A grouting system for large jacket grouting operations

Abstract

The application discloses a grout mixing system for large jacket grouting operation, which comprises a water tank, a mixing tank, a cement tank, a mixed grout pump, a mud tank and a grouting pump arranged on a deck of a ship. A first pipeline is connected between the water tank and the mixing tank, a second pipeline is connected between the mixing tank and the cement tank, the second pipeline is connected with an inlet of the mixed grout pump through a third pipeline, and an outlet of the mixed grout pump is connected with the mixing tank through a fourth pipeline, so that water and cement in the water tank and the cement tank are transported into the mixing tank for mixing. The mixing tank transports cement into the mud tank through the mixed grout pump, and the mud tank is connected with the grouting pump, so that the grouting pump can pour cement into an annular space between a jacket and a steel pipe pile. The grout mixing system for large jacket grouting operation provided by the application can reduce the overall height of grout mixing operation and improve the jacket grouting efficiency by dispersively arranging the water tank, the mixing tank, the cement tank, the mixed grout pump, the mud tank and the grouting pump on the deck.

Description

Technical Field

[0001] This invention belongs to the field of marine oil engineering technology, and in particular relates to a grouting system for large jacket grouting operations. Background Technology

[0002] In the offshore oil and gas industry, after the large jacket foundation is completed and the piles are driven, grouting is needed to fill the annular space between the jacket foundation skirt sleeve and the steel pipe pile, so that the jacket foundation can effectively transfer the upper load it bears to the seabed foundation through the steel pipe pile.

[0003] Currently, integrated grouting equipment, with dimensions of 14.5m x 4.5m x 12m, is commonly used in domestic offshore oil and gas projects. Due to its large size, it can only be used on large crane vessels or on land. All functional components of the integrated grouting equipment are concentrated in one unit. With the increasing grouting volume of large jacket structures (the total grouting volume of extra-large jacket structures exceeds 700m³), existing grouting technologies are no longer sufficient, especially in the grout preparation stage. Problems include: (1) The cement cargo capacity of the supply ship is only 200 tons, which cannot meet the grouting needs of large jacket foundations (the cement design for ultra-large jacket foundations exceeds 1,000 tons). Sometimes it is necessary to transport cement back and forth to the land separately, which wastes a lot of fuel and money. (2) The cement is conveyed from the cement tank of the supply ship to the top inlet of the ash tank. The vertical distance exceeds 20 meters, and the excessive head limits the cement conveying speed. (3) The amount of slurry prepared each time is only 1m³ and the mixing time each time is 2 minutes, resulting in the slurry production capacity of the existing equipment being less than 30m³ / hour, and the phenomenon of the mixing pump waiting for slurry often occurs. (4) For every 1m³ of mud produced, the construction workers need to switch on and off 6 buttons once and accurately measure the weight of water and cement required for mud preparation, which results in high labor intensity for the workers. (5) During the slurry preparation process, the operation steps of adding water first and then cement must be strictly followed, otherwise the slurry will not be mixed sufficiently or even block the mixer. (6) The grouting equipment is 12m high and occupies 65 square meters per unit. Grouting operations can only be carried out on large construction vessels with wide and stable decks. (7) The piston-type slurry pump has large vibration and noise, and the reciprocating motion is prone to pulses, requiring frequent replacement of piston seals; (8) Pulping operations are carried out in a relatively enclosed space, which restricts the volatilization of dust and the flow of heat, causing harm to the health of construction workers; (9) The limited space for operation and maintenance leads to incomplete cleaning of the mixer and agitator.

[0004] Therefore, there is an urgent need to design a grouting system for large-scale jacket grouting operations to solve the problems mentioned above. Summary of the Invention

[0005] To address the technical problems mentioned in the background art, such as low grouting efficiency of existing integrated grouting equipment, high labor intensity of construction personnel, and the need for large vessels to assist in grouting operations, a grouting system for large jacket grouting operations is provided to solve the urgent problems that need to be addressed in the current deep-water jacket installation.

[0006] To achieve the above objectives, the specific technical solution of the grouting system for large-scale jacket grouting operations of the present invention is as follows: A grouting system for large jacket grouting operations includes a water tank, a mixing tank, a mortar tank, a grout pump, a mud tank, and a grouting pump, all installed on the deck of a ship. A first pipe connects the water tank and the mixing tank, a second pipe connects the mixing tank and the ash tank, the second pipe connects to the inlet of the slurry pump via a third pipe, and the outlet of the slurry pump connects to the mixing tank via a fourth pipe, so that the water and cement ash in the water tank and the ash tank are transported to the mixing tank for mixing. The mixing tank delivers cement to the mud tank via a mixing pump. The mud tank is connected to a grouting pump so that the grouting pump can inject cement into the annular space between the guide frame and the steel pipe pile.

[0007] Furthermore, a first valve is provided on the first pipeline. Opening the first valve allows water from the water tank to be injected into the mixing tank.

[0008] Furthermore, a second valve and a fifth valve are installed at intervals on the second pipeline, a third valve is installed on the third pipeline, and a fourth valve is installed on the fourth pipeline. Opening the second valve, the third valve, and the fourth valve starts the mixing pump and begins mixing the liquid in the tank.

[0009] Furthermore, the third pipe is located between the second and fifth valves. Opening the fifth valve allows the cement ash in the ash hopper to enter the mixing tank along with the water flow through the mixing pump for continuous mixing.

[0010] Furthermore, a level gauge is installed inside the mixing tank. When the level gauge detects that the mud level in the mixing tank reaches a preset position, it controls the fifth valve to close.

[0011] Furthermore, the mixing pump and the mud tank are connected by a fifth pipe, which is equipped with a sixth valve. The fourth valve is closed and the sixth valve is opened so that the mixing pump can transport mud from the mixing tank to the mud tank.

[0012] Furthermore, the mud tank is connected to the grouting pump inlet via a sixth pipe, so that the mud is injected into the annular space between the jacket pile sleeve and the steel pipe pile through the grouting pump outlet.

[0013] Furthermore, a seventh valve is provided on the sixth pipeline, and an eighth valve is provided at the outlet of the grouting pump. The sixth valve is closed, and the seventh and eighth valves are opened so that the grouting pump discharges the mud in the mud tank along the outlet of the grouting pump.

[0014] Furthermore, the first, second, third, fourth, fifth, sixth, seventh, and eighth valves are all electrically connected to the central control module, enabling the central control module to remotely control the valves to open or close.

[0015] The grouting system for large-scale guide frame grouting operations of the present invention has the following advantages: By distributing water tanks, mixing tanks, ash tanks, slurry pumps, mud tanks, and grouting pumps on the deck, the overall height of the slurry preparation operation is reduced, allowing it to be carried out on small vessels. Furthermore, by storing raw materials in water and ash tanks and preparing the slurry on-site, multiple mud transports during grouting operations are avoided, reducing the transportation costs of the work vessel. Slurry preparation and grouting can be achieved by remotely controlling the opening and closing of valves, eliminating the need for construction personnel to travel back and forth. This application, by changing the slurry preparation method, improves the efficiency of jacket grouting, eliminates the reliance on large floating cranes for grouting operations, and reduces the labor intensity of workers. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the grouting system for large-scale guide frame grouting operations according to the present invention.

[0017] Explanation of markings in the diagram: 1. Water tank; 2. Mixing tank; 3. Ash tank; 4. Slurry pump; 5. Mud tank; 6. Grouting pump; 7. Guide frame; 8. First pipe; 9. Second pipe; 10. Third pipe; 11. Fourth pipe; 12. Fifth pipe; 13. Sixth pipe; 14. First valve; 15. Second valve; 16. Third valve; 17. Fourth valve; 18. Fifth valve; 19. Sixth valve; 20. Seventh valve; 21. Eighth valve. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of the invention and form different embodiments. For example, in the claims, any of the claimed embodiments can be used in any combination.

[0020] The following is a reference to the appendix. Figure 1 This invention describes a grouting system for large-scale jacket grouting operations.

[0021] like Figure 1 As shown, the grouting system for large-scale jacket grouting operations in this invention includes a water tank 1, a mixing tank 2, a cement hopper 3, a grout pump 4, a mud hopper 5, and a grouting pump 6, all installed on the ship's deck. A first pipe 8 connects the water tank 1 and the mixing tank 2, and a second pipe 9 connects the mixing tank 2 and the cement hopper 3. The second pipe 9 is connected to the inlet of the mixing pump 4 via a third pipe 10, and the outlet of the mixing pump 4 is connected to the mixing tank 2 via a fourth pipe 11, so that water and cement ash in the water tank 1 and the cement hopper 3 are transported to the mixing tank 2 for mixing. The mixing tank 2 transports cement to the mud hopper 5 via the mixing pump 4, and the mud hopper 5 is connected to the grouting pump 6, so that the grouting pump 6 injects cement into the annular space between the jacket 7 and the steel pipe pile.

[0022] By distributing water tank 1, mixing tank 2, ash tank 3, slurry pump 4, mud tank 5, and grouting pump 6 on the deck, the overall height of the slurry preparation operation is reduced, allowing the operation to be carried out on small vessels. Furthermore, by storing raw materials in water tank 1 and ash tank 3 and preparing slurry on-site, multiple mud transportations during grouting operations are avoided, reducing the transportation costs of the work vessel. Slurry preparation and grouting can be achieved by remotely controlling the valves to open or close, eliminating the need for construction personnel to travel back and forth.

[0023] Furthermore, such as Figure 1 As shown, the first pipe 8 is equipped with a first valve 14. Opening the first valve 14 allows water in the water tank 1 to be injected into the mixing tank 2. The second pipe 9 is equipped with a second valve 15 and a fifth valve 18 spaced apart. The third pipe 10 is equipped with a third valve 16. The fourth pipe 11 is equipped with a fourth valve 17. Opening the second valve 15, the third valve 16, and the fourth valve 17 starts the mixing pump 4 and begins mixing the liquid in the mixing tank.

[0024] The third pipe 10 is located between the second valve 15 and the fifth valve 18. The fifth valve 18 is opened so that the cement ash in the ash tank 3 can enter the mixing tank 2 along with the water flow through the mixing pump 4 for continuous mixing. The mixing tank 2 is equipped with a level gauge. When the level gauge detects that the mud level in the mixing tank 2 reaches the preset position, it controls the fifth valve 18 to close.

[0025] In this embodiment, preferably, all cement is stored on-site in mobile ash tanks 3 to avoid the need for supply ships to return to land to replenish cement; the grouting equipment adopts a split skid design, and each functional unit can be flexibly arranged on the ship's deck, reducing the occupancy rate of deck space; compressed air is used to replace the screw device to transport bulk cement, which significantly reduces the equipment height, reduces the requirements for the stability of the construction ship and deck space, and enables grouting operations to be carried out on small auxiliary vessels.

[0026] In a preferred embodiment, a first valve 14 is provided on the first pipeline 8. Opening or closing the first valve 14 can control the amount of water injected from the water tank 1 into the mixing tank 2, thereby controlling the amount of slurry mixed in the mixing tank 2.

[0027] A second valve 15 and a fifth valve 18 are connected at intervals on the second pipe 9. A third pipe 10 is connected between the second valve 15 and the fifth valve 18 on the second pipe 9. The third pipe 10 is connected to the second pipe 9. The mixing pump 4 is connected between the second pipe 9 and the mixing tank 2 through the third pipe 10 and the fourth pipe 11. When the second valve 15, the third valve 16 and the fourth valve 17 are opened and the fifth valve 18 is closed, the mixing pump 4 is started, and the liquid in the mixing tank 2 can be stirred.

[0028] Furthermore, such as Figure 1 As shown, the mixing pump 4 and the mud tank 5 are connected by a fifth pipe 12. The fifth pipe 12 is equipped with a sixth valve 19. The fourth valve 17 is closed and the sixth valve 19 is opened so that the mixing pump 4 can transport mud from the mixing tank 2 to the mud tank 5. The mud tank 5 is connected to the inlet of the grouting pump 6 by a sixth pipe 13 so that the mud can be injected into the annular space between the skirt pile sleeve and the steel pipe pile of the guide frame 7 through the outlet of the grouting pump 6.

[0029] The sixth pipeline 13 is equipped with a seventh valve 20, and the outlet of the grouting pump 6 is equipped with an eighth valve 21. The sixth valve 19 is closed, and the seventh valve 20 and the eighth valve 21 are opened so that the grouting pump 6 can discharge the mud in the mud tank 5 along the outlet of the grouting pump 6. The first valve 14, the second valve 15, the third valve 16, the fourth valve 17, the fifth valve 18, the sixth valve 19, the seventh valve 20 and the eighth valve 21 are all electrically connected to the central control module so that the central control module can remotely control the opening or closing of the valves.

[0030] In this embodiment, preferably, the mixing pump 4 and the mud tank 5 are spaced apart and connected by a fifth pipe 12. A sixth valve 19 is provided on the fifth pipe 12. When the fourth valve 17 is closed, the sixth valve 19 is opened, allowing the mixing pump 4 to transport mud from the mixing tank 2 to the mud tank 5. The use of a large-volume mixing tank 2 and mud tank 5 significantly increases the amount of mud prepared per batch. A mud density monitor is installed in the mixing tank 2 to monitor whether the cement density meets the required concentration. If the concentration is insufficient, water or ash can be added to the mixing tank 2. When the concentration reaches the required standard, the mud can be transported to the mud tank 5.

[0031] The mud tank 5 is connected to the inlet of the grouting pump 6 via a sixth pipe 13. A seventh valve 20 is installed on the sixth pipe 13, and an eighth valve 21 is installed at the outlet of the grouting pump 6. When the sixth valve 19 is closed and the seventh valve 20 and the eighth valve 21 are opened, the mud is injected through the outlet of the grouting pump 6 into the annular space between the skirt pile sleeve and the steel pipe pile of the guide frame 7. In a preferred embodiment, a screw-type grouting pump 4 is used instead of a plunger-type grouting pump, which is superior to the existing plunger-type grouting pump in terms of suction performance, operating noise and vibration, and maintenance costs.

[0032] Preferably, the first valve 14, the second valve 15, the third valve 16, the fourth valve 17, the fifth valve 18, the sixth valve 19, the seventh valve 20, and the eighth valve 21 are all electrically connected to the central control module. The central control module controls the valves to open or close, enabling remote control.

[0033] The working principle of the grouting system for large-scale guide frame grouting operations in this invention is as follows: First, all the cement used for construction is stored in several cement hoppers 3 and transported to the work site to be connected to the second pipeline 9. At this time, the fifth valve 18 is closed. Then, open the first valve 14 and inject the water required for preparing the mud into the mixing tank 2. When the liquid level gauge in the mixing tank 2 detects that the liquid level reaches 0.8m, the first valve 14 automatically closes, the second valve 15, the third valve 16 and the fourth valve 17 are opened, and the centrifugal mixing pump 4 is started to circulate the liquid in the mixing tank 2. Among them: the mixing tank (6m x 2.4m x 2.6m, maximum capacity 30m³) can prepare 20m³ of mud and requires 11.6 tons of water; Then, the fifth valve 18 is opened, and compressed air is used to blow the prepared cement ash from the ash tank 2 to the suction port of the mixing pump 4, and it enters the mixing tank 2 along with the water flow for continuous mixing. When the level gauge detects that the mud level in the tank has risen to 1.4m, the fifth valve 18 is automatically closed, and 20m³ of mud has been formed in the mixing tank 2 at this time. Of which: 25.8 tons of cement ash are required; Then, measure whether the density of the mud reaches 1.86 g / cm³, and add water or cement as needed; Then, the fourth valve 17 is closed and the sixth valve 19 is opened, and the slurry is transported from the mixing tank 2 to the slurry tank 5 by the mixing pump 4; Then, close the sixth valve 19 and open the seventh valve 20 and the eighth valve 21. The screw grouting pump 6 injects the mud from the mud tank 5 into the guide frame 7, and at the same time, the subsequent mud preparation operation is carried out. Then, repeat the above procedure. If the cement in ash hopper 3 is insufficient, replace it with another ash hopper 3 to continue conveying cement. Finally, when the total discharge of the grouting pump reaches the design requirements, the grouting of this pile leg is completed, and the grouting operation of the other pile legs of the guide frame 7 is carried out.

[0034] Based on the grouting system for large jacket grouting operations, this invention improves the efficiency of jacket grouting by changing the grouting method, eliminates the dependence on large floating cranes for grouting operations, reduces the labor intensity of workers, and provides an open working space that facilitates slurry heat dissipation and tank cleaning.

[0035] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A grouting system for large-scale jacket grouting operations, characterized in that, This includes water tanks, mixing tanks, ash tanks, slurry pumps, mud tanks, and grouting pumps installed on the ship's deck; A first pipe connects the water tank and the mixing tank, a second pipe connects the mixing tank and the ash tank, the second pipe connects to the inlet of the slurry pump via a third pipe, and the outlet of the slurry pump connects to the mixing tank via a fourth pipe, so that the water and cement ash in the water tank and the ash tank are transported to the mixing tank for mixing. The mixing tank delivers cement to the mud tank via a mixing pump. The mud tank is connected to a grouting pump so that the grouting pump can inject cement into the annular space between the guide frame and the steel pipe pile. A first valve is installed on the first pipeline. Opening the first valve allows water from the water tank to be injected into the mixing tank. The second pipeline is equipped with a second valve and a fifth valve at intervals, the third pipeline is equipped with a third valve, and the fourth pipeline is equipped with a fourth valve. Open the second valve, the third valve, and the fourth valve to start the mixing pump and begin mixing the liquid in the tank. The mixing pump and the mud tank are connected by a fifth pipe. The fifth pipe is equipped with a sixth valve. The fourth valve is closed and the sixth valve is opened so that the mixing pump can transport mud from the mixing tank to the mud tank. The third pipe is located between the second valve and the fifth valve. Open the fifth valve so that the cement ash in the ash hopper can enter the mixing tank along with the water flow through the slurry pump for continuous mixing. The sixth pipeline is equipped with a seventh valve, and the grouting pump outlet is equipped with an eighth valve. The sixth valve is closed, and the seventh and eighth valves are opened so that the grouting pump can discharge the mud in the mud tank along the grouting pump outlet.

2. The grouting system for large-scale jacket grouting operations according to claim 1, characterized in that, The mixing tank is equipped with a level gauge. When the level gauge detects that the mud level in the mixing tank reaches a preset position, it controls the fifth valve to close.

3. The grouting system for large-scale jacket grouting operations according to claim 1, characterized in that, The mud tank is connected to the grouting pump inlet via a sixth pipe, so that the mud can be injected into the annular space between the jacket pile sleeve and the steel pipe pile through the grouting pump outlet.

4. The grouting system for large-scale jacket grouting operations according to claim 1, characterized in that, The first, second, third, fourth, fifth, sixth, seventh, and eighth valves are all electrically connected to the central control module, enabling the central control module to remotely control the opening or closing of the valves.

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