The invention relates to a device and a method for manufacturing a foundation for a mass located at height, such as the jacket of a wind turbine or a jetty, wherein the foundation comprises a quantity of piles driven into an underwater bottom in a geometric pattern. The invention also relates to an assembly of a jack-up platform and a device coupled thereto with which the method can be performed.
The invention will be elucidated hereinbelow with reference to an offshore wind turbine. The reference to a wind turbine in no way implies that the invention is limited to the use in the context of such a wind turbine. The positioning framework and the method can likewise be applied on any other structure, such as jetties, radar and other towers, platforms and the like. The support structure of a wind turbine normally has a slender design, for instance in the form of a tube or pillar. This pillar structure has to be coupled to a foundation in the ground. For offshore wind turbines, which are placed in relatively shallow water, it is possible to make use of one mast extending from the machinery housing of the wind turbine to the foundation. In addition to such a mono-pole construction, the support structure of an offshore wind turbine can also comprise a tubular upper part and a lower part in the form of a lattice structure, also referred to as a jacket. A large part of the jacket extends underwater, where the jacket finds support on an underwater bottom, in many cases the underwater bottom. Another option is a support structure in the form of a tripod.
A known method for providing a foundation for a mass located at height, such as the jacket of a wind turbine, comprises of providing an offshore platform in the vicinity of the location provided for the foundation, determining the location for each pile, subsequently manipulating each pile using a lifting crane present on the platform and driving each pile into the underwater bottom. Once all the piles have been arranged in the underwater bottom in the desired geometric pattern, thus forming the foundation, the jacket is arranged on the foundation formed by the quantity of piles by arranging legs of the jacket in the piles (also referred to as pin piling) or, in an alternative method, around the piles (also referred to as sleeve piling). The piles are adapted in both cases to be able to receive the legs of the jacket, for instance by providing hollow piles (pin piling) or hollow legs of the jacket (sleeve piling).
It will be apparent that it is of the greatest importance to not only urge the piles into the ground at the correct positions (the horizontal distance between the foundation piles must thus preferably be accurate to several centimetres), but also to ensure that the piles are arranged substantially at a perpendicular angle in the underwater bottom. In view of the large dimensions of structures such as wind turbines, it is only possible in many cases to allow a maximum variation of 1° relative to the vertical direction.
The invention has for its object to provide a device and method for providing a foundation as elucidated above with a greater accuracy than with the known device and method.
The invention provides for this purpose a device which comprises a positioning framework of a number of mutually connected guide tubes arranged in a geometric pattern and adapted to receive and guide a pile to be driven into the underwater bottom, wherein the guide tubes comprise a mechanism with which at least an internal wall part of the guide tubes is displaceable in the radial direction of the guide tubes from a radially inward support position for the pile to a radially more outward position in which the internal wall part substantially releases the pile. The guide tubes of the positioning framework are adapted to receive and guide piles when they are driven into the underwater bottom. At least an internal wall part of the guide tubes will here be situated in a radially inward support position for the pile, in which position the guide tubes have a smallest cross-section which is little larger than the cross-section of the piles, so that the piles at least find support against the internal wall part of the guide tubes. In order to enable easy removal of the positioning framework once the piles have been arranged in the underwater bottom, the positioning framework is preferably raised from a platform to a higher position, preferably guided by the spud poles, wherein during removal of the positioning framework the internal wall part of the guide tubes is situated in a radially more outward position in which the internal wall part substantially releases the pile. The device according to the invention makes it possible to arrange the piles accurately in the underwater bottom, both in respect of their position and in respect of their angle of inclination relative to the vertical direction. The positioning framework can moreover be easily removed by applying displaceable internal wall parts. An alternative method, wherein an internal wall part were to be situated fixedly at a smaller radius over a top part of the guide tubes, could consist of driving the piles so far through the guide tubes that the top of the piles extends further than the underside of the internal wall part. A drawback of such a method is that the guide tubes have to have a great height, and this does not enhance the stability, weight and ease of manipulation of the positioning framework. This is certainly the case when the foundation piles have to have a relatively large protrusion length (above the underwater bottom). The device according to the invention does not have these drawbacks and can, if desired, comprise relatively short guide tubes.
It is not unusual to provide the upper peripheral edge of foundation piles with welded protrusions, such as a weld bead, in order to improve for instance the attachment with grouting. Such protrusions make the guiding in the guide tubes more difficult. The device according to the invention also provides a solution herefor by displacing the internal wall part if desired and hereby leaving space for passage of the protrusions.
In a preferred embodiment of the device the internal wall part extends over practically the whole length of the guide tubes. The guide tubes can hereby be of relatively short length, which is advantageous. The guide tubes preferably have a height (the dimension in the longitudinal direction of the guide tubes) of at least 1 m, more preferably at least 3 m and most preferably at least 5 m, in order to further be able to guarantee the desired guiding function and vertical alignment of the foundation piles. The advantage of the invention becomes most clearly manifest when the height of the guide tubes does not rise above 10 m.
In order to further improve the guiding of the foundation piles it is recommended that the device according to the invention is characterized in that the internal wall part of the guide tubes comprises support ribs extending substantially in the longitudinal direction of the guide tubes.
An internal wall part of the guide tubes can be made displaceable in the radial direction of the guide tubes in any manner. A preferred embodiment of the device according to the invention comprises a positioning framework, the guide tubes of which comprise recesses in the peripheral casing thereof, in which recesses the support ribs can be received. Such an embodiment allows control of the displacement of the support ribs via the outer side of the guide tubes, this for instance improving accessibility in the case of malfunction. The mechanism will generally also be situated outside the guide tubes in this embodiment, this reducing the risk of damage.
In a first preferred embodiment the mechanism comprises a hinged plate which is coupled pivotally to the guide tubes and to which a support rib is attached, wherein the hinged plate is adapted, by means of rotation around a horizontal axis, to displace the support rib connected thereto from the radially inward support position to the radially more outward position.
In a second preferred embodiment the mechanism comprises a ring which is arranged around the peripheral surface of the guide tubes and which is coupled along its inner periphery to the support ribs, wherein the radius of the inner periphery varies in peripheral direction so that a support rib is displaced in radial direction when the ring is rotated.
In a third preferred embodiment the mechanism comprises a ring which is arranged round the peripheral surface of the guide tubes and which is provided along its inner periphery with the support ribs, and which can be divided into two or more ring parts so that a support rib is displaced in radial direction when the ring is divided.
The positioning framework can be moved along and under the guidance of the spud poles by any means known to the skilled person. It is thus possible for instance to suspend the positioning framework from a number of traction cables, wherein the cables can be varied in length by for instance winches arranged on the work deck of the platform. The cable length can be shortened or lengthened using the winches, wherein the positioning framework is respectively lifted or lowered.
In a preferred embodiment of the method according to the invention the positioning framework is further provided with means for guiding the positioning framework along the spud poles of an offshore platform from a high position in the immediate vicinity of the work deck of the platform to a lower position, optionally onto or into the immediate vicinity of the underwater bottom. The guide means are preferably adapted such that they can guide the positioning framework along the spud poles of the platform so that the positioning framework is aligned substantially horizontally in the lower position. This can for instance take place by suspending the positioning framework by means of three, four or even more cables, wherein each cable can be varied in length independently of the other cables by winches. This is particularly important in the case of an underwater bottom which is not wholly flat. The number of cables generally depends on the form of the positioning framework.
The positioning framework according to the invention preferably comprises a lattice structure with a number of guide tubes which are disposed spaced apart at the corner points thereof and which are connected by tubular lattice elements. The dimensions of the positioning framework in the plane are in principle larger than the dimensions out of the plane, wherein the direction out of the plane corresponds to a direction parallel to the lifting or lowering direction of the positioning framework. The guide tubes are adapted to receive and guide the piles for driving into the underwater bottom, and preferably comprise cylindrical casings, the longitudinal axis of which runs parallel to the direction of the positioning framework out of the plane. The guide tubes are arranged in a geometric pattern, this pattern corresponding to the desired geometric pattern of the foundation piles. The tubular lattice elements extending between the guide tubes ensure that guide tubes remain substantially in their position during lifting and lowering of the positioning framework. In the present embodiment the positioning framework is adapted to define a specific geometric pattern of the foundation piles. It is however also possible to make the positioning framework geometrically adaptable, for instance by providing the positioning framework with lattice elements adjustable in length and/or by providing the positioning framework with nodes which mutually connect lattice elements and allow adjustment of the angle between lattice elements. Such an embodiment allows realization of different geometric patterns of the foundation piles.
A preferred embodiment of the method according to the invention comprises of firstly establishing the position for at least one pile and positioning the assembly of platform and positioning framework such that at least one guide tube of the positioning framework is situated directly above said pile position. The arranging of a first pile through the at least one guide tube fixes the positioning framework. In such a position the guide tubes for the other piles will automatically be located in their correct positions because their relative positions are determined by the geometric design of the positioning framework. A position determination for each individual pile is hereby no longer necessary.
In another preferred embodiment of the method according to the invention, wherein the work deck of the platform is provided with at least one opening which is adapted for passage of a pile and which is vertically aligned with one of the guide tubes of the positioning framework, an assembly of platform and positioning framework is positioned such that the opening (also referred to as moon pool) is located directly above said pile position and is aligned with one of the guide tubes. In such an embodiment the positioning framework is placed at least partially overlapping with the jack-up platform (preferably on the underside of the platform), wherein a significant part of the platform is overlapped. Arranging a first pile through the opening and the corresponding guide tube fixes the positioning framework in respect of the platform.
The foundation piles can be arranged in the underwater bottom in any manner, such as for instance by means of a pneumatic or hydraulic hammer, generally from the platform.
In another aspect of the invention a method is provided comprising the step of removing the positioning framework once the piles have been arranged in the underwater bottom, wherein the removal of the positioning framework is performed by lifting thereof with guiding by the spud poles from the lower position to the high position in the vicinity of the work deck of the platform.
The invention further relates to a method for installing on a foundation a mass located at height, such as the jacket of a wind turbine or a jetty, wherein the foundation comprises a number of piles arranged by means of the above described method in an underwater bottom, the method comprising of arranging legs of the mass located at height into or around the piles and anchoring the legs to the piles by means of grouting.
In yet another aspect of the invention an assembly of a jack-up platform and a positioning framework coupled to the platform is provided wherein the positioning framework comprises a number of mutually connected guide tubes arranged in a geometric pattern and adapted to receive and guide a pile to be driven into the underwater bottom, wherein the guide tubes comprise a mechanism with which at least an internal wall part of the guide tubes is displaceable in the radial direction of the guide tubes from a radially inward support position for the pile to a radially more outward position in which the internal wall part substantially releases the pile, and wherein the positioning framework is provided with means for guiding the positioning framework along the spud poles of the platform from a high position in the immediate vicinity of the work deck of the platform to a lower position, optionally onto or into the immediate vicinity of the underwater bottom.
The advantages of such an assembly have already been discussed above in the context of the method and will therefore not be repeated here.
In another preferred embodiment of the invention an assembly is provided in which the work deck of the platform is provided with at least one opening which is adapted for passage of a pile and which is vertically aligned with one of the guide tubes of the positioning framework. Such an opening (or moon pool) will have a cross-section large enough for passage of a pile. The method according to the invention is particularly suitable for application with cylindrical (optionally) hollow foundation piles having an outer diameter of at least 1.2 in, more preferably at least 1.5 in, and most preferably at least 1.8 in, and with an (optional) wall thickness of 0.01 to 0.1 m, more preferably of 0.02 to 0.08 in, and most preferably of 0.04 to 0.06 in. A particularly suitable assembly according to the invention comprises at least one circular opening with a diameter of at least 1.5 in, more preferably at least 2.5 in and most preferably at least 3.0 in.
The method according to the invention is further particularly suitable for cylindrical (hollow) foundation piles with a length of more than 20 in, more preferably at least 25 in and most preferably at least 30 in, and a weight of 20 to 250 tonnes, more preferably of 60 to 200 tonnes and most preferably of 75 to 180 tonnes.
The invention will now be elucidated in more detail with reference to the drawings, without otherwise being limited thereto. In the figures:
Shown with reference to
Guide tubes (2a, 2b, 2c) are held in a fixed position relative to each other by the side lattices (3a, 3b, 3c) and the cross braces (5a, 5b, 5c), this such that guide tubes (2a, 2b, 2c) are arranged in a geometric pattern, this pattern being in the embodiment shown in
Each guide tube (2a, 2b, 2c) comprises a cylindrical peripheral wall (23a, 23b, 23c) which is supported by a base plate (21a, 21b, 21c) and with which positioning framework 1 can find support on the underwater bottom. The dimensions of guide tubes (2a, 2b, 2c) can be selected within wide limits, but have in the shown embodiment a height of about 6 m.
Positioning framework 1 is further providing the means for guiding positioning framework 1 along the spud poles of an offshore platform shown in
A jack-up platform 10 adapted according to the invention is shown in
According to the invention the guide tubes (2a, 2b, 2c) are adapted to receive and guide a pile (13a, 13b, 13c) to be driven into underwater bottom 30. Guide tubes (2a, 2b, 2c) comprise for this purpose a mechanism (25a, 25b, 25c) with which at least an internal wall part of the guide tubes is displaceable in the radial direction of guide tubes (2a, 2b, 2c) from a radially inward support position for the pile (13a, 13b, 13c) to a radially more outward position in which the internal wall part substantially releases the pile (13a, 13b, 13c). If desired, mechanism (25a, 25b, 25c) can be controlled from platform 10. The necessary provisions such as computers, electric power supplies, cabling and the like are present for this purpose, although these will not be discussed in further detail below.
A first preferred embodiment of a guide tube 2 shown in
A second preferred embodiment of a guide tube 2 shown in
A third preferred embodiment of a guide tube 2 shown in
An embodiment of the method according to the invention is shown in a number of steps in
As shown in
In a subsequent step of the method (see
Once pile 40 has been correctly aligned with guide tube 2c, the pile is lowered further until it is partially received in tube 2c. The support ribs (253, 354 or 452) are brought into the radially inward support position for pile 40, after which pile 40 is driven further into underwater bottom 30, wherein pile 40 is supported and guided by the support ribs of guide tube 2c (see
As shown in
The above described sequence of method steps is then repeated a number of times, depending on the desired number of foundation piles which must be arranged in underwater bottom 30. Because guide tubes (2a, 2b, 2c) of positioning framework 1 are automatically situated in the correct positions, all piles can be driven in efficient manner into underwater bottom 30 without losing time in determining the position for each individual pile. Once all piles 40 have been arranged in underwater bottom 30, positioning framework 1 can optionally be removed by being lifted along spud poles (13a, 13b) from the position of use to the rest position close to work deck 11 of platform 10 using winches 15 and lifting cables 35. In order to enable the removal of positioning framework 1 the support ribs (253, 354 or 452) are moved into the radially outward position, wherein the piles are released. If desired, the position of piles 40 and/or the vertical position of the top of each of the piles 40 can be checked using means suitable for the purpose prior to removal of positioning framework 1.
Referring to
The method and assembly of a platform and positioning framework according to the invention allow a pile foundation to be provided in efficient manner, wherein it is not necessary to displace the platform regularly for each pile, whereby much time is gained relative to the known method. The invented method is less dependent on weather conditions and requires in principle no extensive inspection operations underwater, for instance by robots and/or divers.
Number | Date | Country | Kind |
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BE2011/0122 | Feb 2011 | BE | national |