风力发电机单桩首次电子束焊接取得显著成果

 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. 

剑桥真空工程公司（CVE）、SSE Renewables、Sif集团和TWI之间的合作，首次将电子束焊接部分整合到海上风力涡轮机单桩基础（过渡件）中。由此产生的单桩将安装在Dogger Bank风电场的第二阶段，该风电场位于英格兰东北海岸130多公里处。 

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. 

单桩目前使用埋弧焊（SAW）等传统技术制造，但该联盟已经证明，电子束（EB）焊接明显更快，更便宜，更清洁，更节能，并产生具有出色疲劳性能的高质量焊缝。 

INNOVATIVE EBFLOW TECHNIQUE IS 25 X FASTER AND USES 90% LESS ENERGY 创新的EBFLOW技术速度提高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. 

所使用的电子束焊接技术类型 - 称为EbflowTM - 是电子束焊接行业的创新发展。Ebflow不需要在昂贵且尺寸有限的真空室中进行焊接，而是使用局部真空系统，仅在被焊接的接缝周围产生并保持真空。这项技术释放了在大型结构（如最大的单桩）上使用电子束焊接的潜力，同时降低了成本并提高了生产率。CVE开发的这项技术比现有方法焊接单桩的速度快至少25倍，同时比埋弧焊方法节省90%的能源，节省88%的成本，减少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. 

该项目需要在Sif位于鹿特丹的Maasvlakte 2工厂安装Ebflow系统，对直径为8米、壁厚为67-85毫米的轧制罐进行2750毫米长的纵向焊接。第三方检查员和监管机构DNV见证了焊机、焊接程序和操作人员的资格认证，DNV随后颁发了EB焊接和纵向焊缝无损检测（NDT）的技术资格证书。综合性能测试程序证明，Ebflow产生的焊缝的疲劳强度至少与等效弧焊接头相同，如果不是更好的话。

 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. 

该罐于2023年1月被整合到一个单桩过渡件中，并计划于2023年底作为Dogger Bank风电场基础的一部分安装在海上。  

Figure 1. The project team at Sif’s Maasvlakte 2 facility. 图1. Sif的Maasvlakte 2设施的项目团队。

 FIRST-IN-CLASS PROJECT 首创一流的项目

 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风电场SSE可再生能源项目总监Olly Cass表示： “这是一个'首创一流'的项目，将英国的这项创新确立为世界领先的技术。由于单桩型地基占英国项目中使用的地基的90%以上，Ebflow RPEB可以在未来的项目中实现显著的成本节约。 

“These substantial savings will not only benefit the UK offshore engineering industry but could be passed on to UK energy consumers. 

“这些可观的节省不仅将使英国海上工程行业受益，而且可以传递给英国能源消费者。 

“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.” 

“我们很自豪能够在Dogger Bank风电场上率先采用这种创新技术，展示其在关键海上组件上的能力，如果没有与剑桥真空工程（CVE），Sif Group和TWI的出色合作，这是不可能的。我们对通过扩大这种方法可以实现的目标感到兴奋，以便在我们努力实现净零目标时加快步伐。 

咨询电子束焊机：13501282025

Dogger Bank Wind Farm is a joint venture between SSE Renewables, Equinor and Vårgrønn. 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Vårgrønn的合资企业。该风电场分三个阶段建设，装机容量为1.2GW，预计将于今年夏天开始发电。