The disclosure relates to a method of handling a wind turbine component in a wind turbine. Particularly, the method relates to a wind turbine comprising a tower extending in an upwards direction, a load carrying structure extending in an outwards direction and being fixed to the tower, and an energy generating unit fixed to the load carrying structure. Such structures are typically seen in multiple rotor wind turbines. In such wind turbines, the outwards direction is transverse to the upwards direction.
The invention further relates to a lifting system and a crane for handling wind turbine components.
In wind turbines, wind energy is converted into mechanical energy by blades carried by a hub. The hub may be carried by a shaft. The size and weight of the wind turbine tower, nacelle, blades, and drive train have increased over the years and manufacturing, transport, and assembly of the wind turbines have become more and more challenging.
Modern wind turbines may include towers which are more than 100 meters tall.
In multirotor wind turbines the energy generating units may be carried by a load carrying structure which, in turn, is connected to a tower.
A conventional approach for assembly of wind turbines, and particularly the nacelle, includes lifting the components by use of an external crane, e.g. a mobile crane or a floating crane.
Since external crane operations are expensive, the nacelle is sometimes fitted with an internal crane which, once the nacelle is installed, can be used for servicing and minor repair, e.g. for hoisting spare parts from the ground into the nacelle. However, for cost optimization, such integrated cranes are normally small and lacks the capacity to handle large or heavy wind turbine components.
It is an object of the present disclosure to reduce costs in handling wind turbine components, and particularly to facilitate the assembly of wind turbines.
According to these and other objects, the disclosure, in a first aspect, provides a method of handling a wind turbine component in a multiple rotor wind turbine, the method comprising:
In a second aspect, the disclosure provides a wind turbine with a crane.
Due to the crane, time and money can be saved during the installation of the wind turbine. Particularly, the use of a lifting rope for mounting the crane to the attachment point enables the use of the crane for mounting e.g. the energy generating unit and other large components. This enables assembly of the wind turbine without the use of external cranes.
The method may e.g. be applied for mounting a component when erecting the wind turbine or for dismounting or replacing a component during repair or servicing. The mounting or dismounting may include positioning or dispositioning for removing the wind turbine component completely or in parts. The component could e.g. be a part of a drive train, e.g. a rotor shaft, a gear box, a generator, a hub, or a blade for the hub.
In the present context, the term ‘multirotor wind turbine’ should be interpreted to mean a wind turbine comprising two or more rotors or energy generating units mounted on one tower. The load carrying structure is arranged for supporting at least one of the at least two energy generating units and for being connected to a tower of the multirotor wind turbine.
The load carrying structure may be configured for self supporting carrying of the energy generating unit, or it may be configured for being further stiffened or stabilised by additional structures such as tension elements such as guy wires etc. One or more guy wires could be attached during use of the crane, and in one embodiment, they could be removed when the crane is removed or they are left on the wind turbine to support the load carrying structure even when the crane is removed.
Accordingly, the load carrying structure forms a connection between the one or more energy generating units and the tower, and is capable of handling the loads involved with carrying the at least one energy generating unit. Particularly, the load carrying structure may be constituted by a first component and a second component, the components being structurally different. The first component may e.g. be a lightweight component, e.g. a hollow component, a lattice structure or similar relatively light weight structure constituting the largest part of the load carrying structure. The first component may e.g. be a tube. The second component may be arranged as a termination of the first component at the free end furthest away from the tower. The second component could be relatively heavy compared to the first component, and it may e.g. be constituted by a casted component. Particularly, the second component may have a higher rigidity, strength, or hardness than the first component. The second component may be referred to as the ‘bell’.
The energy generating unit is typically arranged at or near the end of the load carrying structure. By the abovementioned first and second components constituting the load carrying structure, the energy generating unit may particularly be fixed to the second component, the bell, either directly or via an adapter.
Typically, two load carrying structures are arranged on opposite sides of the tower to thereby balance forces and loads with respect to the tower. The energy generating units may be arranged at extremities of the load carrying structures, i.e. furthest away from the tower.
The load carrying structure may be attached to the tower via a yaw arrangement whereby the load carrying structure is allowed to perform yawing movements with respect to the tower, thereby allowing the rotors of the energy generating units to be directed into the incoming wind.
In the present context the term ‘energy generating unit’ should be interpreted to mean a part of the wind turbine which transforms the energy of the wind into electrical energy. Normally, this constitutes a nacelle and a rotor.
In the present context the term ‘tower’ should be interpreted to mean a substantially vertical structure, arranged to carry the energy generating units of the multirotor wind turbine, at least partly via one or more load carrying structures. One or more energy generating units could be mounted directly on the tower.
The load carrying structure may particularly be constituted by a compression element which is carried by a tension element. The compression element may e.g. be a rigid tubular steel element or a steel element with any alternative shape making it suitable for compensation of compressive forces. The tension element could be a rod or wire forming a guy wire extending between the tower and the load carrying structure. As mentioned above, the compression element may comprise a first and a second component.
The outwards direction of the load carrying structure could be perpendicular to the upwards direction of the tower, or it could be a direction in the range of 5-25 degrees, such as 15 degrees upwards relative to perpendicular, i.e. pointing upwards.
The crane could be released from the attachment point and removed from the wind turbine once handling of the wind turbine component is ended.
When used herein, the term ‘crane’ could be a machine of any kind and equipped with means enabling its use for hoisting and/or lowering the wind turbine component. Such means may include e.g. a jack-up arrangement and/or a crane rope powered by a lifting power structure, e.g. an electric or hydraulic winch. When used herein, the term ‘crane’ is the crane which according to the invention is lifted to the load carrying structure by the lifting rope. Other cranes are mentioned with a prefix, e.g. ‘internal crane’, ‘external crane’ etc., but the word ‘crane’ without a prefix denotes the crane lifted with the lifting rope.
In one embodiment, the lifting rope is the crane rope and can be winded in or out by the lifting power structure. In this embodiment, the crane rope which constitutes the lifting rope could be attached to an internal hoisting rope of an internal or interim crane, e.g. an internal crane which is small relative to the crane. Herein, an interim crane is a small crane attached only for the purpose of lifting the crane to the load carrying structure. The interim crane thus constitutes an internal crane once it is attached.
By use of the smaller internal crane and the internal lifting rope, the lifting rope could be lifted to the load carrying structure or to the energy generating unit by use of the internal crane. Subsequently, the lifting rope is fixed to the load carrying structure or to the energy generating unit and the crane could be lifted by the lifting rope and by use of the lifting power structure included in the crane, i.e. the crane may lift itself.
The crane may particularly be attached to an attachment point at or near the end of the load carrying structure. By the aforementioned first and second components constituting the load carrying structure, the attachment point may particularly be a point on the second component, i.e. the bell.
The term ‘rope’ should herein be interpreted as any kind of flexible tension member, e.g. in the form of a wire, a chain, or similar element. Typically, the crane includes a sheave around which the crane rope is winded and which forms a point of release for the crane rope.
The lifting rope is attached to the crane and used for lifting the crane from ground or sea level to the load carrying structure. The lifting rope could be any kind of flexible tension member, e.g. in the form of a wire, a chain, or similar element.
The lifting rope could be attached to the fixation structure, i.e. to that part of the crane which is fixed to the attachment point. Particularly, the lifting rope may be attached between the load carrying structure and the fixation structure such that the fixation structure can be lifted directly into a position which is suitable for fixing the crane to the load carrying structure. The lifting rope may also be constituted by the crane rope.
The fixation structure may e.g. be configured to interface the load carrying structure in a predetermined orientation, and the crane could be provided with a weight distribution such that it can be lifted with the lifting rope attached to the fixation structure and be in balance in an orientation, herein referred to as ‘balance orientation’, which matches the predetermined orientation. Herein ‘matches’ means that the crane, when lifted in the fixation structure, maintains an orientation in which the fixation structure can engage and be fixed to the attachment point.
The fixation structure and the attachment point may particularly facilitate geometric locking of the crane to the load carrying structure or energy generating unit. As an example, the fixation structure may include one or more projections cooperative with one or more indentations or holes on the load carrying structure, or the fixation structure may include one or more indentations or holes cooperative with one or more projections on the load carrying structure. Particularly, such projections, or indentations, or holes, could have a cross section suitable for guiding the crane into a correct position on the load carrying structure, e.g. a pyramid or conic shape of projections of the fixation structure or on the load carrying structure. Further, such projections, or indentations, or holes, could have a cross section suitable for preventing reorientation of the crane relative to the load carrying structure, e.g. a non-circular cross section.
The crane may be configured to form contact with the load carrying structure below a geometric centre of a cross section of the load carrying structure transverse to the outwards direction. Further the crane may be provided such that it extends in contact with the load carrying structure from the point below the geometric centre to a point above the geometric centre. In one embodiment, the fixation structure forms a U-shaped, a C-shaped, a horse-shoe-shaped, or a similar shaped structure which can clamp around the load carrying structure from a point below its geometric centre to a point above its geometric centre.
The crane could be provided with a hoisting point, e.g. a sheave, forming a point of suspension of the crane rope, and it could be provided such that the position of the hoisting point is movable relative to the position of the fixation structure. In one example, the crane comprises one or more elements movable relative to each other, e.g. elements linked in hinges and movable by power driven means.
The load carrying structure could be supported by a tension element in the form of a guy wire extending from the tower to a support point on the load carrying structure. The support point may typically be arranged at or near the end of the load carrying structure. By the aforementioned first and second components constituting the load carrying structure, the support point may particularly be a point on the second component, i.e. the bell.
In that way, the crane can be attached in the area where the load carrying structure is supported and the ability to handle heavy wind turbine components by use of the crane is increased while the guy wire prevents deflection of the load carrying structure.
A tagline could be connected to the crane when the crane is lifted by the lifting rope. In that way, the crane could be guided past obstacles during the hoisting procedure, e.g. if the wind turbine comprises more than one load carrying structure and the crane has to be lifted past a lower one of the load carrying structures for fixation to an upper one of the load carrying structures.
Once the crane is fixed to the attachment point, the method may be applied for lifting extension components suitable for extending the crane structure. I.e. the crane can be expanded in size or lifting capability by lifting extension components to the crane by use of the crane. In that way, the method may imply the step of, initially, lifting a relatively small or light weight crane and subsequently expanding the crane by lifting extension components.
Additionally, the method may include the use of the crane for lifting a further crane and fixing the further crane to the load carrying structure. Subsequently, the crane and the further crane may cooperate in handling the wind turbine component.
The crane could be hoisted in one single hoisting procedure and in one single piece after complete assembly of the crane at a factory or at the place where the wind turbine is assembled. Alternatively, the crane could be hoisted in several separate pieces in several subsequent hoisting procedures, and assembled on or at the load carrying structure. In one example, the fixation structure is hoisted firstly and attached to the attachment point, and further components are hoisted subsequently and attached to the fixation structure.
In a second aspect, the disclosure provides a wind turbine comprising a tower extending in an upwards direction, a load carrying structure extending in an outwards direction and being fixed to the tower, and an energy generating unit fixed to the load carrying structure, wherein the outwards direction is transverse to the upwards direction, the wind turbine further comprising a crane attached to an attachment point of the load carrying structure or on the energy generating unit.
The load carrying structure may comprise at least a first component and a second component, and the second component may form an axial termination of the first component and have a higher strength than the first component. In this embodiment, the attachment point may be a point on the second component. Further, in this embodiment, the second component could be a casted component. The second component may form a connection interface to the first component and an interface to the energy generating unit.
The wind turbine may comprise a tension element, e.g. a guy wire, extending between the tower and a support point on the second component.
In further aspects, the disclosure may provide a crane with crane rope powered by a lifting power structure which is sufficiently strong to allow the crane to lift itself.
The invention will now be described in further detail with reference to the accompanying drawings in which
The load carrying structures in a pair of load carrying structures extend in opposite outwards directions away from the tower 102.
Each load carrying structure 103 supports an energy generating unit 105, and each energy generating unit 105 comprises a nacelle 106 and a rotor 107 carrying three wind turbine blades 108. Each energy generating unit 105 is connected to a load carrying structure via a rotational joint.
The load carrying structures 103 are attached to the tower 102 via a yaw arrangement 111, allowing the entire pair of load carrying structures to perform yawing movements with respect to the tower 102 in order to direct the rotors 107 into the incoming wind.
When the multirotor wind turbine 101 is operational, the energy generating units 105 are placed symmetrically around the tower 102 so that the multirotor wind turbine is balanced.
For maintenance and service, components 112 can be hoisted from ground to the nacelle by an internal hoisting rope 113 of an internal crane in the nacelle. The internal crane has very limited lifting capability.
The wind turbine comprises guy wires 114 attached either momentary for the purpose of supporting the load carrying structure while the crane is used or stationary, i.e. also after the crane is removed.
The crane body includes a hinge structure 26 which allows rotation of a first body part 27 relative to a second body part 28 and thus enables movement of the hoisting point 23 relative to the fixation structure 22.
In a front end of the second body part, the crane forms the illustrated hoisting point 23, in an opposite, second, end of the second body part, the crane forms a combined counterweight and control unit 29. The counterweight provides balance relative to the hinge structure 26 and thereby allows lifting of heavy components, and the control structure may include power driven means for driving the crane rope 25.
The energy generating unit 33 comprises an internal crane 34 handling a lifting rope 35. The lifting rope is thereby attached to the load carrying structure via the interface between the energy generating unit 33 and the load carrying structure 31, 32.
In
The attachment point is, in this embodiment, a lower section of the second part 32 of the load carrying structure.
The crane illustrated in
The crane illustrated in
In the following, use of the crane will be described with reference to a specific example and with reference to the
When doing a replacement of main components, a small jack-up barge will carry both an interim crane and a larger crane which is to be used for handling the components to the turbine.
When the barge has been jacked up, a small interim crane, e.g. of the brand ‘Tirak’, will be lifted to the load carrying structure. This procedure is illustrated in
When the crane has reached the top, the crane is bolted to the load carrying structure from the inside, i.e. from inside the hollow part of this structure. This is illustrated in
Following this procedure, the lifting lug 190 is released from the arm 162, c.f.
When the crane has reached an upwards position, the crane will unfold, and is now ready to start lifting and handling components for the wind turbine.
Number | Date | Country | Kind |
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PA 2017 71023 | Dec 2017 | DK | national |
Filing Document | Filing Date | Country | Kind |
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PCT/DK2018/050421 | 12/21/2018 | WO | 00 |