Bulk carrier main deck piping unitized layout structure and installation method

Abstract

The application discloses a bulk carrier main deck pipeline unitized layout structure and a mounting method, and aims to solve the problems of low installation efficiency, disordered layout and inconvenient maintenance of a traditional bulk carrier main deck pipeline. The layout structure comprises longitudinal and transverse modules. The longitudinal modules are arranged along the longitudinal direction of the main deck portside hatch coaming. The integrated function and hydraulic main pipeline are arranged below the large-diameter function pipeline, and the hydraulic pipeline is arranged below the large-diameter function pipeline. The head and tail of the multiple modules are connected to form a longitudinal pipeline penetrating the bow and the stern. The transverse modules are arranged in the front and rear areas of the hatch coaming. The main deck is provided with a pipeline integrated support to realize layered fixation of the pipeline. During installation, the pipeline unit is prefabricated in the workshop, and then is installed on site in the order from back to front. There is no joint pipeline between the units. The upper and lower broken pipelines are staggered, and the flange broken pipelines are aligned. The scheme greatly improves the pipeline unitization rate, reduces the on-site operation amount, improves the installation efficiency, and has good popularization value.

Description

Technical Field

[0001] This invention relates to the field of marine pipeline design and installation technology, specifically to a modular layout structure and installation method for the main deck pipeline of a bulk carrier. Background Technology

[0002] In the field of main deck piping design and construction for bulk carriers, the traditional piping layout and installation model has long followed a decentralized design approach. Various functional pipelines and hydraulic pipelines lack systematic integrated planning. Firefighting pipes, compressed air pipes, water supply pipes, cable pipes, and various hydraulic main pipelines are scattered across different areas of the main deck according to the local structural requirements of the hull, without unified layout specifications or unitized design standards. In existing technologies, the layout of main deck piping is not specifically planned in conjunction with the inherent structure of the hull, such as hatch coamings. Pipelines in key areas such as the port side and fore and aft of the hatch coamings are randomly arranged, with different diameters and functions of pipelines interspersed. Not only is effective protective layout design not adopted for hydraulic main pipelines with smaller diameters and higher protection requirements, but various pipelines are also indiscriminately placed in open areas, ignoring the usage characteristics and environmental adaptability of different pipelines. Meanwhile, in traditional processes, pipeline assembly is mostly completed on-site, with only a small number of individual pipe fittings being prefabricated. Standardized pipeline units are not formed, and a large amount of scattered cutting, splicing, and fixing work is required on-site. Furthermore, when connecting adjacent pipelines, merging pipes are generally installed, the installation sequence is not clearly defined, flange breaks lack a unified alignment standard, and the combination of pipelines and supporting components is not integrated.

[0003] The inherent flaws of these existing technologies stem from the failure to integrate pipeline layout with the industrialized and standardized requirements of shipbuilding during the design phase. They focus solely on the flow-through function of the pipelines, neglecting the impact of layout design on installation efficiency, subsequent maintenance, and pipeline lifespan. Furthermore, the lack of standardized prefabrication and installation processes matching the design during construction leads to a disconnect between design and construction. From a structural design perspective, the decentralized pipeline layout fails to utilize the inherent protective and integrated advantages of the hull structure, leaving critical pipelines such as hydraulic mains directly exposed to the external environment. This makes them susceptible to damage from impacts, rain, and other factors, reducing the overall lifespan of the pipeline system. From a construction perspective, the fragmented on-site assembly method is significantly affected by the construction site, weather conditions, and the skill level of the operators. This not only makes it difficult to guarantee the accuracy of pipeline installation but also significantly increases on-site workload and prolongs the overall shipbuilding production cycle. Furthermore, the irregular piping layout, extensive use of merging pipes, and improper handling of broken flanges have resulted in a chaotic main deck piping arrangement. This not only affects the ship's appearance but also greatly inconveniences subsequent pipe inspection, maintenance, and disassembly, increasing maintenance costs during the ship's operational phase. Additionally, the fragmented installation method can lead to poor sealing of pipe connections, posing certain safety hazards. Currently, this type of design and construction model is no longer suitable for the efficient and standardized construction requirements of large bulk carriers, becoming a significant factor restricting the improvement of main deck construction efficiency and the optimization of piping system reliability.

[0004] For the reasons mentioned above, it is necessary to propose a modular layout structure for the main deck piping of bulk carriers to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to overcome the defects in the prior art and provide a modular layout structure for the main deck piping of a bulk carrier.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows: A modular layout structure for main deck piping of a bulk carrier is used for piping installation on the main deck of a bulk carrier. It includes functional piping, hydraulic main piping and cable transition boxes. The modular layout structure includes longitudinal modules and transverse modules. The longitudinal module is arranged along one longitudinal side of the main deck of the bulk carrier and on the side of the hatch coaming. The longitudinal module includes functional pipelines and hydraulic pipelines, and the main hydraulic pipeline is located below the large-diameter functional pipeline. The cable conduit, winch hydraulic pipe, compressed air pipe, and fire-fighting pipe are centrally arranged in the area before and after the hatch coaming on the main deck of the bulk carrier, forming a transverse module. The hatch cover hydraulic pipe is arranged inside the hatch coaming.

[0007] Furthermore, the main deck is provided with a pipe integrated support structure, which includes a truss and legs. The truss is arranged horizontally in at least one layer, and the legs are vertically fixed to the bottom of the truss. The bottom of the legs is fixedly connected to the main deck. The truss divides the structure into upper and lower pipe arrangement layers.

[0008] Furthermore, the upper pipeline arrangement layer arranges functional pipelines sequentially, and the lower pipeline arrangement layer arranges hydraulic main pipelines sequentially; the functional pipelines are fixed to the upper side of the truss by U-shaped pipe clamps in a supporting manner, and the hydraulic main pipelines are fixed to the lower side of the truss by clamping and positioning frames in a hoisting manner.

[0009] Furthermore, several of the longitudinal modules are connected end to end to form a longitudinal pipeline connecting the bow and stern of the ship.

[0010] Furthermore, the functional pipelines include fire-fighting pipelines, compressed air pipelines, water supply pipelines, and cable pipelines; the main hydraulic pipelines include the anchor winch hydraulic main pipeline and the hatch cover hydraulic main pipeline.

[0011] Furthermore, the longitudinal pipeline is located at the port hatch coaming, and the longitudinal pipeline includes several main longitudinal modules connected end to end, each longitudinal module having a length of 12±5m.

[0012] Furthermore, a cable transition box is installed on the cable conduit, and a T-shaped branch is formed through the cable transition box to connect to the cable conduit of the horizontal module.

[0013] A method for modular installation of piping on the main deck of a bulk carrier, comprising the aforementioned modular layout structure, characterized by the following steps: S1. Assemble the pipelines in each area in the workshop according to the layout and structural requirements to form the corresponding pipeline units; S2. Transport the assembled piping units to the main deck installation site of the bulk carrier and install each piping unit on site in reverse order. S3. During installation, no connecting pipe is installed between adjacent pipe units. Instead, adjacent pipe units are disconnected by staggering their vertical positions. S4. After disconnecting the pipe, align the ends of the flange disconnected pipes inside the pipe unit and between adjacent pipe units to complete the centralized installation of the pipe unit.

[0014] The advantages and beneficial effects of this invention are as follows: 1. The system is divided into longitudinal and transverse modules. The longitudinal modules are arranged along the port hatch coaming and achieve bow-stern connection. The transverse modules are adapted to the layout of the areas fore and aft of the hatch coaming. At the same time, the main hydraulic pipelines are located below the large-diameter functional pipelines to provide effective protection for vulnerable pipelines. The small-diameter hatch cover hydraulic pipelines are arranged separately inside the hatch coaming, taking into account the usage characteristics and installation environment of different pipelines. The pipelines are arranged in an orderly manner and have good protection.

[0015] 2. The pipelines are assembled in a standardized manner in the workshop according to modules. On-site, only unit hoisting and docking are required. At the same time, the unit merging pipes are eliminated, reducing the number of scattered on-site operations. With the standardized installation sequence from back to front, the on-site installation workload is greatly reduced, effectively shortening the ship production cycle.

[0016] 3. The staggered pipe cutting method is adopted, and the flange pipe cutting ends are required to be neatly aligned. This not only improves the installation accuracy and sealing of the pipe connection, but also provides sufficient operating space for later pipe inspection and disassembly, reducing the difficulty of maintenance and management during the ship operation phase. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the cross-sectional structure of the longitudinal module in this invention; Figure 2 This is a top view of a modular layout structure of the main deck piping of a bulk carrier according to the present invention; Figure 3 This is the present invention. Figure 2 Enlarged view of point A in the middle; Figure 4 This is the present invention. Figure 2 Enlarged view of point B in the middle; In the diagram: 1. Main deck; 2. Functional piping; 3. Main hydraulic piping; 4. Cable transition box; 5. Longitudinal module; 6. Lateral module; 7. Integrated support structure; 8. Truss; 9. Outriggers; 10. Piping layout layer; 11. Longitudinal piping; 12. Firefighting piping; 13. Compressed air pipe; 14. Water supply piping; 15. Cable piping; 16. Anchor winch hydraulic main pipe; 17. Hatch cover hydraulic main pipe; 20. U-shaped pipe clamp; 21. Clamping and positioning frame. Detailed Implementation

[0018] The specific embodiments of the present invention will be further described below with reference to examples. These examples are only used to more clearly illustrate the technical solutions of the present invention and should not be construed as limiting the scope of protection of the present invention.

[0019] This technical solution addresses the industry pain points of large workload, low efficiency, and long production cycle in the installation of piping on the main deck of an 88,800-ton bulk carrier. It innovatively designs a modular layout structure of 5 longitudinal modules and 6 transverse modules, and provides a standardized installation method adapted to this structure. The core design concept of workshop prefabrication, modular layout, and on-site installation without closure pipes significantly improves the unitization rate of piping on the main deck, while taking into account the protection of the piping, the convenience of installation, and the maintenance of later. The following will provide a detailed explanation of the overall layout structure design, core component details, structural design principles, and installation methods.

[0020] The modular layout structure of the piping on the main deck 1 of this bulk carrier is mainly used for piping installation on the main deck 1. The entire structure consists of functional piping 2, hydraulic main piping 3, cable transition boxes 4, and integrated pipe support structure 7. Figure 1-4 As shown, the entire deck piping is divided into two major modular structures: longitudinal module 5 and transverse module 6, based on the layout area and functional attributes. This modular, centralized layout replaces the traditional distributed piping arrangement. Simultaneously, the integrated pipe support structure 7 enables layered fixing and precise positioning of the pipes, allowing pipes of different functions and diameters to form an orderly, integrated layout system. Specifically, functional piping 2 includes fire-fighting piping 12, compressed air piping 13, water supply piping 14, and cable piping 15. Hydraulic main piping 3 corresponds to the anchor winch hydraulic main 16 and hatch cover hydraulic main 17 on the main deck 1 of the bulk carrier. These two types of piping, as core components of the layout structure, are arranged in longitudinal module 5 and transverse module 6 respectively, according to functional requirements, pipe diameter, and protection requirements. The cable transition box 4 serves as a core supporting component for cable piping 15, enabling branch connections between longitudinal module 5 and transverse module 6, ensuring the connectivity of the piping system.

[0021] The longitudinal module 5 is a long, strip-shaped integrated pipeline unit arranged along one longitudinal side of the main deck 1 of the bulk carrier. In this embodiment, it is specifically located on the port side of the hatch coaming of the main deck 1. This module integrates both functional pipelines 2 and hydraulic main pipelines 3, serving as the core pipeline channel connecting the bow and stern of the ship. Several longitudinal modules 5 can be connected end-to-end to form a complete longitudinal pipeline 11 running through the bow and stern of the ship, creating an integrated channel for the longitudinal pipelines of the main deck 1. To accommodate the needs of prefabrication in the workshop and on-site installation, the length of a single main pipeline longitudinal module 5 unit constituting the longitudinal pipeline 11 is designed to be 12±5m. Figure 2 As shown, it includes 16 sets of longitudinal modules 5 connected end to end. The black lines on the longitudinal pipe 11 in the figure indicate the connection points between the longitudinal modules 5. A magnified view of the specific connection points is shown below. Figure 4 As shown, this design ensures both standardization and convenience in workshop assembly while adapting to the longitudinal dimensions of different bulk carrier main decks 1, exhibiting good versatility. In the internal layout of the longitudinal module 5, following the design principle of large pipes protecting small pipes and functional layering, larger diameter fire-fighting pipes 12, cable pipes 15, and other functional pipes 2 are arranged on the upper layer, while the main hydraulic pipe 3 is located below the large diameter functional pipes 2. Figure 1 As shown, the shielding effect of the large-diameter functional pipeline 2 provides natural protection for the hydraulic main pipeline 3, preventing damage to the hydraulic main pipeline 3 from collisions with external objects or direct erosion by rainwater in the open environment, thus extending the service life of the hydraulic main pipeline 3. At the same time, the layered arrangement allows the internal pipelines of the vertical module 5 to be arranged in an orderly manner, avoiding interference between different pipelines.

[0022] The transverse module 6 is a piping integration unit located in the area fore and aft of the hatch coaming on the main deck of the bulk carrier. This module is specifically designed based on the installation environment and piping characteristics around the hatch coaming. Only cable conduits, winch hydraulic pipes, compressed air pipes 13, and fire-fighting pipes are centrally arranged and formed into a unitized structure. However, the hatch cover hydraulic pipes, due to their smaller diameter, are vulnerable to damage from external factors in open areas without the protection of larger diameter pipes. Therefore, they are separately arranged inside the hatch coaming, avoiding the risk of damage from open-air installation and ensuring that the piping layout in the area fore and aft of the hatch coaming is more in line with the site environment, preventing confusion in the unitized layout due to mismatched pipe diameters. The longitudinal module 5 and the transverse module 6 are not independent; they are connected via cable conduits 15. Specifically, a cable transition box 4 is installed on the cable conduit 15 of the longitudinal module 5. Figure 3 As shown, the cable conduit 15 is connected to the transverse module 6 via a T-shaped branch formed by the cable transition box 4, so that the cable conduit 15 forms a complete connection system in the longitudinal and transverse directions, ensuring the signal transmission and power supply stability of the cable conduit 15 throughout the deck. At the same time, the T-shaped branch connection method makes the connection of the longitudinal and transverse modules simpler and reduces the amount of on-site splicing work.

[0023] To achieve stable fixing and layered layout of the longitudinal module 5 and the transverse module 6, this technical solution incorporates a pipe integrated support structure 7 on the main deck 1. This support, as the core load-bearing component of the pipeline, mainly consists of trusses 8 and legs 9. Figure 1 As shown, the support leg 9 is vertically fixed to the bottom of the truss 8, and the bottom of the support leg 9 is fixedly connected to the main deck 1, providing stable support for the entire support structure. The truss 8 is horizontally arranged and has at least one layer. Through the separation effect of the truss 8, two layers of pipeline arrangement 10 are formed on the support, providing a structural basis for the layered layout of the longitudinal module 5. In the connection and fixation of the supports and pipelines, the dual-fixation design principle of support + hoisting is followed. The upper pipeline arrangement layer 10 arranges the functional pipelines 2 in sequence. The functional pipelines 2 are fixed to the upper side of the truss 8 in a support manner by U-shaped pipe clamps 20. The clamping force of the U-shaped pipe clamps 20 stably supports the functional pipelines 2 on the truss 8, which is suitable for the weight and arrangement requirements of the upper large-diameter functional pipelines 2. The lower pipeline arrangement layer 10 arranges the hydraulic main pipelines 3 in sequence. The hydraulic main pipelines 3 are fixed to the lower side of the truss 8 in a hoisting manner by clamping and positioning frames 21. The clamping and positioning frames 21 can achieve precise clamping and positioning of the hydraulic main pipelines 3, so that the lower hydraulic main pipelines 3 remain stable in the hoisting state. At the same time, the combination of support and hoisting fixation methods allows the upper and lower pipelines to be arranged without contact, which not only avoids friction damage between different pipelines, but also makes pipeline inspection and disassembly more convenient.

[0024] The design principles of the above-mentioned modular pipeline layout structure revolve around four core elements: modular prefabrication, integrated layout, protective design, and adaptable installation. First, by dividing the pipelines into longitudinal and transverse modules, the main deck 1 pipelines are disassembled into standardized units that can be prefabricated in the workshop, replacing the traditional scattered assembly mode on site and reducing the amount of on-site installation work from the source. Second, the pipeline integrated support structure 7 realizes the integrated and layered layout of the pipelines, allowing pipelines with different functions and diameters to be arranged in an orderly manner, improving the neatness and aesthetics of the pipeline layout. Third, according to the pipe diameter and protection requirements, a protective layout for large pipes is designed with the larger pipes below the pipes, and separate protection arrangements are made for the small diameter hatch cover hydraulic pipes, taking into account the usage characteristics of different pipelines. Finally, the individual longitudinal module 5 is designed with a standardized size of 12±5m, and a T-shaped branch connection method is adopted to make the layout structure adaptable to the installation environment of the main deck 1 of different bulk carriers, improving the versatility and adaptability of the structure.

[0025] In conjunction with the aforementioned modular pipeline layout structure, this technical solution designs a targeted modular installation method for the main deck 1 pipeline of bulk carriers. This method is fully adaptable to the layout characteristics of longitudinal and transverse modules. The core principle is to follow the work principle of full prefabrication in the workshop, no on-site closure of pipes, and precise installation in sequence, so as to minimize on-site work and improve installation efficiency. The specific installation steps are closely linked and highly consistent with the design principles of the layout structure. First, all piping units are assembled in the workshop. Following the layout requirements of longitudinal module 5 and transverse module 6, the pipes are cut, spliced, fixed, and integrated with the supports within the workshop, forming standardized piping units. This step transfers most of the traditional on-site assembly work to the workshop, utilizing the standardized working environment to improve the assembly accuracy of the piping units and avoid the impact of weather, site conditions, and other factors on on-site operations. After the workshop assembly is completed, all prefabricated piping units are transported to the main deck 1 installation site of the bulk carrier. The piping units are installed on-site in a backward-to-forward sequence, adapting to the construction process of the main deck 1 of the bulk carrier. This avoids interference between piping units due to improper installation sequence and improves the orderliness of on-site installation. In the core stage of on-site installation, this technical solution abandons the traditional merging pipe connection method. Instead of merging pipes between adjacent piping units, a staggered vertical approach is used to disconnect adjacent piping units. Figure 1 , 4 As shown, the vertical spacing is staggered. Figure 1 The pipe ends of the upper pipe arrangement layer 10 and the lower pipe arrangement layer 10 are misaligned and form a shape as shown. Figure 4As shown in the top view, the connection ends of the upper and lower pipeline arrangement layers 10 are staggered at the boundary of the longitudinal module 5. This design reduces the material cost and installation workload of the merging pipe and allows the connection ends of adjacent pipeline units to form a staggered layout, reserving sufficient operating space for later pipeline maintenance and disassembly. After the pipe cutting is completed, the flange pipes of all pipeline units are precisely adjusted to keep the flange pipes inside the pipeline unit and the flange pipe ends between adjacent pipeline units neatly aligned. Then, the pipeline units are centrally fixed and installed through flange connection. The neat alignment of the flange pipes ensures the sealing and stability of the pipeline connection and makes the layout of the pipelines on the entire deck neater, which is convenient for later maintenance and management.

[0026] In this embodiment, taking an 88,800-ton bulk carrier as an example, the longitudinal main pipeline includes 516 longitudinal modules and 15 transverse modules arranged before and after the hatch coaming. No connecting pipes are needed between units; the pipes are staggered vertically according to the installation sequence from back to front. The flange pipes within and between units are neatly arranged, facilitating centralized installation and subsequent maintenance. Combining these measures, the total number of units reaches 31, with 645 pipes per unit, achieving a unitization rate of 53.84%.

[0027] The deck has a total of 1,198 pipes, of which 645 are unit pipes, accounting for 53.84%. This lays the foundation for the unitization rate of the entire ship, effectively improves installation efficiency, shortens the production cycle, and makes the pipes more concentrated and aesthetically pleasing. The layout and installation method of this technical solution form a highly compatible organic whole. The layout provides a standardized operational basis for the installation method, while the installation method fully realizes the design advantages of the layout. The combination of the two not only significantly improves the unitization rate of the piping on the main deck 1 of bulk carriers, making the number of unit pipes account for 53.84% of the total number of pipes on the main deck 1, laying a solid foundation for the unitization rate of piping throughout the ship, but also effectively improves the efficiency of piping installation, significantly shortens the ship production cycle, and makes the piping layout on the main deck 1 more concentrated and aesthetically pleasing, reducing the difficulty of later piping maintenance and management. Its design concept and operation method can also provide a reference for the design and installation of main deck 1 piping of similar bulk carriers, and has good industry promotion value.

[0028] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A modular layout structure for piping on the main deck of a bulk carrier, applied to piping installation on the main deck of a bulk carrier, comprising functional piping, main hydraulic piping, and cable transition boxes, characterized in that, The modular layout structure includes vertical modules and horizontal modules; The longitudinal module is arranged along one longitudinal side of the main deck of the bulk carrier and on the side of the hatch coaming. The longitudinal module includes functional pipelines and hydraulic pipelines, and the main hydraulic pipeline is located below the large-diameter functional pipeline. The cable conduit, winch hydraulic pipe, compressed air pipe, and fire-fighting pipe are centrally arranged in the area before and after the hatch coaming on the main deck of the bulk carrier, forming a transverse module. The hatch cover hydraulic pipe is arranged inside the hatch coaming.

2. The modular layout structure of the main deck piping of a bulk carrier according to claim 1, characterized in that, The main deck is equipped with a pipe integrated support structure, which includes a truss and legs. The truss is arranged horizontally at least once, and the legs are vertically fixed to the bottom of the truss. The bottom of the legs is fixedly connected to the main deck. The truss divides the structure into upper and lower pipe arrangement layers.

3. The modular layout structure of the main deck piping of a bulk carrier according to claim 2, characterized in that, The upper pipeline layer arranges functional pipelines in sequence, and the lower pipeline layer arranges hydraulic main pipelines in sequence; the functional pipelines are fixed to the upper side of the truss by U-shaped pipe clamps in a supporting manner, and the hydraulic main pipelines are fixed to the lower side of the truss by clamping and positioning frames in a hoisting manner.

4. The modular layout structure of the main deck piping of a bulk carrier according to claim 1, characterized in that, Several of the longitudinal modules are connected end to end to form a longitudinal pipeline connecting the bow and stern of the ship.

5. The modular layout structure of the main deck piping of a bulk carrier according to claim 1, characterized in that, The functional pipelines include fire-fighting pipelines, compressed air pipelines, water supply pipelines, and cable pipelines; the main hydraulic pipelines include the anchor winch hydraulic main pipeline and the hatch cover hydraulic main pipeline.

6. The modular layout structure of the main deck piping of a bulk carrier according to claim 4, characterized in that, The longitudinal pipeline is located at the port hatch coaming and includes several longitudinal modules connected end to end, each with a length of 12±5m.

7. The modular layout structure of the main deck piping of a bulk carrier according to claim 5, characterized in that, A cable transition box is installed on the cable conduit, and a T-shaped branch is formed through the cable transition box to connect to the cable conduit of the horizontal module.

8. A method for unitized installation of main deck piping on a bulk carrier, comprising the unitized layout structure shown in claim 1, characterized in that, Includes the following steps: S1. Assemble the pipelines in each area in the workshop according to the layout and structural requirements to form the corresponding pipeline units; S2. Transport the assembled piping units to the main deck installation site of the bulk carrier and install each piping unit on site in reverse order. S3. During installation, no connecting pipe is installed between adjacent pipe units. Instead, adjacent pipe units are disconnected by staggering their vertical positions. S4. After disconnecting the pipe, align the ends of the flange disconnected pipes inside the pipe unit and between adjacent pipe units to complete the centralized installation of the pipe unit.

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