風力發(fā)電機單樁首次電子束焊接取得顯著成果
A collaboration between Cambridge Vacuum Engineering (CVE), SSE Renewables, Sif Group, and TWI, has resulted in the first-ever electron beam welded section to be incorporated in an offshore wind turbine monopile foundation (transition piece). The resulting monopile is set for installation in the second phase of Dogger Bank Wind Farm, which is located more than 130km off the Northeast coast of England.
劍橋真空工程公司（CVE）、SSE Renewables、Sif集團和TWI之間的合作，首次將電子束焊接部分整合到海上風力渦輪機單樁基礎（過渡件）中。由此產(chǎn)生的單樁將安裝在Dogger Bank風電場的第二階段，該風電場位于英格蘭東北海岸130多公里處。
Monopiles are currently fabricated using conventional techniques such as submerged arc welding (SAW), but the consortium has demonstrated that electron beam (EB) welding is significantly quicker, cheaper, cleaner, more energy efficient and produces high quality welds with excellent fatigue properties.
單樁目前使用埋弧焊（SAW）等傳統(tǒng)技術制造，但該聯(lián)盟已經(jīng)證明，電子束（EB）焊接明顯更快，更便宜，更清潔，更節(jié)能，并產(chǎn)生具有出色疲勞性能的高質量焊縫。
INNOVATIVE EBFLOW TECHNIQUE IS 25 X FASTER AND USES 90% LESS ENERGY 創(chuàng)新的EBFLOW技術速度提高25倍，能耗降低90% The type of electron beam welding technology used – called EbflowTM – is an innovative development within the electron beam welding industry. Instead of welding inside a costly and size-limiting vacuum chamber, Ebflow uses a local vacuum system that creates and maintains a vacuum around only the seam that is being welded. This technique unleashes the potential to use EB welding on large structures, such as the biggest monopiles, while reducing costs and enhancing productivity. The technology – developed by CVE – has been shown to weld monopiles at least 25 times faster than current methods, whilst using 90% less energy, costing 88% less, and producing 97% less CO2 emissions than SAW methods.
所使用的電子束焊接技術類型 - 稱為EbflowTM - 是電子束焊接行業(yè)的創(chuàng)新發(fā)展。Ebflow不需要在昂貴且尺寸有限的真空室中進行焊接，而是使用局部真空系統(tǒng)，僅在被焊接的接縫周圍產(chǎn)生并保持真空。這項技術釋放了在大型結構（如最大的單樁）上使用電子束焊接的潛力，同時降低了成本并提高了生產(chǎn)率。CVE開發(fā)的這項技術比現(xiàn)有方法焊接單樁的速度快至少25倍，同時比埋弧焊方法節(jié)省90%的能源，節(jié)省88%的成本，減少97%的二氧化碳排放。
The project required installation of an Ebflow system at Sif’s Maasvlakte 2 facility in Rotterdam to perform several longitudinal welds on 2750 mm length seams on 8m diameter rolled cans with a wall thickness of between 67-85mm. Qualification of the welding machine, weld procedures and operators were witnessed by third party inspectors and the regulatory body, DNV, which subsequently issued a technology qualification for EB welding and non-destructive testing (NDT) of the longitudinal seams produced with the process. The comprehensive performance testing programme proved that Ebflow produces welds with fatigue strength that is at least as good, if not better, than observed in equivalent arc welded joints.
該項目需要在Sif位于鹿特丹的Maasvlakte 2工廠安裝Ebflow系統(tǒng)，對直徑為8米、壁厚為67-85毫米的軋制罐進行2750毫米長的縱向焊接。第三方檢查員和監(jiān)管機構DNV見證了焊機、焊接程序和操作人員的資格認證，DNV隨后頒發(fā)了EB焊接和縱向焊縫無損檢測（NDT）的技術資格證書。綜合性能測試程序證明，Ebflow產(chǎn)生的焊縫的疲勞強度至少與等效弧焊接頭相同，如果不是更好的話。
The resulting can was incorporated into a monopile transition piece in January 2023 and is scheduled to be installed offshore as part of a foundation in Dogger Bank Wind Farm in late 2023.
該罐于2023年1月被整合到一個單樁過渡件中，并計劃于2023年底作為Dogger Bank風電場基礎的一部分安裝在海上。
Figure 1. The project team at Sif’s Maasvlakte 2 facility. 圖1. Sif的Maasvlakte 2設施的項目團隊。
FIRST-IN-CLASS PROJECT 首創(chuàng)一流的項目
Olly Cass, SSE Renewables Project Director for Dogger Bank Wind Farm said: “This is a ‘first-in-class’ project, establishing this UK innovation as a world-leading technology. With monopile type foundations accounting for over 90% of foundations used in UK projects, Ebflow RPEB could realise significant cost savings on future projects.
Dogger Bank風電場SSE可再生能源項目總監(jiān)Olly Cass表示： “這是一個'首創(chuàng)一流'的項目，將英國的這項創(chuàng)新確立為世界領先的技術。由于單樁型地基占英國項目中使用的地基的90%以上，Ebflow RPEB可以在未來的項目中實現(xiàn)顯著的成本節(jié)約。
“These substantial savings will not only benefit the UK offshore engineering industry but could be passed on to UK energy consumers.
“這些可觀的節(jié)省不僅將使英國海上工程行業(yè)受益，而且可以傳遞給英國能源消費者。
“We’re proud to be pioneering this innovative technique on Dogger Bank Wind Farm by demonstrating its capabilities on a critical offshore component and this would not have been possible without the great collaborative work with Cambridge Vacuum Engineering (CVE), Sif Group, and TWI. We’re excited about what could be achieved by scaling up this method to pick up the pace as we work towards net zero targets.”
“我們很自豪能夠在Dogger Bank風電場上率先采用這種創(chuàng)新技術，展示其在關鍵海上組件上的能力，如果沒有與劍橋真空工程（CVE），Sif Group和TWI的出色合作，這是不可能的。我們對通過擴大這種方法可以實現(xiàn)的目標感到興奮，以便在我們努力實現(xiàn)凈零目標時加快步伐。
咨詢電子束焊機：13501282025
Dogger Bank Wind Farm is a joint venture between SSE Renewables, Equinor and V?rgr?nn. The farm is being built in three 1.2GW phases and is expected to start generating power this summer.
Dogger Bank Wind Farm是SSE Renewables，Equinor和V?rgr?nn的合資企業(yè)。該風電場分三個階段建設，裝機容量為1.2GW，預計將于今年夏天開始發(fā)電。
