CN112523963A - Installation process of offshore wind turbine generator set - Google Patents
Installation process of offshore wind turbine generator set Download PDFInfo
- Publication number
- CN112523963A CN112523963A CN202011315424.9A CN202011315424A CN112523963A CN 112523963 A CN112523963 A CN 112523963A CN 202011315424 A CN202011315424 A CN 202011315424A CN 112523963 A CN112523963 A CN 112523963A
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- Prior art keywords
- tower
- hoisting
- hub
- flange
- blade
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
- F03D13/10—Assembly of wind motors; Arrangements for erecting wind motors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
- B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING
- B63B73/00—Building or assembling vessels or marine structures, e.g. hulls or offshore platforms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/04—Auxiliary devices for controlling movements of suspended loads, or preventing cable slack
- B66C13/08—Auxiliary devices for controlling movements of suspended loads, or preventing cable slack for depositing loads in desired attitudes or positions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C23/00—Cranes comprising essentially a beam, boom, or triangular structure acting as a cantilever and mounted for translatory of swinging movements in vertical or horizontal planes or a combination of such movements, e.g. jib-cranes, derricks, tower cranes
- B66C23/18—Cranes comprising essentially a beam, boom, or triangular structure acting as a cantilever and mounted for translatory of swinging movements in vertical or horizontal planes or a combination of such movements, e.g. jib-cranes, derricks, tower cranes specially adapted for use in particular purposes
- B66C23/36—Cranes comprising essentially a beam, boom, or triangular structure acting as a cantilever and mounted for translatory of swinging movements in vertical or horizontal planes or a combination of such movements, e.g. jib-cranes, derricks, tower cranes specially adapted for use in particular purposes mounted on road or rail vehicles; Manually-movable jib-cranes for use in workshops; Floating cranes
- B66C23/52—Floating cranes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
Abstract
The invention relates to an installation process of an offshore wind turbine generator system, which comprises the steps of platform ship moving positioning and jacking, positioning barge anchoring and positioning, transportation barge positioning, tower turnover, blade refuting, fan tower hoisting, engine room hub hoisting and blade hoisting, wherein the fan tower hoisting comprises bottom section tower hoisting, middle section tower hoisting and upper section tower hoisting. The invention has the following advantages: through installing fixedly to a tower section of thick bamboo segmentation, realize quick location, guarantee the stationarity and the levelness that a tower section of thick bamboo was lifted by crane, realize the quick accurate location of blade.
Description
The technical field is as follows:
the invention relates to the field of wind power generation, in particular to an installation process of an offshore wind turbine generator system.
Background art:
an offshore wind generating set (offshore wind generating set or offshore wind turbine for short) is a novel power generation device for offshore wind resource power generation, and generally comprises a tower head (a wind wheel and a cabin), a tower cylinder and a pile foundation, wherein the bottom end of the tower cylinder is fixed on the pile foundation, the tower head is installed at the top end of the tower cylinder, the pile foundation is arranged on the seabed and used for supporting and fixing the tower cylinder, and the pile foundation plays a vital role in the safety of the whole offshore wind generating set.
Because the offshore environment is complex and variable, the offshore wind turbine generator is harder to install than a land wind turbine generator from the construction of a pile foundation to the installation of the whole offshore wind turbine generator, the length of a tower barrel of the wind turbine generator is generally 70-80 meters, if the offshore wind turbine generator is integrally hoisted and installed on the pile foundation, the hoisting levelness of the tower barrel cannot be ensured in the hoisting process, and particularly under the conditions of strong sea wind and floating sea waves, the tower barrel is more prone to shaking, and great difficulty is brought to the hoisting and installation of the tower barrel; secondly, when installing the hub of wind turbine generator system blade and cabin on the sea, can't realize quick location installation, the blade blocks easily, needs to dismantle and reinstall, consuming time and wasting force.
The invention content is as follows:
the invention aims to overcome the defects and provide an installation process of an offshore wind turbine generator, which realizes quick positioning by installing and fixing tower sections, ensures the stability and levelness of tower hoisting, and realizes quick and accurate positioning of blades.
The purpose of the invention is realized by the following technical scheme: an installation process of an offshore wind turbine generator system comprises the steps of platform ship moving positioning and jacking, positioning barge anchoring and taking place, transportation barge taking place, tower barrel turning and blade refuting, fan tower barrel hoisting, cabin hub hoisting and blade hoisting installation, wherein the fan tower barrel hoisting comprises bottom section tower barrel hoisting, middle section tower barrel hoisting and upper section tower barrel hoisting.
The invention is further improved in that: the method comprises the following specific steps:
s1, carrying out positioning and jacking on the platform: the method comprises the following steps that a ship positioning system and 4 970KW omnibearing side thrusters are arranged on a platform transfer ship, 1 500T crawler crane is arranged on a deck of the platform transfer ship, a deck reinforcing base formed by splicing I-steel and wood plates is arranged at the bottom of the crawler crane, the platform transfer ship is anchored and positioned in place by using the ship positioning system, and after the ship is positioned in place, platform jacking operation is carried out;
s2, positioning barge anchoring in place and transporting barge in place: arranging the positioning barge and a wharf in a T shape, throwing four V-shaped anchors front, back, left and right, after the positioning barge is thrown and positioned, enabling the transportation barge to arrive at a construction site and berth between the positioning barge and a platform for ship transfer, and tying the transportation barge at the side of the positioning barge by using anchor cables;
s3, turning over the tower and tipping the blades: after the fan is installed, the crawler crane moves to the middle position of the ship, the groveling arm is placed on the bow rest arm, constructors temporarily fix the crawler crane host, when the next site is reached, the temporary fixation is removed, the crawler crane moves to the ship port of the platform ship moving, and the main crane is matched with the main crane to perform tower barrel turning and blade refunding work;
s4, hoisting a fan tower drum: a. preparing a transition section flange, flattening salient points and burrs of the transition section flange by using a flat file, cleaning and drying an O-shaped groove of the transition section flange, inserting a fine wire into a gasket groove of the transition section flange, installing an O-shaped ring, and fixing the transition section flange on a pile foundation; b. hoisting a bottom section tower drum, installing a tower drum hoisting tool on an upper flange of the bottom section tower drum, slowly applying a force to a platform ship moving main hook until the force is applied for 100t, suspending the hoisting, removing the hoisting tool and a bolt part of the bottom section tower drum by a constructor by using an impact wrench, tying 2 pulling-up ropes with the length of 3-5 meters on the upper flange of the bottom section tower drum to be used as marks, drawing two steel wire ropes, connecting one ends of the steel wire ropes to the upper flange of the bottom section tower drum, connecting the other ends of the steel wire ropes to winch rollers on two sides of the stern of the platform ship moving, hoisting the bottom section tower drum, turning a suspension arm left, and rotating the suspension arm to the upper part of a; c. connecting bottom section tower drums, suspending hoisting when the bottom section tower drums are hoisted to be right above a pile foundation, observing, inserting bolts and tripping the bottom section tower drums by 6-8 constructors through a trestle on the pile foundation, observing the positions of marking lines by the constructors at the flanges of the transition sections, instructing winch operators, lowering the bottom section tower drums after the lower flanges of the bottom section tower drums are aligned according to the marking directions by adjusting the winch, keeping the distance between the flanges of the transition sections of the pile foundation and the lower flanges of the bottom section tower drums between 10cm and 12cm, inserting the lengthened bolts from the bottoms of the flanges of the transition sections, positioning the washers with the chamfer surfaces onto nuts, removing steel wire ropes after the bolts between the two flanges are installed with 1/3, continuously installing 2/3 bolts, and completing and loosening and fastening all the bolts; e. according to the steps a to c, a middle tower barrel and an upper tower barrel are gradually installed from bottom to top;
s5, hoisting a nacelle hub: the method comprises the following steps that a wind rope is tied between a wind rope winch and a wind rope limiting space, a lifting ring is placed on a T-shaped support, the lifting ring on the T-shaped support is lowered to a cabin and hub lifting point accessory, the lifting direction of the T-shaped support is the same as the direction of a hub, the cabin and the hub are lifted integrally through a main crane of a platform ship moving machine, a constructor uses a vibration wrench to detach a transportation bolt at the bottom of the cabin, and a guide pin penetrates through a zero mark on a flange at the bottom of the cabin; after the dismantling is finished, the main crane continues to lift until the main crane exceeds the highest obstacle of the rotation path of the platform transfer ship by 1m, the large arm rotates leftwards until the large arm rotates to a position 5m away from the top of the tower cylinder and stops, a constructor above the tower cylinder checks the lifting position height of the engine room and continues to lift until the engine room is lifted to a position 0.5m above the tower cylinder and stops, the engine room yaws until the guide pin is at the correct position, the levelness of the engine room is adjusted by using a safety rope, and the constructor on the tower cylinder instructs the main crane to continue to get off the hook until the guide pin passes through a hole in an upper flange of an upper section; when the cabin is within 20cm from the flange of the upper tower drum, an electric lower hook is hooked, a constructor in the tower deflects to the cabin until a hole of the flange at the bottom of the cabin is aligned with a hole of the flange on the top tower drum, finally, the flange at the bottom of the cabin is connected with the flange on the top tower drum through a bolt, and then, a stair and a temporary lamp in the cabin are installed;
and S6, hoisting and mounting the blade.
The invention is further improved in that: in step S3, the step of turning over the tower cylinder is: and (3) carrying out transportation, berthing and positioning barge on the tower cylinder, enabling the positioning barge to be close to the platform for ship movement, performing refund of the tower cylinder by using a main crane and a crawler crane of the platform for ship movement, slowly lifting the tower cylinder after two crane lifting riggings of the platform for ship movement are installed, and performing turnover operation of the tower cylinder after the tower cylinder is lifted from a deck for 3 meters.
The invention is further improved in that: in the step S3, the blades are refuted onto the positioning ship, the engine room and the tower are refuted onto the platform moving ship, and the turning operation is performed after the refuting is finished.
The invention is further improved in that: in the step S4, before the wind turbine tower drum is hoisted, cable laying and electrical equipment installation in the tower drum are checked, flange end faces of the bottom section tower drum, the middle section tower drum and the upper surface of the pile foundation transition section flange are cleaned, sealant is coated on the upper surface of the transition section flange, and lubricating oil is injected into the threaded hole of the transition section flange.
The invention is further improved in that: in step S4, after the bottom tower, the middle tower, and the upper tower are hoisted, hoisting post-processing is performed, specifically:
A. cleaning the contact surface of the equalizer, and cleaning permanent grounding wires of the bottom section tower cylinder, the middle section tower cylinder, the upper section tower cylinder and the transition section flange piece;
B. installing a cotter pin on the door handle to fix the tower door, connecting the temporary power supply cable to the power supply device through the tower door, and connecting the cable to the socket of the 690V power supply unit frame;
C. the parallelism between a flange on the bottom section tower barrel after initial installation and the horizontal plane and the perpendicularity between the longitudinal axis and the horizontal plane are checked, and if the parallelism and the perpendicularity do not meet requirements, adjustment can be carried out through adjusting bolts and adding shims;
D. installing stretching heads of a hydraulic stretcher on the bolts, and connecting the stretching heads in series by using hydraulic pipes;
E. checking the joint between the stretching head and the hydraulic pipe fitting to ensure that the conditions of no reverse installation, no neglected installation, no in-place installation and the like are met;
F. and after the stretching head is installed, stretching operation is carried out, and after the stretching operation is finished, the tower drum is removed to hoist the steel wire rope and the tool.
The invention is further improved in that: the total structural length of the tower barrel at the bottom end is 12.64m, the outer circles of the upper flange and the lower flange of the tower barrel are phi 5500mm, the central circle is phi 5140mm, the holes are 148x phi 52mm, the total weight of the tower barrel at the bottom section is 84.7t, the total weight of internal TU/PU equipment is 30t, and the total hoisting weight is 120 t.
The invention is further improved in that: the total structural length of the middle-section tower barrel is 22.4m, the outer circles of the upper flange and the lower flange of the tower barrel are phi 5500mm, the central circle is phi 5140mm, the holes are 148x phi 52mm, the total weight of the middle-section tower barrel is 85t, the total weight of internal accessories is 30t, and the total hoisting weight is 115 t.
The invention is further improved in that: the total structural length of the top section tower barrel is 36m, the total weight of the top section tower barrel is 81.9t, the excircle of a lower flange of the top section tower barrel is phi 5500mm, the central circle is phi 5140mm, holes are 148x phi 52mm, the excircle of an upper flange of the top section tower barrel is phi 3120mm, and the holes are 116x phi 33 mm.
The invention is further improved in that: the specific steps of step S6 are:
A. yawing the engine room, namely yawing the engine room to the position where the blades are installed, keeping an engine room switch on and finely adjusting the engine room;
B. positioning a blade bearing, connecting a hydraulic pipe to a hydraulic pump station by using a quick connector, connecting the other end of the hydraulic pipe to the left side of the top and the right side of the top of a hydraulic distribution block by using a quick connector, connecting a hose of a blade barring gear device to an external hub barring gear device, connecting the hose of the blade barring gear device to an external hydraulic pump by using an external hub climbing gear device, connecting a hydraulic station power supply of the hub climbing gear device, rotating a handle on an internal hydraulic station to the position of the hub barring gear device, starting a crane maintenance hydraulic station on a cabinet, rotating a switch to a running position, using a control box of the hub barring gear device, then pressing a button on a remote controller, activating the hydraulic hub barring gear device, opening a top cabin door on the front face of a cabin, and rotating a hub to a position entering the hub by using the hydraulic hub;
C. applying high-speed shaft brake, starting a turning gear motor and releasing power, using a steering gear motor to rotate a hub until a high-speed shaft lock is locked, moving a handle to the right, locking a high-speed shaft rotor, and fixing the handle by using a locking bolt after the high-speed shaft brake is completed;
D. the hub is locked at the high-speed shaft of the gearbox, the brake is in a service state, a top cabin door on the front face of the cabin is opened, the cabin door of the hub is disassembled and placed in the cabin, and the cabin door on the left side of the front side panel of the cabin is disassembled and placed in the cabin;
E. measuring the angle of a blade bearing, rotating a hub by using a hub barring gear device until the blade bearing and a blade root flange form an angle of 1-2 degrees, and measuring the angle by using a digital level meter;
F. hoisting the blades, namely winding hoisting binding bands on the blades, fixing the vortex protector on the hoisting binding bands of the blades, fixing the vortex protector on a hoisting device of the platform ship moving by using a rope, hoisting the blades and visually inspecting the balance state of the hoisting device and the blades;
G. installing a blade, namely hoisting the blade to a correct installation position by rotating and hoisting a crane, wherein before installation, a blade bearing is located at 0 degree, a variable pitch angle is arranged at the 12-1 point position, the blade is hoisted and guided into the blade bearing, in the guiding process, an operator in a hub performs variable pitch on the blade bearing through a control box or a remote controller so as to match with the guiding of the blade, a blade bolt is screwed through a socket wrench, and a crane hook descends in the process of connecting the blade until the load weight of the crane hook is at least 100kg lighter than that of the blade hoisting device, but the load weight is not 1000kg lighter than that of the hoisting device; pulling out a plug of the emergency forced release system, rewinding the cable to the lifting device, and lifting the lifting device away from the blade; rotating the hub clockwise or anticlockwise and locking the rotor to enable the blade to be at a position right below the hub, screwing all the bolts again by using a 1000Nm socket wrench, screwing all the bolts by changing the pitch, and hoisting and installing the rest of the blade after the screwing is finished;
H. and (4) post-processing, namely after a plurality of blades are installed, disassembling the hub turning gear device, and ensuring that the installed blades are changed to a stop position before personnel leave the hub.
Compared with the prior art, the invention has the following advantages:
1. according to the invention, the tower barrel is installed and fixed in sections, so that the quick positioning is realized, and the hoisting stability and levelness of the tower barrel are ensured;
2. when each section of the tower barrel is installed, the steps of marking, drawing the steel wire rope, inserting the bolt for positioning, disassembling the steel wire rope and fastening the bolt under the condition that the adjacent two flanges keep a certain distance are adopted, so that the sections of the tower barrel can be accurately positioned under the condition that the perpendicularity is kept in the hoisting process, and the tower barrels are stably connected.
3. According to the invention, a foundation is provided for accurate installation and positioning of the blades by yawing the cabin, positioning the blade bearing, applying high-speed shaft braking, entering the hub and measuring the angle of the blade bearing, so that the blades are prevented from being clamped due to deviation during installation, and the blades are quickly and accurately positioned.
The specific implementation mode is as follows:
for the purpose of enhancing understanding of the present invention, the present invention will be further described in detail with reference to the following examples, which are provided for illustration only and are not to be construed as limiting the scope of the present invention.
The invention relates to an installation process of an offshore wind turbine generator system, which comprises the steps of platform ship moving positioning and jacking, positioning barge anchoring and positioning, transportation barge positioning, tower turnover, blade refuting, fan tower hoisting, cabin hub hoisting and blade hoisting, wherein the fan tower hoisting comprises bottom section tower hoisting, middle section tower hoisting and upper section tower hoisting.
The invention is further improved in that: the method comprises the following specific steps:
s1, carrying out positioning and jacking on the platform: the method comprises the following steps that a ship positioning system and 4 970KW omnibearing side thrusters are arranged on a platform transfer ship, 1 500T crawler crane is arranged on a deck of the platform transfer ship, a deck reinforcing base formed by splicing I-steel and wood plates is arranged at the bottom of the crawler crane, the platform transfer ship is anchored and positioned in place by using the ship positioning system, and after the ship is positioned in place, platform jacking operation is carried out;
s2, positioning barge anchoring in place and transporting barge in place: arranging the positioning barge and a wharf in a T shape, throwing four V-shaped anchors front, back, left and right, after the positioning barge is thrown and positioned, enabling the transportation barge to arrive at a construction site and berth between the positioning barge and a platform for ship transfer, and tying the transportation barge at the side of the positioning barge by using anchor cables;
s3, turning over the tower and tipping the blades: after the fan is installed, the crawler crane moves to the middle position of the ship, the groveling arm is placed on the bow rest arm, constructors temporarily fix the crawler crane host, when the next site is reached, the temporary fixation is removed, the crawler crane moves to the ship port of the platform ship moving, and the main crane is matched with the main crane to perform tower barrel turning and blade refunding work;
s4, hoisting a fan tower drum: a. preparing a transition section flange, flattening salient points and burrs of the transition section flange by using a flat file, cleaning and drying an O-shaped groove of the transition section flange, inserting a fine wire into a gasket groove of the transition section flange, installing an O-shaped ring, and fixing the transition section flange on a pile foundation; b. hoisting a bottom section tower drum, installing a tower drum hoisting tool on an upper flange of the bottom section tower drum, slowly applying a force to a platform ship moving main hook until the distance reaches 100t, suspending the hoisting, removing the hoisting tool and a bolt part of the bottom section tower drum by a constructor by using an impact wrench, tying 2 pulling ropes with the length of 3-5 meters on the upper flange of the bottom section tower drum to be used as marks, drawing two steel wire ropes, connecting one ends of the steel wire ropes to the upper flange of the bottom section tower drum, connecting the other ends of the steel wire ropes to winch rollers on two sides of the stern of the platform ship moving, hoisting the bottom section tower drum, turning a suspension arm left, and rotating the suspension arm to the upper part of a pile foundation after the; c. connecting bottom section tower drums, suspending hoisting when the bottom section tower drums are hoisted to be right above a pile foundation, observing, inserting bolts and tripping the bottom section tower drums by 6-8 constructors through a trestle on the pile foundation, observing the positions of marking lines by the constructors at the flanges of the transition sections, instructing winch operators, lowering the bottom section tower drums after the lower flanges of the bottom section tower drums are aligned according to the marking directions by adjusting the winch, keeping the distance between the flanges of the transition sections of the pile foundation and the lower flanges of the bottom section tower drums between 10cm and 12cm, inserting the lengthened bolts from the bottoms of the flanges of the transition sections, positioning the washers with the chamfer surfaces onto nuts, removing steel wire ropes after the bolts between the two flanges are installed with 1/3, continuously installing 2/3 bolts, and completing and loosening and fastening all the bolts; e. according to the steps a to c, a middle tower barrel and an upper tower barrel are gradually installed from bottom to top;
s5, hoisting a nacelle hub: the method comprises the following steps that a wind rope is tied between a wind rope winch and a wind rope limiting space, a lifting ring is placed on a T-shaped support, the lifting ring on the T-shaped support is lowered to a cabin and hub lifting point accessory, the lifting direction of the T-shaped support is the same as the direction of a hub, the cabin and the hub are lifted integrally through a main crane of a platform ship moving machine, a constructor uses a vibration wrench to detach a transportation bolt at the bottom of the cabin, and a guide pin penetrates through a zero mark on a flange at the bottom of the cabin; after the dismantling is finished, the main crane continues to lift until the main crane exceeds the highest obstacle of the rotation path of the platform transfer ship by 1m, the large arm rotates leftwards until the large arm rotates to a position 5m away from the top of the tower cylinder and stops, a constructor above the tower cylinder checks the lifting position height of the engine room and continues to lift until the engine room is lifted to a position 0.5m above the tower cylinder and stops, the engine room yaws until the guide pin is at the correct position, the levelness of the engine room is adjusted by using a safety rope, and the constructor on the tower cylinder instructs the main crane to continue to get off the hook until the guide pin passes through a hole in an upper flange of an upper section; when the cabin is within 20cm from the flange of the upper tower drum, an electric lower hook is hooked, a constructor in the tower deflects to the cabin until a hole of the flange at the bottom of the cabin is aligned with a hole of the flange on the top tower drum, finally, the flange at the bottom of the cabin is connected with the flange on the top tower drum through a bolt, and then, a stair and a temporary lamp in the cabin are installed;
and S6, hoisting and mounting the blade.
According to the invention, the tower barrel is installed and fixed in sections, so that the quick positioning is realized, and the hoisting stability and levelness of the tower barrel are ensured; when each section of the tower barrel is installed, the steps of marking, drawing the steel wire rope, inserting the bolt for positioning, disassembling the steel wire rope and fastening the bolt under the condition that the adjacent two flanges keep a certain distance are adopted, so that the sections of the tower barrel can be accurately positioned under the condition that the perpendicularity is kept in the hoisting process, and the tower barrels are stably connected.
Further, in step S3, the step of turning over the tower drum is: and (3) carrying out transportation, berthing and positioning barge on the tower cylinder, enabling the positioning barge to be close to the platform for ship movement, performing refund of the tower cylinder by using a main crane and a crawler crane of the platform for ship movement, slowly lifting the tower cylinder after two crane lifting riggings of the platform for ship movement are installed, and performing turnover operation of the tower cylinder after the tower cylinder is lifted from a deck for 3 meters.
Further, in step S3, the blade is refuted to the positioning ship, the nacelle and the tower are refuted to the platform moving ship, and the turning operation is performed after the refuting is completed.
Further, in step S4, before the wind turbine tower drum is hoisted, cable laying and electrical equipment installation in the tower drum are checked, the flange end faces of the bottom section tower drum, the middle section tower drum and the upper surface of the pile foundation transition section flange are cleaned, a sealant is coated on the upper surface of the transition section flange, and lubricating oil is injected into the threaded hole of the transition section flange.
Further, in step S4, after the hoisting of the bottom tower drum, the middle tower drum and the upper tower drum is completed, the hoisting post-treatment is performed, specifically:
A. cleaning the contact surface of the equalizer, and cleaning permanent grounding wires of the bottom section tower cylinder, the middle section tower cylinder, the upper section tower cylinder and the transition section flange piece;
B. installing a cotter pin on the door handle to fix the tower door, connecting the temporary power supply cable to the power supply device through the tower door, and connecting the cable to the socket of the 690V power supply unit frame;
C. the parallelism between a flange on the bottom section tower barrel after initial installation and the horizontal plane and the perpendicularity between the longitudinal axis and the horizontal plane are checked, and if the parallelism and the perpendicularity do not meet requirements, adjustment can be carried out through adjusting bolts and adding shims;
D. installing stretching heads of a hydraulic stretcher on the bolts, and connecting the stretching heads in series by using hydraulic pipes;
E. checking the joint between the stretching head and the hydraulic pipe fitting to ensure that the conditions of no reverse installation, no neglected installation, no in-place installation and the like are met;
F. and after the stretching head is installed, stretching operation is carried out, and after the stretching operation is finished, the tower drum is removed to hoist the steel wire rope and the tool.
Further, the total structural length of the tower barrel at the bottom end is 12.64m, the outer circles of the upper flange and the lower flange of the tower barrel are phi 5500mm, the center circle is phi 5140mm, the holes are 148x phi 52mm, the total weight of the tower barrel at the bottom section is 84.7t, the total weight of internal TU/PU equipment is 30t, and the total hoisting weight is 120 t.
Furthermore, the total structural length of the middle-section tower barrel is 22.4m, the outer circles of the upper flange and the lower flange of the tower barrel are phi 5500mm, the center circle is phi 5140mm, the holes are 148x phi 52mm, the total weight of the middle-section tower barrel is 85t, the total weight of internal accessories is 30t, and the total hoisting weight is 115 t.
Furthermore, the total structural length of the top section tower barrel is 36m, the total weight of the top section tower barrel is 81.9t, the outer circle of a lower flange of the top section tower barrel is phi 5500mm, the center circle is phi 5140mm, holes are 148x phi 52mm, the outer circle of an upper flange of the top section tower barrel is phi 3120mm, and the holes are 116x phi 33 mm.
Further, the specific step of step S6 is:
A. yawing the engine room, namely yawing the engine room to the position where the blades are installed, keeping an engine room switch on and finely adjusting the engine room;
B. positioning a blade bearing, connecting a hydraulic pipe to a hydraulic pump station by using a quick connector, connecting the other end of the hydraulic pipe to the left side of the top and the right side of the top of a hydraulic distribution block by using a quick connector, connecting a hose of a blade barring gear device to an external hub barring gear device, connecting the hose of the blade barring gear device to an external hydraulic pump by using an external hub climbing gear device, connecting a hydraulic station power supply of the hub climbing gear device, rotating a handle on an internal hydraulic station to the position of the hub barring gear device, starting a crane maintenance hydraulic station on a cabinet, rotating a switch to a running position, using a control box of the hub barring gear device, then pressing a button on a remote controller, activating the hydraulic hub barring gear device, opening a top cabin door on the front face of a cabin, and rotating a hub to a position entering the hub by using the hydraulic hub;
C. applying high-speed shaft brake, starting a turning gear motor and releasing power, using a steering gear motor to rotate a hub until a high-speed shaft lock is locked, moving a handle to the right, locking a high-speed shaft rotor, and fixing the handle by using a locking bolt after the high-speed shaft brake is completed;
D. the hub is locked at the high-speed shaft of the gearbox, the brake is in a service state, a top cabin door on the front face of the cabin is opened, the cabin door of the hub is disassembled and placed in the cabin, and the cabin door on the left side of the front side panel of the cabin is disassembled and placed in the cabin;
E. measuring the angle of a blade bearing, rotating a hub by using a hub barring gear device until the blade bearing and a blade root flange form an angle of 1-2 degrees, and measuring the angle by using a digital level meter;
F. hoisting the blades, namely winding hoisting binding bands on the blades, fixing the vortex protector on the hoisting binding bands of the blades, fixing the vortex protector on a hoisting device of the platform ship moving by using a rope, hoisting the blades and visually inspecting the balance state of the hoisting device and the blades;
G. installing a blade, namely hoisting the blade to a correct installation position by rotating and hoisting a crane, wherein before installation, a blade bearing is located at 0 degree, a variable pitch angle is arranged at the 12-1 point position, the blade is hoisted and guided into the blade bearing, in the guiding process, an operator in a hub performs variable pitch on the blade bearing through a control box or a remote controller so as to match with the guiding of the blade, a blade bolt is screwed through a socket wrench, and a crane hook descends in the process of connecting the blade until the load weight of the crane hook is at least 100kg lighter than that of the blade hoisting device, but the load weight is not 1000kg lighter than that of the hoisting device; pulling out a plug of the emergency forced release system, rewinding the cable to the lifting device, and lifting the lifting device away from the blade; rotating the hub clockwise or anticlockwise and locking the rotor to enable the blade to be at a position right below the hub, screwing all the bolts again by using a 1000Nm socket wrench, screwing all the bolts by changing the pitch, and hoisting and installing the rest of the blade after the screwing is finished;
H. and (4) post-processing, namely after a plurality of blades are installed, disassembling the hub turning gear device, and ensuring that the installed blades are changed to a stop position before personnel leave the hub.
According to the invention, a foundation is provided for accurate installation and positioning of the blades by yawing the cabin, positioning the blade bearing, applying high-speed shaft braking, entering the hub and measuring the angle of the blade bearing, so that the blades are prevented from being clamped due to deviation during installation, and the blades are quickly and accurately positioned.
It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (10)
1. The installation process of the offshore wind turbine generator set is characterized by comprising the steps of moving a platform to position and lift, anchoring and taking place of a positioning barge, taking place of the transportation barge, turning over a tower drum, refuting blades, hoisting a fan tower drum, hoisting a cabin hub and hoisting the blades, wherein the fan tower drum is sequentially hoisted and comprises bottom section tower drum hoisting, middle section tower drum hoisting and upper section tower drum hoisting.
2. The offshore wind turbine installation process of claim 1, comprising the following specific steps:
s1, carrying out positioning and jacking on the platform: the method comprises the following steps that a ship positioning system and 4 970KW omnibearing side thrusters are arranged on a platform transfer ship, 1 500T crawler crane is arranged on a deck of the platform transfer ship, a deck reinforcing base formed by splicing I-steel and wood plates is arranged at the bottom of the crawler crane, the platform transfer ship is anchored and positioned in place by using the ship positioning system, and after the ship is positioned in place, platform jacking operation is carried out;
s2, positioning barge anchoring in place and transporting barge in place: arranging the positioning barge and a wharf in a T shape, throwing four V-shaped anchors front, back, left and right, after the positioning barge is thrown and positioned, enabling the transportation barge to arrive at a construction site and berth between the positioning barge and a platform for ship transfer, and tying the transportation barge at the side of the positioning barge by using anchor cables;
s3, turning over the tower and tipping the blades: after the fan is installed, the crawler crane moves to the middle position of the ship, the groveling arm is placed on the bow rest arm, constructors temporarily fix the crawler crane host, when the next site is reached, the temporary fixation is removed, the crawler crane moves to the ship port of the platform ship moving, and the main crane is matched with the main crane to perform tower barrel turning and blade refunding work;
s4, hoisting a fan tower drum: a. preparing a transition section flange, flattening salient points and burrs of the transition section flange by using a flat file, cleaning and drying an O-shaped groove of the transition section flange, inserting a fine wire into a gasket groove of the transition section flange, installing an O-shaped ring, and fixing the transition section flange on a pile foundation; b. hoisting a bottom section tower drum, installing a tower drum hoisting tool on an upper flange of the bottom section tower drum, slowly applying a force to a platform ship moving main hook until the distance reaches 100t, suspending the hoisting, removing the hoisting tool and a bolt part of the bottom section tower drum by a constructor by using an impact wrench, tying 2 pulling ropes with the length of 3-5 meters on the upper flange of the bottom section tower drum to be used as marks, drawing two steel wire ropes, connecting one ends of the steel wire ropes to the upper flange of the bottom section tower drum, connecting the other ends of the steel wire ropes to winch rollers on two sides of the stern of the platform ship moving, hoisting the bottom section tower drum, turning a suspension arm left, and rotating the suspension arm to the upper part of a pile foundation after the; c. connecting bottom section tower drums, suspending hoisting when the bottom section tower drums are hoisted to be right above a pile foundation, observing, inserting bolts and tripping the bottom section tower drums by 6-8 constructors through a trestle on the pile foundation, observing the positions of marking lines by the constructors at the flanges of the transition sections, instructing winch operators, lowering the bottom section tower drums after the lower flanges of the bottom section tower drums are aligned according to the marking directions by adjusting the winch, keeping the distance between the flanges of the transition sections of the pile foundation and the lower flanges of the bottom section tower drums between 10cm and 12cm, inserting the lengthened bolts from the bottoms of the flanges of the transition sections, positioning the washers with the chamfer surfaces onto nuts, removing steel wire ropes after the bolts between the two flanges are installed with 1/3, continuously installing 2/3 bolts, and completing and loosening and fastening all the bolts; e. according to the steps a to c, a middle tower barrel and an upper tower barrel are gradually installed from bottom to top;
s5, hoisting a nacelle hub: the method comprises the following steps that a wind rope is tied between a wind rope winch and a wind rope limiting space, a lifting ring is placed on a T-shaped support, the lifting ring on the T-shaped support is lowered to a cabin and hub lifting point accessory, the lifting direction of the T-shaped support is the same as the direction of a hub, the cabin and the hub are lifted integrally through a main crane of a platform ship moving machine, a constructor uses a vibration wrench to detach a transportation bolt at the bottom of the cabin, and a guide pin penetrates through a zero mark on a flange at the bottom of the cabin; after the dismantling is finished, the main crane continues to lift until the main crane exceeds the highest obstacle of the rotation path of the platform transfer ship by 1m, the large arm rotates leftwards until the large arm rotates to a position 5m away from the top of the tower cylinder and stops, a constructor above the tower cylinder checks the lifting position height of the engine room and continues to lift until the engine room is lifted to a position 0.5m above the tower cylinder and stops, the engine room yaws until the guide pin is at the correct position, the levelness of the engine room is adjusted by using a safety rope, and the constructor on the tower cylinder instructs the main crane to continue to get off the hook until the guide pin passes through a hole in an upper flange of an upper section; when the cabin is within 20cm from the flange of the upper tower drum, an electric lower hook is hooked, a constructor in the tower deflects to the cabin until a hole of the flange at the bottom of the cabin is aligned with a hole of the flange on the top tower drum, finally, the flange at the bottom of the cabin is connected with the flange on the top tower drum through a bolt, and then, a stair and a temporary lamp in the cabin are installed;
and S6, hoisting and mounting the blade.
3. The offshore wind turbine installation process of claim 2, wherein in step S3, the step of turning over the tower is: and (3) carrying out transportation, berthing and positioning barge on the tower cylinder, enabling the positioning barge to be close to the platform for ship movement, performing refund of the tower cylinder by using a main crane and a crawler crane of the platform for ship movement, slowly lifting the tower cylinder after two crane lifting riggings of the platform for ship movement are installed, and performing turnover operation of the tower cylinder after the tower cylinder is lifted from a deck for 3 meters.
4. The offshore wind turbine installation process of claim 2, wherein in step S3, the blades are refunded to the positioning vessel, the nacelle and the tower are refunded to the platform moving vessel, and the turning operation is performed after the refunding is completed.
5. The offshore wind turbine installation process of claim 2, wherein in step S4, before hoisting the wind turbine tower, cable laying and electrical equipment installation in the tower are checked, the flange end faces of the bottom tower, the middle tower and the upper surface of the pile foundation transition section flange are cleaned, the upper surface of the transition section flange is coated with a sealant, and lubricating oil is injected into the threaded hole of the transition section flange.
6. The offshore wind turbine installation process of claim 2, wherein in step S4, after the bottom tower, the middle tower and the upper tower are hoisted, hoisting post-treatment is performed, specifically:
A. cleaning the contact surface of the equalizer, and cleaning permanent grounding wires of the bottom section tower cylinder, the middle section tower cylinder, the upper section tower cylinder and the transition section flange piece;
B. installing a cotter pin on the door handle to fix the tower door, connecting the temporary power supply cable to the power supply device through the tower door, and connecting the cable to the socket of the 690V power supply unit frame;
C. the parallelism between a flange on the bottom section tower barrel after initial installation and the horizontal plane and the perpendicularity between the longitudinal axis and the horizontal plane are checked, and if the parallelism and the perpendicularity do not meet requirements, adjustment can be carried out through adjusting bolts and adding shims;
D. installing stretching heads of a hydraulic stretcher on the bolts, and connecting the stretching heads in series by using hydraulic pipes;
E. checking the joint between the stretching head and the hydraulic pipe fitting to ensure that the conditions of no reverse installation, no neglected installation, no in-place installation and the like are met;
F. and after the stretching head is installed, stretching operation is carried out, and after the stretching operation is finished, the tower drum is removed to hoist the steel wire rope and the tool.
7. The installation process of the offshore wind turbine generator system according to any one of claims 2 to 6, wherein the total structural length of the bottom tower is 12.64m, the outer circles of the upper and lower flanges of the tower are phi 5500mm, the center circle is phi 5140mm, the holes are 148x phi 52mm, the total weight of the bottom tower is 84.7t, the total weight of the internal TU/PU equipment is 30t, and the total hoisting weight is 120 t.
8. The offshore wind turbine installation process of any one of claims 2 to 6, wherein the total structural length of the middle tower is 22.4m, the outer circles of the upper and lower flanges of the tower are phi 5500mm, the center circle is phi 5140mm, the holes are 148x phi 52mm, the total weight of the middle tower is 85t, the total weight of the internal accessories is 30t, and the total hoisting weight is 115 t.
9. The offshore wind turbine installation process of any one of claims 2 to 6, wherein the total structural length of the top tower section is 36m, the total weight of the top tower section is 81.9t, the outer circle of the lower flange of the top tower section is phi 5500mm, the center circle is phi 5140mm, the hole is 148x phi 52mm, the outer circle of the upper flange of the top tower section is phi 3120mm, and the hole is 116x phi 33 mm.
10. The installation process of the offshore wind turbine generator system according to any one of claims 2 to 6, wherein the step S6 comprises the following steps:
A. yawing the engine room, namely yawing the engine room to the position where the blades are installed, keeping an engine room switch on and finely adjusting the engine room;
B. positioning a blade bearing, connecting a hydraulic pipe to a hydraulic pump station by using a quick connector, connecting the other end of the hydraulic pipe to the left side of the top and the right side of the top of a hydraulic distribution block by using a quick connector, connecting a hose of a blade barring gear device to an external hub barring gear device, connecting the hose of the blade barring gear device to an external hydraulic pump by using an external hub climbing gear device, connecting a hydraulic station power supply of the hub climbing gear device, rotating a handle on an internal hydraulic station to the position of the hub barring gear device, starting a crane maintenance hydraulic station on a cabinet, rotating a switch to a running position, using a control box of the hub barring gear device, then pressing a button on a remote controller, activating the hydraulic hub barring gear device, opening a top cabin door on the front face of a cabin, and rotating a hub to a position entering the hub by using the hydraulic hub;
C. applying high-speed shaft brake, starting a turning gear motor and releasing power, using a steering gear motor to rotate a hub until a high-speed shaft lock is locked, moving a handle to the right, locking a high-speed shaft rotor, and fixing the handle by using a locking bolt after the high-speed shaft brake is completed;
D. the hub is locked at the high-speed shaft of the gearbox, the brake is in a service state, a top cabin door on the front face of the cabin is opened, the cabin door of the hub is disassembled and placed in the cabin, and the cabin door on the left side of the front side panel of the cabin is disassembled and placed in the cabin;
E. measuring the angle of a blade bearing, rotating a hub by using a hub barring gear device until the blade bearing and a blade root flange form an angle of 1-2 degrees, and measuring the angle by using a digital level meter;
F. hoisting the blades, namely winding hoisting binding bands on the blades, fixing the vortex protector on the hoisting binding bands of the blades, fixing the vortex protector on a hoisting device of the platform ship moving by using a rope, hoisting the blades and visually inspecting the balance state of the hoisting device and the blades;
G. installing a blade, namely hoisting the blade to a correct installation position by rotating and hoisting a crane, wherein before installation, a blade bearing is located at 0 degree, a variable pitch angle is arranged at the 12-1 point position, the blade is hoisted and guided into the blade bearing, in the guiding process, an operator in a hub performs variable pitch on the blade bearing through a control box or a remote controller so as to match with the guiding of the blade, a blade bolt is screwed through a socket wrench, and a crane hook descends in the process of connecting the blade until the load weight of the crane hook is at least 100kg lighter than that of the blade hoisting device, but the load weight is not 1000kg lighter than that of the hoisting device; pulling out a plug of the emergency forced release system, rewinding the cable to the lifting device, and lifting the lifting device away from the blade; rotating the hub clockwise or anticlockwise and locking the rotor to enable the blade to be at a position right below the hub, screwing all the bolts again by using a 1000Nm socket wrench, screwing all the bolts by changing the pitch, and hoisting and installing the rest of the blade after the screwing is finished;
H. and (4) post-processing, namely after a plurality of blades are installed, disassembling the hub turning gear device, and ensuring that the installed blades are changed to a stop position before personnel leave the hub.
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