The invention relates to a method for mounting a super structure on a foundation pile. The invention relates to a method for mounting a super structure over a top end of a foundation pile, for forming a slip joint between the super structure and the said top end of the foundation pile. The invention further relates to structures for use in such mounting.
In for example onshore and offshore structures slip joints are used for mounting super structures on foundation piles, such as monopiles driven into a land surface or a sea bed. This means generally that a super structure having a suitable mounting opening is slipped over a truncated conical shaped upper end of a pile. The opening has an inner surface which is shaped according to said conical upper end, such that it can be slipped over said end and forced onto said end by force of gravity. Such joints rely on gravity and friction between the outer surface of said upper end of the pile and the inner surface of the super structure for maintaining the super structure in position, even at high loads working on the super structure and foundation, such as for example due to waves and/or wind. Such slip joint is for example known from WO2020/106146 or WO2018/070868.
When installing a super structure onto a top end of a foundation pile, for forming a slip joint, the super structure is traditionally lifted by a crane to a position above the top end of the foundation pile, such that the opening of the super structure can be lowered over the top end of the foundation pile. This requires relatively high precision since the opening is generally not much larger than the cross section at the top of the top end of the foundation pile over which said opening has to be fitted. During mounting of the super structure, such as for example a platform, the super structure will be suspended from the crane and hence will be susceptible to external forces, such as wind. Moreover, if the super structure is an off-shore structure which is to be placed using a lifting vessel, also waves will effect the precision with which the structure can be lowered onto the foundation pile. This means that the mounting of the super structure is highly dependent on good weather conditions, with for example no or only limited winds and no or only limited waves. Which limits the time frame during which such mounting operations can be performed significantly and may lead to relatively long waiting periods for personnel and equipment, which can be highly cost inefficient. This may even make such projects only possible during relatively short seasons. Moreover, during such mounting operations damage may occur to the super structure and/or the foundation pile, because of for example sudden gusts of wind or waves which may result in the suspended super structure making sudden and non-controllable movements relative to the foundation pile, which may result in collisions.
In off-shore mounting it is known to use installation platforms which are fixed at the sea bed near the foundation pile, in order to avoid influence of waves to a high extend. This is however time consuming and costly because of the equipment and personnel necessary. Moreover, even if using such platforms the influence of wind on the suspended super structure will not be eliminated.
There is a need for an improved method and equipment for mounting of a super structure onto a foundation pile.
In the present disclosure in one aspect a method is disclosed for mounting a super structure over a top end of a foundation pile, wherein the top end has a truncated conical shape and the super structure has an opening fitting over said top end. In an aspect of the present disclosure a guide structure is placed at said top end, comprising at least one sloping guide surface. Thereafter said super structure is lowered over the guide structure onto the top end of the foundation pile. During lowering of the super structure onto the foundation pile the guide surface of the guide structure can guide the super structure, such that wind and/or waves will have less impact on the positioning of the super structure.
The opening preferably has a truncated conical peripheral surface fitting over said top end of the foundation pile.
When using a method according to the disclosure a side ways movement of the super structure relative to the foundation pile will be prevented or at least limited by the guide surface of the guide structure. By the sloping guide surface upon further lowering of the super structure the guide surface will increasingly center the super structure relative to the top end of the foundation pile, making positioning of the super structure more easily possible, even at relatively high winds and/or waves.
Preferably in a method according to the disclosure after mounting of the super structure the guide structure is removed from the foundation pile. The guide structure can for example be reused for mounting a further super structure to a further foundation pile. Furthermore by removing the guide structure the top end of the foundation pile, especially the top surface of said top end comes available again, for example for mounting a further super structure, such as for example but not limited to a tower of a wind turbine generator, as for example disclosed in WO2020/106146.
In an aspect according to the disclosure a guide structure can be used having an upper part with a cross section increasing in dimensions, especially diameter, in a downward direction, i.e. in a direction during use towards the foundation pile. Preferably the said upper part is substantially conical or truncated conical. In an aspect according to the disclosure such guide structure can be used having a lower part, connected to the upper part, which lower part has a decreasing cross section in a direction away from the upper part. The lower part preferably has a substantially conical or truncated conical configuration.
In a very suitable configuration a guide structure is used in which an upper part is provided, having a conical or truncated conical shape and a lower part is used also having a conical or truncated conical shape, the upper and lower part having decreasing cross sections in opposite directions. Said upper and lower part in such embodiment preferably meet at an interface plane, wherein the upper part extends radially outward relative to the lower part, such that a support element is provided with which the guide structure can be supported on the upper end of the foundation pile, the lower part extending into an open upper end of said foundation pile, the upper part extending upward from said end.
With such embodiment of a guide structure the advantage can be obtained that the guide structure can be self-centering when being lowered to the foundation pile. Preferably the lower part in such embodiment has a maximum cross section at or near the interface plane between the upper and lower parts which is substantially equal to the inner cross section of the open end of the foundation pile.
In an aspect of the disclosure a method is further characterized in that at least during use the guide structure and the super structure are suspended from a support frame, wherein preferably the guide structure is suspended such that it extends at least partly below the super structure. With such method the super structure and the guide structure can be lifted together, and be lowered onto the foundation pile together. This will further reduce the time involved in mounting the super structure. In such method when suspended from the support frame preferably the guide structure extends partly below the super structure, such that said part of the guide structure is mounted to, especially entered into an open end of the open end of the foundation pile, before the super structure is moved over said top end of the foundation pile.
In embodiments of a method according to the disclosure the guide structure and the super structure, suspended from the support frame, are lifted to a position above the upper end of the foundation pile, such that the guide structure, especially a lower part thereof, is suspended directly above the top end of the foundation pile, especially an open top end of said foundation pile. Thereafter the support frame is lowered such that the guide structure is at least partly inserted into said open top end of the foundation pile, where after the support frame is lowered further, such that the super structure is lowered over an outer surface of the top end of the foundation pile, forming a slip joint with the foundation pile. Then the super structure is released from the support frame and the support frame is lifted again, pulling the guide structure away from the foundation pile.
A method according to the disclosure is especially but not exclusively suitable for mounting a platform with an upper side and a lower side, and wherein the said opening extends through the platform, from the upper side to the lower side. In such method the guide structure can easily be suspended from a suspension element extending through said opening, said suspension element being connected to a support frame extending above the platform and the guide structure.
In embodiments according to the disclosure the guide structure can be a relatively open structure, such that wind can pass largely through said guide structure.
The present disclosure is further directed to a novel guide structure for use in mounting a super structure onto a foundation pile.
In an aspect of the disclosure a guide structure is provided which comprises an upper part and a lower part, wherein the upper part comprises or forms a guide surface and the lower part is designed for engaging a top end of a foundation pile, such that during use the lower part enables centering of the guide structure relative to the top end of the foundation pile and the guide surface extends above the top end of the foundation pile for guiding a super structure during lowering of the super structure onto the top end of the foundation pile.
The present disclosure is further directed to an assembly of a guide structure according to the disclosure and a super structure, wherein the assembly further comprises a support frame, wherein the super structure and the guide structure are supported by, preferably suspended from the support frame.
The present disclosure is further directed to a foundation pile for supporting at least one super structure, especially a monopile for mounting at least a platform by a slip joint, wherein the foundation pile is provided at a top end with a removable guide structure for guiding said super structure relative to the top end during mounting of said super structure.
Embodiments of methods, structures and assemblies according to the disclosure will be discussed hereafter, with reference to the drawings, which are only given by way of example and should by no means be understood as limiting the scope of the disclosure or protection in any way or form. These examples are given in order to better understand the invention and are not restrictive. In these drawings:
In this description the same or similar parts will be referred to by the same or similar reference signs. Though different embodiments or parts thereof are shown also combinations of embodiments of the methods and structures or parts thereof should be considered having been disclosed herein.
In this description an offshore structure should be understood as at least including any structure founded in or on the bottom of a body of water, including but not limited to the bottom of a sea or ocean. In this disclosure an offshore structure can for example be a wind mill, drilling rig, electrical unit such as a transformer, or the like, preferably supported at least partly above a water surface of the body of water where the structure is positioned. On-shore structures can be the same or similar constructions, but then provided on land.
In this description a platform mounted or to be mounted on a pile as disclosed should be understood as meaning at least but not limited to a platform surrounding at least partly the pile. Preferably the platform forms a slip joint with the pile, but alternatively the platform can be mounted differently, for example bolted to the pile. Such platform can be suitable for landing of a vessel for transferring people and/or products to and from the offshore structure, and/or for people to move around the pile and/or tower or leg mounted on the pile safely. In the present disclosure if used with a tower mounted on the pile too, a platform is mounted prior to fixing a tower to the pile, such that personnel can enter onto the platform and assist in positioning and fixing, such as for example bolting the tower to the pile.
In this description words like substantially or about should be understood as meaning that for a given value or aspect this word is used with small deviations considered allowable, for example deviations of less than 20% of such given value, such as less than 15%, for example less than 10%, or at least deviations due to normal tolerances, such as for example manufacturing tolerances.
In this description embodiments are disclosed and discussed, wherein it should be understood that parts of the disclosed and discussed embodiments can also be combined for forming different embodiments.
In this description a foundation pile should be understood at least as meaning a pile, such as for example but not limited to a monopile commonly known and used as a foundation pile for for example on-shore or off-shore wind turbine generators, landing platforms, artificial islands or the like. Preferably a foundation pile according to the disclosure has a truncated conical top end with an open upper end, wherein the pile more preferably is a substantially hollow monopile, for example made primarily of metal and/or concrete. In this description a slip joint should be understood in its common meaning. A slip joint can be formed directly between an inner surface of an opening of the super structure and an outer surface of the foundation pile or a transition piece of said foundation pile. A slip joint can also be formed between such surfaces, wherein at least one filling element is provided between said surfaces, for example adhered to one of such surfaces, which at least one filling element can for example be made of a material more compressible that the materials of the super structure and of the foundation pile, such as for example a plastic material, such as for example but not limited to PU.
In
The platform 1 has an opening 13 extending through the platform 1, from an upper side 1A to a lower side 1B, which opening 13 in this embodiment has a truncated conical inner peripheral surface 14, which can form a slip joint with the outer surface 4 of the top end 2 of the pile 3, in a known manner.
In
The upper part 11A has a configuration with an increasing cross section towards the lower part 11B, and is in this embodiment shown as a substantially conical or truncated conical part 11A. Said upper part can have a circular cross section with an increasing, preferably constantly increasing diameter DA towards said lower part 11B with a top angle which is two times angle β. Said lower part 11B preferably has a configuration with a decreasing cross section in a direction away from the upper part 11A, and is in this embodiment shown as a substantially conical or truncated conical part 11B. Said lower part 11B can also have a circular cross section with a decreasing, preferably constantly decreasing diameter DB in a direction away from said upper part 11A. The lower part 11B also has a sloping outer surface 16, sloping inward and downward, with a top 17 facing downward. The outer surface 16 is also a guide surface and extends at an angle γ relative to the axis X-X, such that the top 17 has an angle of two times γ. The angle β is, and preferably both the angles β and γ are, preferably larger that the angle α, such that the outer surface 4 slopes steeper than at least the surface 15.
The upper part 11A interfaces with the lower part 11B at an interface plane 18, wherein at the interface plane 18 the upper part 11A extends radially outward from the lower part 11B, such that a support portion 19 is provided by an end 20 of the upper part 11A at the interface plane 18. In this embodiment the support portion 19 is substantially ring shaped with a width W defined by the maximum diameter DA(max) of the upper part 11A minus the maximum diameter DB(max) of the lower part 11B.
The guide structure 11 is suspended from the support frame 8 with the top 21 extending inside the opening 13 or below it, most or all of the guide structure extending below the lower side 1B of the platform 1. The pile 3 has an open upper side 22. The rim 6 is ring shaped, with an inner diameter Din which is substantially the same or slightly larger than the maximum outer diameter DB(max) of the lower part 11B of the guide structure 11, and an outer diameter Dout which is preferably substantially the same as the maximum outer diameter DA(max) of the upper part 11A of the guide structure 11.
As can be seen in
As can be seen in
When lowering the support frame 8 further, the platform 1 will be lowered further too, moving with the opening 13 over the upper part 11A of the guide structure 11, to a position as schematically shown in
After properly positioning the platform 1 onto the upper end 2 of the pile 3, forming a slip joint, the first suspension elements 9 can be released from the platform 1, where after the support frame 8 can be moved upward again, as shown in
In a method according to the disclosure, by providing a guide structure 11, such problems are prevented in a surprising manner. As can be seen schematically in
In
In the embodiments shown in
In these embodiments the guide surfaces 15, 16 are formed by outward facing portions 31 of the sloping profiles 30B, which virtually form a conical or truncated conical surface as shown for example in
Advantageously in a method according to the disclosure the guide structure 11 is only provided at the top end of the pile 3 after the foundation pile 3 has been driven into the ground, such as for example in a water bedding or on-shore into dry land. This allows for commonly known pile drivers or similar drive means to engage the top end of the pile for driving it into the ground, without the risk of damaging the guide structure. When using a pile which is not to be driven into the ground by engaging the top end, for example with a foundation pile build up from segments, a guide structure may be removably attached to the top end separately.
In the embodiments shown the pile 3 and the guide structure 11 have circular cross sections perpendicular to the axis X-X. This means that the guide structure 11 can be mounted to the top end 2 of the pile 3 in any rotation position around the longitudinal axis X-X cq center line 24. In embodiments however the pile 3, especially the rim 6 and the opening 6A defined thereby can be formed other than circular, for example oval or with a partially straight edge, wherein the guide structure, especially a lower part 11B thereof can be formed accordingly, such that by lowering the guide structure into the opening 6A it will be forced to rotate around the centerline 24 to a position in which it fits inside said opening. In such embodiment for example the opening 13 in the platform can accordingly be non-circular, the upper part 11A of the guide structure being formed again accordingly, such that also the platform is forced, when being lowered over the guide structure, to take the appropriate position relative to the guide structure and hence relative to the pile 3. This can for example be advantageous when a specific predefined rotational position of the platform relative to the pile is desired.
The embodiments as disclosed are shown by way of example only and should not be construed as limiting the scope of the disclosure. Many variations are possible within the scope of the invention as defined by the claims. For example the super structure mounted on the pile can be of a different structure and can for example be supported by a series of piles as disclosed. A guide structure can be formed differently, for example by using plates for forming a skeleton, instead of next to profiles as shown. A guide structure and a platform or other super structure may be placed in separate steps, for example by lifting the guide structure onto the pile first and then lifting the super structure onto the pile. This can for example be advantageous when the super structure does not have an opening extending all the way through it, such as a tower. The guide structure can be made such that it can easily be dismantled, such that it can be removed in parts.
These and other amendments, including but not limited to combinations of embodiments or parts thereof as disclosed are also considered to have been disclosed within the ambit of the claims.
Number | Date | Country | Kind |
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2031453 | Mar 2022 | NL | national |
Filing Document | Filing Date | Country | Kind |
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PCT/NL2023/050163 | 3/29/2023 | WO |