ultra-long-distance grabbing and lifting construction method

Abstract

The invention provides a high-mountain wind power plant single-blade high-fall ultra-long-distance grabbing and lifting construction method which comprises the steps that a main lifting position is arranged on a mountain top platform, a blade vehicle is arranged at a preset position of an uphill road, and the lifting amplitude is increased within a standard lifting range by adjusting the main lifting position on the platform and lowering a main arm; a clamp type single-blade hoisting tool is adopted, so that a main hoisting station can hoist a blade on a road below the main hoisting station on a platform, and high-fall ultra-long-distance grabbing and hoisting construction of the single blade is completed. According to the method, the problems that a hoisting platform is narrow and the blade cannot be transported to a machine position are solved, and the project progress is accelerated while the hoisting safety is guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of wind power construction, and in particular to a method for high-drop ultra-long-distance grabbing and hoisting construction of a single blade in a high-mountain wind farm. Background Art

[0002] With the vigorous promotion of high-power, long-blade, high-tower wind turbines, the trend of large-scale wind turbine lifting and hoisting machinery has been driven.

[0003] Three-blade hoisting is still the most common method of wind turbine installation. Specifically, three-blade hoisting is to transport the three blades to the wind turbine hoisting platform on the top of the mountain, assemble the three blades and the hub together for overall hoisting. As the wind rotors become larger and larger, traditional three-blade wind rotor hoisting faces multiple challenges. The windward area of the large wind rotor becomes larger, resulting in lateral loads exceeding the lateral resistance of the crane, which can easily cause safety accidents. At the same time, ground assembly occupies too much space and is limited in special terrains such as mountains and woodlands.

[0004] Therefore, the three-blade hoisting method has disadvantages such as large footprint, high risk, and low efficiency. It has certain risks when hoisting ultra-high towers and ultra-long blades, and the hoisting cost is high. It can no longer meet the needs of large-scale development of domestic wind power.

[0005] Due to the above reasons, three-blade hoisting is no longer advantageous in some high-mountain wind farms. Due to the constraints of the above factors, some mountain wind farms have begun to use single-blade hoisting.

[0006] However, the wind turbines in high-altitude wind farms are installed on mountain ridges, and have the characteristics of high base altitude, steep mountains, narrow lifting platforms, and high gust wind speeds, which have a great impact on the lifting of wind turbines. Even the lifting of single blades is difficult to construct.

[0007] The main difficulties include site constraints such as the narrow lifting platform and the inability to transport the blades directly to the machine position. In order to overcome the above difficulties, it is urgently necessary to improve the blade lifting work in high-altitude wind farms. Summary of the Invention

[0008] The purpose of the present invention is to address the shortcomings of the existing technology and provide a method for high-drop, ultra-long-distance grabbing and lifting of single blades in high-mountain wind farms, which overcomes the problem of narrow lifting platforms and the inability to transport blades to the machine site, ensuring lifting safety while accelerating the project progress.

[0009] In order to achieve the above object, the technical solution adopted by the present invention is: a high-drop ultra-long-distance grabbing and lifting construction method for a single blade in a high-mountain wind farm, comprising the following steps: Step 1) Main crane position confirmation: Based on the relative position of the mountain access road and the mountaintop platform, the main crane position is recalculated on the mountaintop platform so that the main crane's lifting radius can cover part of the mountain access road; Step 2) Foundation adjustment in the main crane area: After determining the main crane position, re-press and re-check the foundation based on the site's bearing capacity test results. At the same time, check that the inclination of the slewing support installation plane is within a safe range. Step 3) Single blade lifting preparation: Move the lifting device to the determined location and assemble it. The single blade lifting device uses two sets of hydraulically driven clamp-type single blade lifting tooling; Step 4) Grab the blade: The blade vehicle transfers the blade to the predetermined position on the uphill road. The main crane is controlled to move the clamp-type single-blade lifting tooling to above the predetermined position. The two clamp-type single-blade lifting tools clamp the two lifting positions of the blade and slowly lift it. When the lifting force equals the deadweight of the blade and the tooling, the fixing bolts between the blade and the vehicle are loosened to separate the blade. After slowly lifting it to a set height above the elevation of the mountaintop platform, the main boom is rotated and raised simultaneously to lift the blade above the wind turbine platform. The direction of the blade is synchronously adjusted using the guy rope. Step 5) Blade installation: Determine the blade installation angle, control the blade posture, align the blade with the pitch bearing, and then install the blade.

[0010] Preferably, in step 1), in the process of recalculating the position of the main crane, it is necessary to calculate the total weight Qtotal to be lifted and the minimum value of the rated weight Qrated of the main crane under specific working conditions, and query according to the main crane performance table, under the condition that the main arm length, the body counterweight and the additional counterweight are certain, the maximum lifting radius R that meets the lifting requirements is obtained; while ensuring the safety of the main crane from the slope, adjust the position of the main crane and the distance between the blade vehicle on the uphill road. After adjustment, the distance between the main crane and the blade vehicle is r. At this time, the operating radius r of the main crane is less than the maximum lifting radius R, and lifting can be carried out.

[0011] Preferably, in step 1), the process of calculating the minimum value of the total weight Qtotal to be hoisted and the rated weight Qrated of the main crane under specific working conditions is as follows: Q 总 =Q 叶 +Q 钩 +Q 具 Where: Q 总 -Total weight being lifted Q 叶 —The weight of the lifted blade Q 钩 —Hook weight Q 具 —Weight of sling Q 额 =KQ总 / P Where: Q 额 —Rated weight of main crane under specific working conditions K—dynamic load coefficient Q 总 -Total weight being lifted P—The maximum load rate of the lifting machinery when lifting alone.

[0012] Preferably, in step 2), the inclination of the slewing bearing installation plane is not greater than 1%.

[0013] Preferably, in step 3), a diesel generator and a backup power supply are integrated on the spreader to provide clamping power.

[0014] Preferably, in step 5), the process of determining the blade installation angle is as follows: The horizontal position perpendicular to the tower is defined as the 0° position, the counterclockwise upward position from the 0° position is defined as the + angle position, and the clockwise downward position from the 0 degree position is defined as the - angle position. The posture and clamping position requirements of the single-blade hoist for clamping the blade are as follows: the PS side of the blade faces upward, and the mold seam is rotated clockwise by 2.5 bolt holes in a horizontal posture.

[0015] Preferably, in step 5), the process of installing the blades is as follows: After the blades are correctly docked with the pitch bearings, install all nuts, then remove the auxiliary wooden planks and tighten all bolts manually with an open-end wrench. At this time, the 12 blade root bolts facing the process holes are stretched to the required pressure value, and the single-blade hoist is used to realize the function of rotating the blades around the X-axis by ±5°. Then, by controlling the single-blade hoist and the pitch drive, the pitch bearings are rotated 3.75° in the same direction at the same time. At this time, the 12 blade root bolts facing the process holes are stretched to the required pressure value. Then, the blade tooling bolts are removed through the process holes, the blade root bolts are reinstalled, and the bolts are stretched to the required pressure value. After the above conditions are met, the single-blade hoist is unhooked, and the installation of this wind turbine is completed.

[0016] Preferably, the height of the blade vehicle set on the uphill road is lower than the height of the mountain top platform.

[0017] Preferably, the uphill road is a winding mountain road.

[0018] Preferably, the required pressure value is 470kN.

[0019] Compared with the existing technology, the present invention has outstanding substantive features and significant progress. Specifically, the present invention optimizes the hoisting for the special terrain of the mountains, sets the hoisting platform on the mountaintop platform, and sets the blade vehicle on the mountain road. Due to the large height difference between the two, the traditional hoisting method is changed on site, and an innovative single-blade high-drop ultra-long-distance grabbing and lifting technology is adopted. By adjusting the position of the main crane on the platform and using a clamp-type single-blade lifting tool, the blade is lifted directly from the road below the platform, which greatly shortens the length of the road reconstruction. At the same time, the windward area of the single-blade hoisting under this method is reduced, and the influence of wind load on hoisting is reduced, which can significantly extend the operation window period and speed up the progress of the project. The process is advanced, the construction is efficient, and it has obvious economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the hoisting position of the high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-altitude wind farm according to the present invention.

[0021] Figure 2 This is a schematic diagram of the traditional lifting position.

[0022] Figure 3 It is a schematic diagram of the actual application scenario of the high-drop ultra-long-distance grabbing and lifting construction method for a single blade in a high-altitude wind farm according to the present invention.

[0023] Figure 4 It is a schematic diagram of the blade installation angle.

[0024] Figure 5 It is a schematic diagram of the blade installation process one by one.

[0025] Figure 6 It is a schematic diagram of the blade suspended in the air.

[0026] In the picture: 1. Uphill road; 2. Original main crane; 3. Blades; 4. Main crane after adjustment; 5. Wind turbine platform. DETAILED DESCRIPTION

[0027] The technical solution of the present invention is further described in detail below through specific implementation methods.

[0028] like Figures 1-6 As shown, a high-drop ultra-long-distance grabbing and lifting construction method for a single blade in a high-mountain wind farm includes the following steps: (1) Confirmation of main crane position After the turbine hub is installed, recalculate the main crane position based on the relative positions of the road and platform. Calculate the total weight of the load from the blades and the hoisting device. According to Article 5.1.1 of GB / T37898-2019 (Safety Technical Regulations for Wind Turbine Hoisting), the load factor of the hoisting machinery should be less than 90%. Calculate the crane's required rated capacity and operating conditions.

[0029] Q 总 =Q 叶 +Q 钩 +Q 具 (Formula: 5-1) Where: Q 总 -Total weight being lifted Q 叶 —The weight of the lifted blade Q 钩 —Hook weight Q 具 —Weight of sling Q 额 =KQ 总 / P (Formula: 5-2) Where: Q 额 —Rated weight of main crane under specific working conditions K—dynamic load coefficient Q 总 -Total weight being lifted P—maximum load rate of the lifting machinery when lifting alone According to the above formula, the total weight Q to be lifted can be calculated 总 And the rated weight of the main crane under specific working conditions Q 额 Minimum value. The performance table shows the maximum lifting radius R that meets lifting requirements, given a certain main boom length, ballast weight, and additional counterweight. Using the crane diagram example and on-site measurements, adjust the main crane position on the diagram to meet the lifting requirements under the given conditions. While ensuring the main crane is safely away from the slope, adjust the distance between the main crane and the blade vehicle. When the adjusted distance between the main crane and the blade lifting position r is less than the maximum lifting radius R, lifting can begin.

[0030] (2) Main crane position adjustment After replanning the main crane's position, organize a bearing capacity test for that location. The tested foundation bearing capacity should not be lower than the required calculated data. If the bearing capacity test does not meet the requirements, re-pressurization and re-inspection should be carried out. At the same time, the ground that meets the bearing capacity and inclination requirements should be marked. The inclination of the slewing bearing mounting surface should not exceed 1% to prevent the crane from exceeding the range during pre-lift adjustments. The main crane position should be a safe distance away from the edge.

[0031] (3) Preparation of single blade spreader The spreader is transported to the lifting platform via a flatbed truck and assembled under the manufacturer's guidance. The single-blade spreader consists of two hydraulic systems, remotely controlled for gripping the blades. A diesel generator and backup power supply are installed on the spreader to power the system. The assembled spreader is then placed on a dedicated bracket for standby use.

[0032] (4) Blade grabbing, lifting and steering Once the blade truck is in place, according to the pre-planned position, the main crane lifts the single blade and grabs it. The hydraulic arm of the tooling presses the blade tightly and slowly lifts it. Once the lifting force equals the weight of the blade and tooling, the bolts securing the blade to the vehicle are loosened, the blade is removed from the transport vehicle, and then slowly lifted. Once the blade is lifted to 2 meters above the platform elevation, the main boom rotates and simultaneously raises the arm, lifting the blade above the wind turbine platform. Four sets of guy ropes adjust the blade's direction, ensuring precise alignment and installation after lifting.

[0033] (5) Blade installation First, define the blade installation angle. The horizontal position perpendicular to the tower is defined as the 0° position, the counterclockwise upward position from the 0° position is defined as the + angle position, and the clockwise downward position from the 0° position is defined as the - angle position.

[0034] Use a single blade hanger to clamp the blade (select the corresponding single blade hanger to clamp the blade). The single blade hanger clamps the blade with the following posture and clamping position requirements: the blade PS side is facing up, and the mold seam is horizontal, rotate clockwise 2.5 bolt hole positions (9.375 degrees), such as Figure 4 shown.

[0035] The blades rise slowly, and the main hoist and cable wind system are operated to move the blades to the vicinity of the installation position. During the process, the cable wind ropes are strictly controlled to prevent the blades from colliding.

[0036] After the blades are properly aligned with the pitch bearing, all nuts are installed. The auxiliary wooden planks are then removed and all bolts are manually tightened to 250 N·m using an open-end wrench. The 12 blade root bolts facing the process holes are now tensioned to 470 kN. The single-blade hoist allows for ±5° rotation of the blade about the X-axis. The single-blade hoist and the pitch drive are then controlled to simultaneously rotate the pitch bearing 3.75° in the same direction. At this point, the 12 blade root bolts facing the process holes are tensioned to 470 kN. The three blade fixture bolts are then removed through the process holes, and the three blade root bolts are reinstalled (with the exposed length of the bolts and other bolts being 83-85 mm). The bolts are then tensioned to 470 kN. Once these conditions are met, the single-blade hoist is unhooked, and the wind turbine is hoisted.

[0037] The present invention was experimented with during the wind turbine hoisting construction of the Baimashan Wind Farm Project, a wind-solar-storage integrated project in Pinglu, Qinzhou, Guangxi, undertaken by the 11th China Water Resources and Hydropower Engineering Bureau Co., Ltd.

[0038] The project is located in Guangxi Zhuang Autonomous Region, where the terrain is complex, the mountain drop is large, and the transportation of blades is difficult. The present invention introduces a single-blade lifting tool to directly grab the blades for high-altitude blade installation. Some blades that cannot reach the machine platform can be directly lifted on the transport vehicle under the platform, reducing the requirements for the construction platform for wind turbine lifting. Especially for complex mountain wind farms, it can effectively reduce the demand for land acquisition and reduce the damage to vegetation and mountains. At the same time, compared with the wind rotor lifting, the windward area of the single-blade lifting is reduced, and the impact of wind load on the lifting is reduced, which can significantly increase the blade lifting speed. In combination with the wind rope, the lifting wind speed is increased from 6m / s to 8m / s, which significantly extends the operation window period and improves the project progress.

[0039] Finally, it should be noted that: The above describes in detail the preferred embodiments of this patent, but this patent is not limited to the above embodiments. Various changes can be made within the scope of knowledge possessed by ordinary technicians in this field without departing from the purpose of this patent.

Claims

1. A high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm, characterized by: The following steps are involved: Step 1) Main crane position confirmation: Based on the relative position of the mountain access road and the mountaintop platform, the main crane position is recalculated on the mountaintop platform so that the main crane's lifting radius can cover part of the mountain access road; Step 2) Foundation adjustment in the main crane area: After determining the main crane position, re-press and re-check the foundation based on the site's bearing capacity test results. At the same time, check that the inclination of the slewing support installation plane is within a safe range. Step 3) Single blade lifting preparation: Move the lifting device to the determined location and assemble it. The single blade lifting device uses two sets of hydraulically driven clamp-type single blade lifting tooling; Step 4) Grab the blade: The blade vehicle transfers the blade to the predetermined position on the uphill road. The main crane is controlled to move the clamp-type single-blade lifting tooling to above the predetermined position. The two clamp-type single-blade lifting tools clamp the two lifting positions of the blade and slowly lift it. When the lifting force equals the deadweight of the blade and the tooling, the fixing bolts between the blade and the vehicle are loosened to separate the blade. After slowly lifting it to a set height above the elevation of the mountaintop platform, the main boom is rotated and raised simultaneously to lift the blade above the wind turbine platform. The direction of the blade is synchronously adjusted using the guy rope. Step 5) Blade installation: Determine the blade installation angle, control the blade posture, align the blade with the pitch bearing, and then install the blade.

2. The high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm according to claim 1 is characterized in that: In step 1), when recalculating the main crane position, it is necessary to calculate the total weight to be lifted Qtotal and the minimum rated weight Qrated of the main crane under specific working conditions. According to the main crane performance table, the maximum lifting radius R that meets the lifting requirements is determined when the main boom length, body counterweight and additional counterweight are constant. While ensuring the safety of the main crane from the slope, the position of the main crane and the distance between the blade vehicle on the uphill road are adjusted. The distance between the main crane and the blade vehicle after adjustment is r. At this time, the operating radius r of the main crane is less than the maximum lifting radius R, and lifting can be carried out.

3. The high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm according to claim 2 is characterized in that: In step 1), the process of calculating the minimum value of the total weight to be hoisted Qtotal and the rated weight of the main crane under specific working conditions Qrated is as follows: Q 总 =Q 叶 +Q 钩 +Q 具 Where: Q 总 -Total weight being lifted Q 叶 —The weight of the lifted blade Q 钩 —Hook weight Q 具 —Weight of sling Q 额 =KQ 总 / P Where: Q 额 —Rated weight of main crane under specific working conditions K—dynamic load coefficient Q 总 -Total weight being lifted P—The maximum load rate of the lifting machinery when lifting alone.

4. The high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm according to claim 3 is characterized by: In step 2), the inclination of the slewing bearing installation plane shall not exceed 1%.

5. The high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm according to claim 4 is characterized in that: In step 3), a diesel generator and a backup power supply are integrated on the spreader to provide clamping power.

6. The high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm according to claim 5 is characterized in that: In step 5), the process of determining the blade installation angle is as follows: The horizontal position perpendicular to the tower is defined as the 0° position, the counterclockwise upward position from the 0° position is defined as the + angle position, and the clockwise downward position from the 0 degree position is defined as the - angle position. The posture and clamping position requirements of the single-blade hoist for clamping the blade are as follows: the PS side of the blade faces upward, and the mold seam is rotated clockwise by 2.5 bolt holes in a horizontal posture.

7. The high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm according to claim 6 is characterized in that: In step 5), the process of installing the blades is as follows: After the blades are correctly docked with the pitch bearings, install all nuts, then remove the auxiliary wooden planks and tighten all bolts manually with an open-end wrench. At this time, the 12 blade root bolts facing the process holes are stretched to the required pressure value, and the single-blade hoist is used to realize the function of rotating the blades around the X-axis by ±5°. Then, by controlling the single-blade hoist and the pitch drive, the pitch bearings are rotated 3.75° in the same direction at the same time. At this time, the 12 blade root bolts facing the process holes are stretched to the required pressure value. Then, the blade tooling bolts are removed through the process holes, the blade root bolts are reinstalled, and the bolts are stretched to the required pressure value. After the above conditions are met, the single-blade hoist is unhooked, and the installation of this wind turbine is completed.

8. The high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm according to claim 1 is characterized in that: The height of the blade vehicle set on the uphill road is lower than the height of the mountain top platform.

9. The high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm according to claim 1 is characterized by: The road up the mountain is a winding road.

10. The high-drop ultra-long-distance grabbing and hoisting construction method for a single blade in a high-mountain wind farm according to claim 7 is characterized in that: The required pressure value is 470kN.

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