Recently, with the completion of docking of the last ring pile, the single pile of the second stage project of Putian Pinghai Wind Power Co., Ltd., which was produced by the branch's Electrical and Mechanical Engineering Department, was successfully completed, which lasted only 100 days!
This monopile is 6 meters to 7.3 meters in diameter with a taper transition of 77 meters long, a plate thickness of 75 millimeters and a weight of about 930 tons. It is a veritable 'big thing'. This single pile is the largest single pile in China at present, and it was also the first time the Bureau produced it. Such a single pile.
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In recent years, with the full implementation of the planning and layout of offshore wind projects in Fujian Province, the Branch's Electrical and Mechanical Engineering Department seized the opportunity to take advantage of several offshore wind power projects to actively develop offshore wind power single pile processing technology and broaden the product range.
For the Department of Mechanical and Electrical Engineers, it is undoubtedly a huge challenge to make a 'big thing' with a maximum pile diameter of 7.3 meters. The Electrical and Mechanical Engineering Department conducted a survey of several companies that have the production capacity of large-diameter steel pipe piles for offshore wind turbines. In the past, the experience of making small pipe piles has improved a complete set of assembly line processes and a dedicated research team has been established to ensure the smooth production of wind power single piles.
Wind power pile
Since the plate thickness of a single pile reaches 80mm, the welding process needs to be carefully explored. It is not only necessary to avoid the occurrence of cold cracks after welding, but also to ensure that there are no supernormal defects in the weld and to avoid rework.
Can the quality of the weld be passed? The degree of ellipticity of the steel pipe pile is not enough? The appearance of the weld is beautiful... Many welding problems that have not been encountered before come one after another. Facing these problems, the Mechanical and Electrical Engineering Department has established a technical team, at the beginning of construction. The multi-references to the welding seam construction, understanding of the various welding problems that may arise during different welding processes when welding the slabs, continuous testing, and the welding process tends to be mature. After the welding of the slabs, many The amount of sub-quality detection, strict implementation of the welding process specification in the welding process, real-time monitoring of temperature, current, voltage, 24 hours of uninterrupted construction to improve the welding quality and efficiency.
CNC cutting
At the same time, the Electrical and Mechanical Engineering Department also invited the senior technicians and quality inspectors of branch offices to explain the causes and preventive measures of the welding knowledge and welding quality of the laid-off workers, and to strengthen them through theoretical examinations and field operation examinations.
Longitudinal weld gas throwing teaching
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The 'bump' of single tube sections weighing more than 40 tons is a big problem. From the splicing of steel plates, overturning, lifting of pipe sections, lifting of small sections, etc., it is necessary to facilitate operation and ensure safety and reliability. This requires design. The production of a special hoisting machine number can be met. In order to meet the actual construction requirements, the technical staff of the mechanical and electrical engineering department designed and produced the corresponding tooling spreader in collaboration with the design department to operate, saving costs and making the construction proceed in an efficient and orderly manner. .
Pipe section move
After 7.3 meters in diameter, the back section is rolled and back-rounded. The rounding is required to be accurate to within 5 mm, especially after the taper. The lateral thrust is downward and the rolling pressure is different, resulting in inconsistent circularity. The machine has a certain degree of performance deficiencies and cannot meet the required ellipticity standards. The Electrical and Mechanical Engineering Department has introduced a team of domestically experienced team members with extensive experience in the construction of steel pipe piles to make small work pieces to make up for their deficiencies and to make the pipe sections meet the regulatory requirements. , Improve the accuracy of the circle return. CNC processing personnel will number the spliced steel plate, so that each plate has an independent and unique part number, which is convenient for construction and material tracking. Compare the steel plate model with the table marked model number repeatedly. After confirmation, the numerical control file of its own part number is called to make the steel plate size reach the standard size required for rolling, which greatly shortens the time and cost of the subsequent process.
Tube section roll
Technician Performs Non-destructive Testing of Circular Longitudinal Welding
The precision control of the flange splicing can be described as extremely 'demanding'. The base top flange surface should be tilted from 0.5 to 1.5 mm. The top surface of the flange after welding must not be valgused. To solve this problem, senior welding technician Huang Cuilian and senior fitter technician Chen Yousheng In cooperation with each other, 8 points are marked on the top of the flange in the process of flange splicing. Precision instruments are used to measure the flatness and inclination of the flanges. During the welding process, inspection is performed with a ruler to facilitate the process of flange welding. Can control its accuracy and ensure its inward inclination.
Flange docking
In terms of quality management, the Electrical and Mechanical Engineering Department used the form of 'Internet+' to realize the informatization of quality inspection management. Each pipe section was sprayed with its own two-dimensional code, and after each process was completed, The quality inspection information and various data are recorded in the system in a timely manner to ensure that each process can be traced back to ensure the quality and production progress of the pipe piles.
Technician Scans QR Code to View Tube Information
The single-pile construction lasted for 100 days, which effectively promoted the construction progress of the Putian Pinggu Wind Power Project. As a large-scale steel pipe pile production line for offshore wind power, the Electrical and Mechanical Engineering Department will carry forward the concept of 'Sanhang Seiko' ingenuity' and promote three. Aviation brand building and promotion, to achieve the production capacity of large steel pipe piles, and strive to produce large steel pipe piles with an annual output of 20,000 tons or more in 2018.