OFFSHORE VESSEL, PREFERABLY A VESSEL FOR INSTALLING AN OFFSHORE WIND POWER PLANT, CRANE FOR PROVIDING SUCH A VESSEL AND METHOD FOR USING SUCH A CRANE, PREFERABLY FOR TURNING A MONOPILE ON ITS EDGE

DE602019067479T2Active Publication Date: 2025-03-19ITREC BV
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Patent Information

Application Number
DE602019067479
Authority / Receiving Office
DE · DE
Patent Type
Patents
Current Assignee / Owner
Priority Date
2018-11-26
Filing Date
2019-05-31
Publication Date
2025-03-19
Estimated Expiration
2039-05-31

AI Technical Summary

Technical Problem

The increasing size and weight of offshore wind turbine foundation piles require more efficient and capable crane systems to handle larger loads, as existing methods are complicated and often necessitate larger cranes to manage extreme loads, which can be taxing on equipment and increase operational risks.

Method used

An offshore wind turbine installation vessel equipped with a crane featuring a computerized crane control system that coordinates slew motion, luffing motion, and hoisting operations to move loads along a predefined trajectory, optimizing the path for efficient and safe handling of larger piles, allowing smaller cranes to manage heavier loads effectively.

Benefits of technology

The system enables efficient and fast upending of wind turbine foundation piles with smaller cranes, reducing the workload for operators, minimizing load on the crane structure, and optimizing operational windows, thus enabling the use of lighter cranes for larger piles without the need for dedicated heavy-lift vessels.

✦ Generated by Eureka AI based on patent content.
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Description

[0001] The present disclosure relates to a vessel comprising a crane provided with a computerized crane control system, and to a crane for providing such a vessel.

[0002] The present disclosure also relates to a vessel configured for installation of a pile adapted to support an offshore wind turbine. The present disclosure further relates to a crane configured for upending a pile, and to a pile upending system, comprising at least one crane and a pile holder or upending cradle.

[0003] The invention relates to an offshore wind turbine installation vessel, and to a method for installation of a pile adapted to support an offshore wind turbine.

[0004] In a known method for installing an offshore wind turbine, the foundation, in the form of a pile, is installed first by driving the pile into the sea bottom after which the wind turbine is installed on the pile, either by installing the wind turbine at once as a whole or by assembling the wind turbine in parts on the pile. It is for example known to transport masts, or mast sections, complete with nacelle and blades mounted thereon, in an right standing position. The completed mast or completed mast section is installed onto the pile.

[0005] There is a trend towards larger wind turbines and a desire to install offshore wind turbines at locations with larger water depths than currently encountered. Both result in larger and heavier foundations. Hence, it is expected that in the near future piles need to be installed that are larger than 100 meters, possibly 120 meters or larger. The weight of such piles may be larger than 1000mt, possibly 1300mt or above.

[0006] Typically, these large piles are transported in a horizontal orientation. The foundation piles preferably are stored on a storage deck. When the vessel has arrived at the installation site, i.e. the location where the pile has to be driven into the sea floor, a pile is upended and is lifted into an overboard installation position. See for example EP2886722.

[0007] Publication WO2018088900 discloses a crane comprising a main boom and a jib. The main boom is positioned using a luffing assembly and the jib is moved relative to the boom using a variable length stay mechanism to set the position of the jib. The crane can be provided with a control device programmed to fold the jib towards the main boom and lower the main boom, and thus move the boom with the jib into a parking position.

[0008] Publication WO2018052291 discloses a crane that is configured to lift asymmetrical loads. The crane is provided with two hoisting system to enable the crane to not only lift but also to up-end monopiles. One hoisting system is used to lift the top end of a monopile while the other hoisting system is used to hold and lift the lower end of the monopile.

[0009] The upending process may involve a single crane. The crane lifts the pile at a top end thereof, while a lower end of the pile is supported in a upending cradle mounted on the deck of the vessel. The upending cradle is configured to support the lower end of the pile, preferably pivot with the lower end of the pile, while the pile is upended.

[0010] Also, the upending process may involve two cranes, both cranes lifting the pile at a top end thereof, while a lower end of the pile is supported in a upending cradle mounted on the deck of the vessel.

[0011] An alternative upending process involves two cranes. One crane lifts the pile at a top end of the pile, while the other crane lifts the pile at a lower end of the pile. Once the pile has been lifted, the first crane lifts the top end of the pile, while the other crane supports the lower end of the pile, preferably at a substantially constant height. As an alternative, the first crane may lift the top end of the pile, while the second crane lowers the opposite end of the pile.

[0012] Both upending processes are complicated. Furthermore, the increase in pile sizes requires larger cranes as well. To allow for a crane driver to utilise the full operational window of the crane, the crane preferably should be able to support loads up to or above twice the size of the load actually being hoisted. This is in particular the case with piles, which due to their weight and length may potentially cause extreme loads on the crane and other upending equipment.

[0013] It is therefore an object of the invention to provide an offshore vessel comprising a crane capable of efficiently, i.e. fast and / or with comparatively large loads, transporting loads.

[0014] This object is achieved by providing an offshore wind turbine installation vessel according to claim 1.

[0015] It is an object of the invention to provide an offshore wind turbine installation vessel capable of efficiently, i.e. fast and / or with comparatively small cranes, upending a wind turbine foundation pile.

[0016] In accordance with the invention, the offshore vessel as defined by claim 1, comprises: a hull having a storage deck, wherein the storage deck is configured for storage thereon of one or more wind turbine foundation piles, e.g. monopiles, in horizontal orientation thereof, said foundation piles each having a lower end configured to be driven into the seabed and a top end; a crane comprising: a crane base secured to the hull, a slewable superstructure mounted on the crane base and slewable about a vertical slew axis relative to the crane base, a slew drive configured to cause slew motion of the superstructure about the slew axis, a boom structure comprising a boom that is pivotally connected to the superstructure about an inner pivot axis, a luffing mechanism comprising a luffing drive and configured to cause luffing motion of the boom structure, a hoisting assembly comprising a hoisting winch and a hoisting winch driven cable, a load connector, wherein the winch driven cable extends in a multi-fall arrangement between a sheave set on the boom structure and a sheave set on the load connector, a pile holder having an upending cradle, a computerized crane control system linked to the slew drive, the luffing drive, and the hoisting winch, which computerized crane control system is programmed to perform a routine, providing a coordinated pattern of slew motion of the superstructure and of luffing motion of the boom structure, as well as operation of the hoisting winch, so that the load connector moves along a predefined trajectory, and wherein the computerized crane control system is programmed to perform a foundation pile installation routine providing the coordinated pattern of slew motion of the superstructure and of luffing motion of the boom structure, as well as operation of the hoisting winch so that the load connector moves from a foundation pile pick up position thereof where the load connector is connected to the top end of a horizontally oriented foundation pile stored on the deck to a foundation pile overboarding position thereof wherein the foundation pile is vertical suspended from the load connector, outside of the hull, wherein the upending cradle is configured to support the lower end or a lower section of the foundation pile during upending of the foundation pile during the foundation pile installation routine, and wherein the trajectory is predefined relative to a pivot axis of the upending cradle of the pile holder, and, preferably, the curved trajectory of movement of the load connector lies within a plane that is perpendicular to the pivot axis of the upending cradle.

[0017] Thus, a vessel according to the claimed invention comprises a crane configured to transport a load along a predefined trajectory. The trajectory has a start position and an end position. The start and end position do not necessarily need to be a position in which the load is on a support surface. For example, the crane driver may use the crane to lift a container from a vessel into a position, which position than becomes the start position from which the crane transports the container along a predefined trajectory, for example from a supply vessel into a position above a rig, after which the crane driver takes over and lowers the container on the deck of the rig.

[0018] The crane running an installation routine reduces the workload of the crane driver, who can now fully concentrate on monitoring the process, and who may intervene if that is deemed necessary. Thus, the crane driver is able to better monitor the overall process. Also, because the load connector is moved along an optimal path, the crane movement can be optimised and the load can be moved efficiently. This may also reduce the time required for hoisting the load to its destination.

[0019] Thus, the offshore vessel according to the invention is capable of efficiently, i.e. fast and / or with comparatively small cranes, upending a wind turbine foundation pile.

[0020] Furthermore, because the trajectory of the load connector can be controlled by the computerized crane control system, the crane can move the load connector along the ideal path for handling a load, i.e. an optimal combination of a path that allows for quickly moving the load to is destination and the path that is least taxing to the crane structure and capacity. Thus, the crane can be used for lifting larger loads with less risk, and the operational window of the crane can be used optimally.

[0021] In a preferred embodiment, the computerised crane control system comprises data on the capacity of the crane, and uses this data to determine an optimal trajectory as the predefined trajectory, preferably in combination with data on the load to be transported, for example data on the weight and / or size of the load. This data may be provided by the crane driver.

[0022] In a further embodiment, the computerised crane control system is configured to collect data on the load, for example is provided with sensors that can determine the weight of the load when lifted by the crane. In addition or as an alternative, the crane is for example provided with camera's that provide data on the size of the load to be transported along the predefined trajectory.

[0023] In an embodiment, the computerise crane control system is configured to collect further data, for example wind direction and wind force, to generate a predefined trajectory that is least taxing on the crane.

[0024] In a further embodiment, the computerised crane control system is configured to adjust the predefined trajectory while the load is being transported along it, for example sensors of the computerised crane control system detect an increase in wind force.

[0025] In an embodiment, the computerised crane control system is configured to compute the predefined trajectory, based on a start position and an end position entered by the crane driver.

[0026] It is an object of the invention to provide an offshore wind turbine installation vessel capable of efficiently, i.e. fast and / or with comparatively small cranes, upending a wind turbine foundation pile.

[0027] According to the invention, the computerized crane control system is programmed to perform a foundation pile installation routine, so that the load connector moves from a foundation pile pick up position thereof, where the load connector is connected to the top end of a horizontally oriented foundation pile stored on the deck, to a foundation pile upended position thereof, wherein the foundation pile is vertically suspended from the load connector.

[0028] In the upended position the foundation pile is supported by the crane. The foundation pile may be suspended above the vessel, to enable the crane driver to perform further crane operations. Thus, the upending of the foundation pile can be fully controlled by the computerised crane control system, and the subsequent positioning of the foundation pile relative to an installation site, to a pile gripper mounted to the hull of the vessel, or to a pile gripper mounted to the hull of another vessel, can be fully controlled by the crane driver.

[0029] In a further embodiment, the computerised crane control system is configured to perform other pile transportation routines. In an embodiment, the computerised crane control system is configured to control the positioning of the suspended foundation pile in a pile gripper mounted to the hull of the vessel, e.g. to align the foundation pile with the pile gripper, and to subsequently lower the pile into the pile gripper. In an embodiment, the computerised crane control system is configured to control the lowering of a pile received in a pile gripper towards the sea floor.

[0030] The invention therefore provides an offshore wind turbine installation vessel, wherein the storage deck is configured for storage thereon of one or more wind turbine foundation piles, e.g. monopiles, in horizontal orientation thereof, said foundation piles each having a lower end configured to be driven into the seabed and a top end, wherein the winch driven cable extends in a multi-fall arrangement between a sheave set on the boom structure and a sheave set on the load connector, wherein the computerized crane control system is programmed to perform a foundation pile installation routine providing the coordinated pattern of slew motion of the superstructure and of luffing motion of the boom structure, as well as operation of the hoisting winch so that the load connector moves from a foundation pile pick up position thereof where the load connector is connected to the top end of a horizontally oriented foundation pile stored on the deck to a foundation pile overboarding position thereof wherein the foundation pile is in vertical suspended from the load connector, outside of the hull, and preferably is aligned with a pile gripper configured to maintain the wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed.

[0031] In an embodiment, the vessel further comprises a pile gripper, preferably arranged in proximity of the crane, configured to maintain a wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed. In such an embodiment, the computerised crane control system is preferably configured to align a foundation pile supported by the load connector with the pile gripper, more in particular with positioning the foundation pile in the pile gripper.

[0032] In an embodiment, the pile gripper is moveably supported by the hull of the vessel, and is provided with a pile gripper control system configured to position the pile gripper relative to the vessel, such that it is aligned with a foundation side installation site adjacent the vessel. In such an embodiment, the pile gripper control system is provided to compensate for movement of the vessel relative to the installation site.

[0033] In a further embodiment, the computerised crane control system is linked with the pile gripper control system, to enable the computerised crane control system to take into account the movement of the pile gripper, and thus keep a foundation pile received in the pile gripper and supported by the load connector substantially vertical while the pile gripper is moved relative to the vessel, and thus relative to the crane mounted on the vessel. This is in particular beneficial when the computerised crane control system is configured to position the a foundation pile in the pile gripper and / or when the computerised crane control system is configured to control at least part of the lowering of the foundation pile towards the seafloor.

[0034] In an embodiment, the computerised crane control system is configured to track the positon of a pile gripper, e.g. comprises a position determining device to be mounted on the pile gripper, or is provided with sensors, e.g. cameras, configured to track the position of the pile gripper, which pile gripper is mounted on the vessel on which the crane is also mounted, or which is mounted on another vessel located adjacent the vessel on which the crane is mounted.

[0035] According to the invention, the computerized crane control system is programmed to perform a foundation pile installation routine, so that the load connector moves from a foundation pile pick up position thereof, wherein the load connector is connected to the top end of a horizontally oriented foundation pile stored on the deck, to a foundation pile overboarding position thereof, wherein the foundation pile is vertically suspended from the load connector, outside of the hull.

[0036] Which predefined trajectory should be selected and how the predefined trajectory should be shaped may be entered by the crane driver. For example, the crane driver may transport a load using the crane, track the trajectory along which the load is transported using the computerised crane control system, save that trajectory as a predefined trajectory in a memory of the computerised crane control system. In another embodiment, the crane driver enters a start position for the load connector and an end position for the load connector, and the computerised crane control system generates an optimal trajectory between both positions, which trajectory is saved in a memory of the computerised crane control system as a predefined trajectory. For example, the crane driver may enter the start position and the end position of the load connector by moving the load connector in said positions. Alternatively, the crane driver may indicate the positions by indicating them on a screen of the computerised crane control system, or enter the coordinates of the positions using a key pad of the computerised crane control system.

[0037] The predefined trajectory can be predefined in three dimensions relative to the vessel on which the crane is mounted, more in particular relative to the crane mounted on said vessel. The predefined trajectory may also be predefined relative to an object, for example relative to the slewing axis of the crane, relative to the pivot axis of an upending cradle of a pile holder, relative to the bottom end of a pile supported by the load connector or relative to a pile gripper mounted on the hull of the vessel or mounted on the hull of a vessel adjacent the vessel on which the crane is mounted, etc.

[0038] When the lower end of the foundation pile is supported in an upending cradle, which upending cradle is configured to pivot with the lower end of the pile while the pile is upended, the predefined trajectory for upending the pile is defined relative to the pivot axis of the foundation pile, e.g. relative to a pivot axis of a pivotably supported clamp of the upending cradle, the clamp securing the bottom section of the pile relative to an upending pivot axis. In such an embodiment, the computerized crane control system is programmed to perform a foundation pile installation routine that is configured to move the top end of the pile along a fixed trajectory relative to the upending cradle.

[0039] In an embodiment, the computerised crane control system comprises an autonomous gps device, which gps device is configured to be mounted on the top end of a foundation pile. The gps device is linked to the computerised crane control system, which is configured use the gps date provided by the gps device to move the upended pile into a predetermined gps position.

[0040] In an embodiment, the computerised crane control system comprises an autonomous gps device, which gps device is configured to be mounted on the top end of a foundation pile. The gps device is linked to the computerised crane control system, which is configured use the gps date provided by the gps device to move the upended pile into a predetermined gps position.

[0041] In a further embodiment, the foundation pile, when supported in the foundation pile overboarding position, is aligned with a pile gripper configured to maintain the wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed.

[0042] According to the invention, the crane comprises a computerized crane control system, which computerized crane control system is programmed to perform a foundation pile installation routine providing a coordinated pattern of slew motion of the superstructure, of luffing motion of the boom structure, and of hoisting by the hoisting winch.

[0043] Thus, the computerized crane control system is capable of moving the load connector, and thus the load supported by the load connector, from a foundation pile pick up position to a foundation pile overboarding position, along a predefined trajectory.

[0044] The predefined trajectory can for example be obtained by running a simulation on shore, and transferring the movements of the load connector from the simulator to the computerized crane control system, after running a successful installation procedure. Alternatively, a crane driver may program an ideal trajectory into the computerized crane control system. Also, the computerized crane control system may be configured to record the trajectory of movement of the load connector during a first installation, which recorded movements can subsequently be used as installation routine in subsequent installations.

[0045] Because the trajectory of the load connector can be controlled using the computerized crane control system, the installation routine can be set up to move the load connector along the ideal path for handling a load, i.e. an optimal combination of a path that allows for quickly moving the load to is destination and the path that is least taxing to the crane structure and capacity. Thus, the operational window of the crane can be used optimally, and it is no longer required to use for example a crane that can handle at least two times the load that is actually being hoisted.

[0046] The crane running an installation routine reduces the workload of the crane driver, who can now fully concentrate on monitoring the process, and who may intervene if that is deemed necessary. Thus, the crane driver is able to better monitor the overall process. Also, because the load connector is moved along an optimal path, the crane movement can be optimised and the load can be moved efficiently. This may also reduce the time required for hoisting the load to its destination.

[0047] Thus, the offshore vessel according to the invention is capable of efficiently, i.e. fast and / or with comparatively small cranes, upending a wind turbine foundation pile.

[0048] In an embodiment, the vessel further comprises a pile gripper, preferably arranged in proximity of the crane, configured to maintain a wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed. Thus, the vessel can be used for the full installation process, i.e. during the upending of the pile and also during the pile driving.

[0049] In such an embodiment, the vessel preferably also supports a pile driving device on the storage deck, and the crane is configured to lift the pile driving device into a position onto the pile supported by the pile gripper. In an embodiment, the computerized crane control system is configured to run a pile driving device installation routine, the routine preferably comprising lifting the pile installation device form the storage deck, and landing the pile installation device on a pile supported by the pile gripper.

[0050] In an embodiment, the invention provides a crane comprising computerized crane control system that allows for running sub routines in a hoisting process. For example, the installation routine may comprises the actual upending process, ending in the pile being supported in the upright position, after which the crane driver takes over and hoists the pile into a position for landing the pile in the pile gripper, after which a pile gripper landing routine is run that moves the pile into the pile gripper, after which the crane driver again takes over and lowers the pile towards the sea floor.

[0051] In a preferred embodiment, the computerized crane control system is provided with one or more input devices, e.g. sensors or cameras, to track the position of the load and / or to monitor the environment, for example the relative position of the vessel or an upending cradle mounted on the vessel, and is configured to dynamically amend the installation routine using the information provided by the one or more input devices. For example, to computerised crane control system may adjust the position of the boom and hoisting winch to compensate for titling of the vessel due to a change in load distributed over the working deck.

[0052] In an embodiment, the invention provides a crane with a computerized crane control system that is capable of running one or more routines, for example a load lifting routine, or a load landing routine, in which a basic routine of movements is dynamically adjusted to compensate for changes in the environment.

[0053] For example, in addition to the computerized crane control system, a crane may be provided with a multiple scanners that provide spatial information on objects located in the crane working area, e.g. the top end of a pile, e.g. a pile supported in by pile gripper mounted to the hull of the vessel. A basic routine of movements for landing a pile driver onto the top end of the pile may be adjusted based on this real time spatial information to compensate for movements of the vessel supporting the crane relative to the pile supported by the sea floor.

[0054] According to the invention, the vessel comprises an upending cradle configured to support the lower end or a lower section of the foundation pile during upending of the foundation pile during the foundation pile installation routine.

[0055] Such an upending cradle is configured to assist in the upending process by keeping the lower end of the pile at a substantially fixed, or controlled, position, and by guiding the pivoting movement of the lower end of the pile.

[0056] According to the invention, the computerized crane control system is programmed to perform a foundation pile installation routine that is configured to move the top end of the pile along a fixed trajectory relative to the upending cradle.

[0057] It is submitted that an optimal trajectory of the load connector allows for minimizing the loads exerted on the upending cradle in the horizontal plane. This is in particular the case when the upending cradle comprises a pivotably supported clamp, to secure the bottom section of the pile relative to an upending pivot axis. Moving the top end of the pile along a curved trajectory having the pivot point at its centre minimises loads on the upending cradle. Preferably, the curved trajectory of movement of the load connector lies within a plane that is perpendicular to the pivot axis. Thus, forces directed perpendicular to that plane, i.e. for example parallel to the pivot axis, can be kept to a minimum.

[0058] However, performing such an exact hoisting movement is difficult for a crane driver, because it involves a combination of slewing, luffing and hoisting movements. The programmable computerized crane control system enables a fully controlled movement of the load connector, and thus for a minimal load on the upending cradle. The latter can thus be of a compact, low weight design.

[0059] Moving the top end of the pile along a curved trajectory having the pivot point at its centre minimises loads on the upending cradle. Preferably, the curved trajectory of movement of the load connector lies within a plane that is perpendicular to the pivot axis. Thus, forces directed perpendicular to that plane, i.e. for example parallel to the pivot axis, can be kept to a minimum.

[0060] In an embodiment, the upending cradle comprises a pivotably supported clamp, to secure the bottom section of the pile relative to an upending pivot axis, and the computerised crane control system is configured to measure the angle of the clamp and use this information in controlling the trajectory of the load connector. Preferably, computerised crane control system is provided with one or more sensors, and / or is linked to one or more sensors provided on the pivotable support clamp, which sensors monitor the angle of the pivotable support clamp, and thus monitor the angle relative to the horizontal of the pile supported by the clamp. Thus, this information on the angle of the pile can be used to control, for example adjust, the predefined trajectory of the load connector.

[0061] In addition, or as an alternative, the computerised crane control system comprises one or more sensors that monitor the force exerted by the pile onto the cradle and / or by the cradle onto the deck of the vessel. For example, the during the hoisting process, the movement of the load connector in the upward direction may be to fast compared to the movement towards the cradle, causing a the cradle to be pulled towards the load connector. The movement of the load connector can be adjusted to keep the pulling force minimal, preferably clause to zero.

[0062] In an embodiment, the vessel is provided with an upending cradle track, and the upending cradle is mounted on that cradle track and is configured to move along a track, during the upending of the foundation pile. By thus moving the cradle, the top end of the pile can be lifted in a purely vertical direction, which facilitates the lifting process. The installation routine may be used to adjust the hoisting speed such that it keeps up with the movement of the upending cradle along the track. In an embodiment, the cradle is provided with a drive, for enabling controlled movement of the cradle along the track, and the computerized crane control system is configured to at least monitor the movement of the cradle, preferably control the drive and thus control the movement of the cradle along the track.

[0063] In a further embodiment, the upending cradle is configured to support the foundation pile at the lower end thereof, when the pile has been upended.

[0064] In an embodiment, the upending cradle is configured to guide the foundation pile, while the pile, in an upended position, is lowered towards the sea floor. In such an embodiment, the upending cradle is configured to also be used as a pile gripper, and thus extend beyond the periphery of the vessel to maintain a wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed.

[0065] In an embodiment, the vessel, preferably the crane of the vessel, further comprises an observation system linked to the computerized crane control system, for tracking movement of the load connector and / or the top end of the wind turbine foundation piles during the foundation pile installation routine, which observation system comprises: at least one camera, preferably mounted to the boom, to register a crane working area view, preferably a crane working area top view, of the working area of the crane, an augmentation system, linked with the at least one camera and with the crane control system, and configured to combine graphic crane information, e.g. hoisting speed, wind direction, with the real time view registered by the camera into an augmented crane working area view; and a display, e.g. a monitor or a head up display, linked to the augmentation system to present the augmented working area view to a crane driver.

[0066] The observation system enables the crane driver to monitor the movement of the load connector, and thus the load supported thereby. In a preferred embodiment, the display projects the programmed trajectory of the load connector according to the installation routine and the actual position, preferably the actual trajectory, of the load connector to facilitate monitoring the routine by the crane driver. The crane driver may stop or overrule the routine if the discrepancy between the actual track and the predetermined track becomes too large. In a further preferred embodiment, the computerized crane control system allows for the crane driver to adjust the routine to keep the load connector on track, without having to stop the routine.

[0067] In an embodiment, the crane driver is allowed to move the load connector towards or away of a predefined trajectory, for example by using a joystick to adjust the position of the load connector relative to the predefined trajectory in a horizontal plane and a handle to adjust the position of the load connector relative to the predefined trajectory in the vertical direction.

[0068] In an embodiment, the computerised crane control system allows for the crane driver to position a marker in for example a top view of the crane working area, and subsequently activate the computerised crane control system to automatically move the load connector into the position of the marker.

[0069] In an embodiment, the computerized crane control system comprises an input device, e.g. a key pad, a slot for connecting an information carrier, a wireless connection, etc, that is configured to receive a foundation pile installation routine, to enable the computerized crane control system to perform said foundation pile installation routine.

[0070] In an embodiment, the computerized crane control system comprises a control device that is configured to receive a command to start the foundation pile installation routine of the computerized crane control system.

[0071] In a further embodiment, the computerized crane control system comprises a control device that is configured to receive a command to stop the foundation pile installation routine of the computerized crane control system.

[0072] In an embodiment, the crane is a mast crane, which mast crane preferably is arranged along portside or starboard side of the vessel. In a further embodiment, the vessel comprises two similar mast cranes, both provided with a computerized crane control system, one crane located along the portside and one crane located along the starboard side of the vessel. Mounting the crane or cranes along the portside and / or starboard side of the vessel allows for the center of the vessel to be used for stacking one or more foundation piles, the foundation piles preferably extending in a longitudinal direction of the vessel.

[0073] In an embodiment, the crane is a first crane and the vessel further comprises a second crane, which second crane is similar to the first crane, for in addition to the first crane support a foundation pile, wherein the computerized crane control system is linked to a slew drive, a luffing drive, and a hoisting winch of the second crane, and wherein the computerized crane control system is programmed to perform the foundation pile installation routine providing a coordinated pattern of slew motion of the superstructure and of luffing motion of the boom structure, as well as operation of the hoisting winch of both the first crane and the second crane so that the load connector of the first crane and the load connector of the second crane each move from a foundation pile pick up position thereof where the load connector is connected to a horizontally oriented foundation pile stored on the deck to a foundation pile upended position thereof wherein the foundation pile is in vertical position and is suspended from at least the load connector of the first crane.

[0074] The invention furthermore provides a method for installation of a pile adapted to support an offshore wind turbine, using a vessel according to the invention, the method comprising the following steps: a. transporting a pile in a horizontal orientation to an offshore installation site; b. positioning the pile in a pile holder on an installation vessel while being in a horizontal orientation parallel to a longitudinal axis of the vessel, wherein the pile holder engages with a circumference of the pile at a lower side thereof to hold the pile in order to limit movement of the lower side of the pile in a direction perpendicular to a longitudinal axis of the pile, and wherein the pile holder engages with a lower end of the pile in order to limit movement of the pile in a direction parallel to the longitudinal axis of the pile; c. lifting an upper end portion of the pile, preferably with the lower side in the pile holder, thereby rotating the pile from a horizontal orientation to a vertical orientation about a substantially horizontal rotation axis perpendicular to the longitudinal axis of the vessel, preferably wherein, after rotating the pile from the horizontal orientation to the vertical orientation, the pile is located outside the contour of the vessel seen from above to be lowered into the water; d. lowering the pile into the water while being held by the pile holder, e. wherein during step c, and preferably also step d, is / are performed by the computerized crane control system of a vessel according to the invention, and wherein the vessel preferably also carries out step a and step b.

[0075] In a further method according to the invention, step d. comprises: lowering the pile until the pile reaches the sea bottom and until passive lowering of the pile, i.e. lowering of the pile due to the pile sinking into the sea floor due to gravity, stops. It is submitted that the invention, in particular the crane according to the invention, can also be used in lifting piles or mast sections that have been transported to the installation site in an upended position. For example, the piles can be stored on the storage deck with a vertical orientation, requiring one or more cranes to lift the upended pile form the vessel onto the installation site, for example lower the pile into a pile gripper configured to maintain a wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed. The invention allows for using a comparatively light crane, or to use two cranes in unison, for hoisting the pile because the computerised control system, more in particular the foundation pile installation routine, allows to optimally utilise the cranes capacity. Thus there is no need for large cranes, for example cranes mounted on a dedicated crane vessel.

[0076] The present disclosure furthermore provides a pile upending system, comprising at least one crane and a pile holder to be mounted on a vessel, wherein the pile holder comprises an upending cradle to engage a circumference of the pile at a lower side thereof and to hold the pile in order to limit movement of the lower side of the pile in a direction perpendicular to a longitudinal axis of the pile, and wherein the pile holder engages with a lower end of the pile in order to limit movement of the pile in a direction parallel to the longitudinal axis of the pile. The pile holder allows for lifting an upper end portion of a pile, of which pile the lower side is engaged by the pile holder, to thereby rotate the pile from a horizontal orientation to a vertical orientation about a substantially horizontal rotation axis.

[0077] In an embodiment according to the invention, the wind turbine installation vessel is provided with a pile gripper. A pile gripper is configured to maintain the wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed. In a further embodiment, the pile holder is configured to also function as a pile gripper. In such an embodiment, the upending cradle is configured to guide the foundation pile, while the pile, in an upended position, is lowered towards the sea floor. In such an embodiment. When the upending cradle is configured to be used as a pile gripper, it is able to support the upended pile in an outboard position, i.e. outside the contour of the vessel when seen in top view.

[0078] In an embodiment, the pile holder is configures for, after rotating the pile from the horizontal orientation to the vertical orientation, engage the pile while it is located outside the contour of the vessel, and to hold the pile while lowering the pile into the water. In such an embodiment, the pile holder is configured to be used as a pile gripper.

[0079] As such, the pile holder can be addressed as upending cradle, and, depending on its configuration as a pile gripper.

[0080] By enabling the pile holder to also function as a pile gripper, instead of providing the vessel with a separate pile gripper, there is no need for the pile to be transported into the pile gripper, once it has been upended. This shortens the installation process.

[0081] The present disclosure furthermore provides a pile upending system, comprising at least one crane with a computerized crane control system programmed to run a foundation pile installation routine, and an upending cradle configured to support the lower end or a lower section of a foundation pile during upending of the foundation pile during the foundation pile installation routine.

[0082] The examples described above are presented with reference to providing an offshore vessel comprising a crane, or a crane for providing such a vessel. However, as will be understood by one skilled in the art, the devices and techniques described herein may be applied to provide cranes, e.g. mast cranes, around the leg cranes, knuckle boom cranes, for any suitable offshore vessel, e.g. a jack-up vessel, a drilling vessel, a semisubmersible, etc. Furthermore, some aspects of the invention may also be used with surface based cranes, for example harbour cranes, building cranes, etc.

[0083] Advantageous embodiments of a vessel according to the invention and a method according to the invention are disclosed in the sub claims and in the description, in which the invention is further illustrated and elucidated on the basis of a number of exemplary embodiments, of which some are shown in the schematic drawing. In the figures, components corresponding in terms or construction and / or function are provided with the same last two digits of the reference numbers.

[0084] In the figures, Fig. 1 shows a perspective view of an offshore wind turbine installation vessel according to the invention during a pile upending routine, the vessel comprising a crane and further comprising a pile holding system, for supporting a pile in a horizontal position, the pile holding system comprising a pile gripper for positioning the pile when in a vertical orientation; Fig. 2 shows a perspective view of the vessel of figure 1, with the pile has been lifted into a substantially vertical orientation, Fig. 3 shows a top view of an offshore wind turbine installation vessel according to the invention, the vessel comprising a first crane and a second crane, the vessel further comprising an upending cradle moveably supported on a cradle track; Fig. 4 shows a side view of the vessel of figure 3 at the start of a pile installation routine; Fig. 5 shows a side view of the vessel of figure 3 during the pile installation routine; Fig. 6 shows a side view of the vessel of figure 3 at the end of the pile installation routine; Fig. 7 shows a rear view of the vessel of figure 3 at the end of the pile installation routine; Fig. 8 shows a perspective view of a jack up vessel according to the invention, the vessel comprising a first crane and a second crane, the first crane and the second crane hoisting a pile onto the storage deck of the vessel using a hoisting routine to control the movements of the cranes; and Fig. 9 shows a side view of a jack up vessel according to the invention, the vessel comprising a first crane and a second crane, the first crane and the second crane hoisting a top structure onto the storage deck of the vessel using a hoisting routine to control the movements of the cranes.

[0085] Figure 1 depicts an offshore wind turbine installation vessel 1 according to the invention. The vessel comprises a hull 2 and a crane 3. In the particular embodiment shown, the vessel is furthermore provided with a pile gripper 22, which pile gripper also functions as an upending cradle. More in particular, the pile gripper also functions as a pile holder, i.e. is configured to engage a circumference of the pile at a lower side thereof and to hold the pile in order to limit movement of the lower side of the pile in a direction perpendicular to a longitudinal axis of the pile.

[0086] The hull 2 is provided with a storage deck 4 configured for storage thereon of one or more wind turbine foundation piles 5, e.g. monopiles, in horizontal orientation thereof. The foundation piles 5 each having a lower end 6, configured to be driven into the seabed, and a top end 7.

[0087] The crane 8 comprises a crane base 9, which crane base 9 is secured to the hull 2, and a slewable superstructure 10 mounted on the crane base 9, and slewable about a vertical slew axis relative to the crane base.

[0088] The crane 8 further comprises a slew drive 11, a boom structure 12, a luffing mechanism 13, a hoisting assembly 14 and a load connector 15.

[0089] The slew drive 11 is configured to cause slew motion of the superstructure 10 about the slew axis.

[0090] The boom structure 12 comprises a boom 16 that is pivotably connected to the superstructure 10, such that it can pivot about a horizontal inner pivot axis.

[0091] The luffing mechanism 13 comprising a luffing drive 17 and is configured to cause a luffing motion of the boom structure 12. Thus, the luffing mechanism can be used to pivot the boom upwards or downwards.

[0092] The hoisting assembly 14 comprises a hoisting winch 18 and a hoisting winch driven cable 19. In the embodiment shown, the winch driven cable 19 extends in a multi-fall arrangement between a sheave set on the boom structure 12 and a sheave set on the load connector 15.

[0093] According to the invention, the crane 2 comprises a computerized crane control system 20 linked to the slew drive 11, the luffing drive 17, and the hoisting winch 18.

[0094] The computerized crane control system 20 is programmed to perform a foundation pile installation routine providing a coordinated pattern of slew motion of the superstructure 10 and of luffing motion of the boom structure 12, as well as operation of the hoisting winch 18 so that the load connector 15 moves from a foundation pile pick up position 21 thereof, in which the load connector 15 is connected to the top end 7 of a horizontally oriented foundation pile 5 stored on the storage deck 4, to a foundation pile overboarding position thereof, in which the foundation pile 5 is in vertical position suspended from the load connector 15, outside of the hull 2.

[0095] In the particular embodiment shown, the foundation pile, when supported in the foundation pile overboarding position, is aligned with the pile gripper 22. This position is depicted in figure 2. The pile gripper 22 is configured to maintain the wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed.

[0096] In the embodiment shown, the upending cradle is configured to travel across the deck to engage the bottom end of a pile supported on the support deck of the vessel. Subsequently, the top end of the pile is lifted slightly by the crane. Then, the cradle can move back towards the edge of the deck, while the crane moves to top end of the pile, such that the pile is kept in a substantially horizontal position. Once the upending cradle is positioned adjacent the edge of the deck, as shown in figure 1 and figure 2, the upending routine can be started.

[0097] It is submitted that the movement by the crane of the top end of the pile while the upending cradle is moved to the edge of the deck requires a slewing movement, a luffing movement and possibly a hoisting movement. It is difficult to control the crane such that the top end of the pile does not significantly change in height, which might cause the op end or the bottom end of the pile to contact the deck of the vessel and potentially damaging it, or deviates towards the left or right, which might put a strain on the upending cradle and potentially damaging it. Therefore, this hoisting routing is preferably also performed by the computerized crane control system.

[0098] The offshore wind turbine installation vessel 1 enables a method for installation of a pile adapted to support an offshore wind turbine, according to the invention.

[0099] The method comprising the following steps: a. transporting a pile, preferably on the installation vessel, in a horizontal orientation to an offshore installation site; b. positioning the pile in a pile holder on an installation vessel while being in a horizontal orientation parallel to a longitudinal axis of the vessel, wherein the pile holder engages with a circumference of the pile at a lower side thereof to hold the pile in order to limit movement of the lower side of the pile in a direction perpendicular to a longitudinal axis of the pile, and wherein the pile holder engages with a lower end of the pile in order to limit movement of the pile in a direction parallel to the longitudinal axis of the pile; c. using the computerised crane control system to move the load connector along a predefined trajectory 27, and thus lifting an upper end portion of the pile, with the lower side of the pile in the pile holder, thereby rotating the pile from a horizontal orientation to a vertical orientation about a substantially horizontal rotation axis perpendicular to the longitudinal axis of the vessel, which is shown in figure 1; after rotating the pile from the horizontal orientation to the vertical orientation, the pile being located outside the contour of the vessel, when seen from above, to be lowered into the water, which is shown in figure 2; d. lowering the pile into the water while being held by the pile holder. Thus, the pile holder also functions as a pile gripper.

[0100] With the vessel 1 depicted in figure 1, step c and step d are performed by the computerised crane control system of the vessel 1. The vessel furthermore is also able to carry out step a and step b.

[0101] It is submitted that in the embodiment shown in figure 1 and figure 2, the vessel 1 is provided with a pile upending system. The pile upending system comprises the crane 8 and the upending cradle 22. The upending cradle functions as a pile holder and as a pile gripper.

[0102] The pile holder, more in particular the upending cradle 22, is mounted on the vessel, and is configured to engage a circumference of the pile at a lower side thereof and to hold the pile in order to limit movement of the lower side of the pile in a direction perpendicular to a longitudinal axis of the pile. Thus the pile holder engages a lower end of the pile in order to limit movement of the pile in a direction parallel to the longitudinal axis of the pile. In figure 1, the cradle functions as a pile holder, i.e. to position the pile during the upending process. In figure 2, the cradle functions as a pile gripper, i.e. to position the pile during the lowering process. To enable the pile holder, more in particular the upending cradle, to function as a pile gripper, the pile holder should be able to engage the pile in an outboard position, i.e. outside the contour of the vessel, when seen in top view.

[0103] Thus, the upending cradle allows for lifting an upper end portion of a pile, of which pile the lower side is engaged by the cradle in its function as pile holder, to thereby rotate the pile from a horizontal orientation to a vertical orientation about a substantially horizontal rotation axis.

[0104] In the embodiment shown, the upending cradle 22 comprises a pivotably supported clamp, to secure the bottom section of the pile relative to an upending pivot axis, and the computerised crane control system 20 is configured to measure the angle of the clamp and use this information in controlling the trajectory of the load connector. Preferably, the computerised crane control system is provided with one or more sensors, and / or is linked to one or more sensors provided on the pivotable support clamp, which sensors monitor the angle of the pivotable support clamp, and thus monitor the angle relative to the horizontal of the pile supported by the clamp. Thus, this information on the angle of the pile can be used to control, for example adjust, the predefined trajectory of the load connector.

[0105] In addition, or as an alternative, the computerised crane control system comprises one or more sensors that monitor the force exerted by the pile onto the cradle and / or by the cradle onto the deck of the vessel. For example, the during the hoisting process, the movement of the load connector in the upward direction may be too fast compared to the movement towards the cradle, causing a the cradle to be pulled towards the load connector. The movement of the load connector can be adjusted to keep the pulling force minimal, preferably clause to zero.

[0106] In the embodiment shown, the crane 3 is a mast crane, and is mounted in line with the central axis of the vessel. In a further embodiment, for example shown in figures 3-7, a vessel comprises two similar cranes, both provided with a computerized crane control system, one crane located along the portside and one crane located along the starboard side of the vessel.

[0107] Figure 3 shows a top view of an offshore wind turbine installation vessel 101 according to the invention, the vessel comprising a first crane 103a and a second crane 103b, the vessel 101 further comprising an upending cradle 122 moveably supported on a cradle track 123.

[0108] The second crane 103b is similar to the first crane 103a. The computerized crane control system of the first crane 103a is linked to a slew drive, a luffing drive, and a hoisting winch of the second crane. The computerized crane control system is programmed to perform the foundation pile installation routine providing a coordinated pattern of slew motion of the superstructure and of luffing motion of the boom structure, as well as operation of the hoisting winch of both the first crane and the second crane so that the load connector of the first crane and the load connector of the second crane each move from a foundation pile pick up position thereof, where the load connector is connected to a horizontally oriented foundation pile stored on the deck, to a foundation pile upended position thereof, wherein the foundation pile is in vertical position and is suspended by both the first crane and the second crane.

[0109] Figure 4 shows a side view of the vessel 101 of figure 3 at the start of a pile installation routine.

[0110] Figure 5 shows a side view of the vessel 101 of figure 3 during the pile installation routine.

[0111] Figure 6 shows a side view of the vessel 101 of figure 3 at the end of the pile installation routine.

[0112] Figure 7 shows a rear view of the vessel 101 of figure 3 at the end of the pile installation routine.

[0113] In an embodiment, the vessel 201 is provided with an upending cradle track 200. The cradle track comprises two rails 12. The upending cradle 222 is mounted on the cradle track and is configured to move along a track, during the upending of the foundation pile. By thus moving the cradle 222, the top end of the pile 205 can be lifted in a purely vertical direction, which facilitates the lifting process. It is to be noted that in the embodiment shown, the length of the pile is such that the tope end, i.e. the end that has to be engaged by the hoisting devices of the first crane and the second crane, extends outside the contour of the vessel. Thus the cradle track does not extend up to the position at which the cranes engage the pile. Therefore, only during the first part of the upending process, the cranes can lift the top end in the vertical direction, while the bottom end of the pile is skidded towards the cranes by the upending cradle moving along the cradle track.

[0114] In the embodiment shown, the position of the upending cradle is tracked by the computerised crane control system. Thus, the installation routine run by the crane control system can be used to adjust the hoisting speed such that it keeps up with the movement of the upending cradle along the track. In an embodiment, the cradle is provided with a drive, for enabling controlled movement of the cradle along the track, and the computerized crane control system is configured to at least monitor the movement of the cradle, preferably control the drive and thus control the movement of the cradle along the track.

[0115] In an embodiment, the vessel, preferably the crane of the vessel, further comprises an observation system linked to the computerized crane control system, for tracking movement of the load connector and / or the top end of the wind turbine foundation piles during the foundation pile installation routine, which observation system comprises: at least one camera, preferably mounted to the boom, to register a crane working area view, preferably a crane working area top view, of the working area of the crane, an augmentation system, linked with the at least one camera and with the crane control system, and configured to combine graphic crane information, e.g. hoisting speed, wind direction, with the real time view registered by the camera into an augmented crane working area view; and a display, e.g. a monitor or a head up display, linked to the augmentation system to present the augmented working area view to a crane driver.

[0116] The observation system enables the crane driver to monitor the movement of the load connector, and thus the load supported thereby. In a preferred embodiment, the display projects the programmed trajectory of the load connector according to the installation routine and the actual position, preferably the actual trajectory, of the load connector to facilitate monitoring the routine by the crane driver. The crane driver may stop or overrule the routine if the discrepancy between the actual track and the predetermined track becomes too large.

[0117] In a further preferred embodiment, the computerized crane control system allows for the crane driver to adjust the routine to keep the load connector on track, without having to stop the routine.

[0118] In an embodiment, the crane driver is allowed to move the load connector towards or away of a predefined trajectory, for example by using a joystick to adjust the position of the load connector relative to the predefined trajectory in a horizontal plane and a handle to adjust the positon of the load connector relative to the predefined trajectory in the vertical direction.

[0119] The crane show in figure 1 and figure 2, furthermore comprises an observation system comprising an augmentation system.

[0120] The observation system comprises a camera 25 mounted to the boom of the crane, to register a crane working area top view, of a working area of the crane,

[0121] The observation system further comprises an augmentation system and a display.

[0122] The augmentation system is linked with the camera and with the crane control system, and is configured to combine graphic crane information, e.g. hoisting speed, wind direction, with the real time view registered by the camera into an augmented crane working area view.

[0123] The display, e.g. a monitor or a head up display, is linked to the augmentation system to present the augmented working area view to a crane driver. The display is preferably provided in the crane driver cabin, or on a mobile device for controlling the crane for example while standing on the deck.

[0124] Thus, the crane provides a crane driver with a real time overview of the crane working area, which view is alternative to the direct view of the crane driver. In addition, a top view of the crane working area provides visual information on objects set up next to each other, which are not visible in the direct view of the crane driver.

[0125] Furthermore, the overview combines a digital representation and / or actual picture of the crane working area, combined with graphic crane information. The term 'crane information" may refer to any type of information relevant to the hoisting process, and may comprise information on the load to be lifted, on the vessel on which the load is located, wind direction, logistic planning information, etc.

[0126] In an embodiment, the augmentation system comprises spatial information of the vessel and the crane, for example comprises a 3D model of the vessel and the crane, and is configured to use this spatial information to present the crane driver with potential collision objects, e.g. a control station located adjacent the storage deck of the vessel. Also, the spatial information may be combined with functional information, such as areas that are designated 'storage area' and are thus accessible for landing loads, and areas that are designated 'personnel area' and are thus off limits to the crane.

[0127] Also, the spatial information can be combined with logistic information, for example to identify different loads stacked on the deck, but also to present the crane driver with information on which load should be handled first or where a particular load should be landed on the deck.

[0128] In the embodiment shown, the observation system comprises multiple spatial sensors 26, in the embodiment shown laser scanners, to register the surroundings of the crane. Thus, the spatial information available to the augmentation system can be updated. Changes in the environment, for example due to stacking objects on the storage deck, can be incorporated in the augmented view.

[0129] The spatial sensors are located on the boom of the crane, such that the area scanned by the sensors moves with the crane when the latter is slewed by the slew drive. In an embodiment, additional sensors can be mounted on the vessel, for example along different positions along a storage deck, to provide spatial information of an area from different angles. In an embodiment, the load connector is provided with sensors and / or camera's to scan the crane working area and / or provide information, e.g. a real time top down view of the working area, to the crane driver.

[0130] In an embodiment, the observation system comprises a camera and optical recognition software, to monitor presence of personnel in the crane working area, and the augmentation system is configured to signal and indicate the presence of personal in the crane working area to the crane driver. In an embodiment, the personnel device, e.g. rfid tags or reflectors on a helmet or jacket, to optimize tracking of the load connector by the camera and / or sensors of the computerized crane control system.

[0131] In a further embodiment, the observation system is linked to the computerized crane control system, and the latter is configured to stop the movement, or adjust the trajectory, of the load connector to prevent a collision from occurring or to prevent a load from being moved in a position above, or within a predetermined range of, personal personnel detected by the observation system.

[0132] Furthermore, in the embodiment shown, the crane is provide with a collision prevention system. The system comprises multiple proximity detectors, in the embodiment shown the spatial sensors 26 that are also used to update the spatial information available to the augmentation system to provide the augmented system with a real time representation of the surroundings of the crane. In an alternative embodiment, as an alternative or as a back up, to the spatial sensors, the collision prevention system is provided with simple proximity detector devices.

[0133] The proximity detectors are located along the boom structure to scan a collision safety zone extending adjacent the boom structure, to detect an object entering the collision safety zone during a slew motion and / or a luffing motion and to subsequently present a crane driver with a warning signal and / or stop the slew motion and / or luffing motion of the boom to prevent a collision with the detected object.

[0134] The collision prevention system is particularly beneficial when performing crane operations under conditions with poor visibilities, for example at night, or with severe weather conditions, such as rain, fog or snow.

[0135] Preferably, the data obtained by the proximity detectors is graphically presented to the crane driver, for example on a display in the operator cabin. In addition, if the crane boom enters a dangerous zone, an audible alarm and / or visual alarm will be activated.

[0136] It is submitted that the invention is not limited to up-ending a pile. In an embodiment, a crane comprising a computerized crane control system according to the invention can also be used for transporting a load other than a pile, such as for example a container, along a predefined trajectory from one location to another location, for example from a supply vessel onto a rig.

[0137] It is submitted that the invention, in particular the crane according to the first aspect of the invention, can also be used in lifting piles or mast sections that have been transported to the installation site in an upended position.

[0138] Figure 8 shows a perspective view of a jack up vessel 201, the vessel 201 comprising a first crane 203a and a second crane 203b, the first crane 203a and the second crane 203b hoisting a pile 205 onto the storage deck 204 of the vessel 201 using a routine, more in particular a hoisting routine, to control the movements of the cranes 203a, 203b

[0139] Figure 9 shows a side view of a jack up vessel 201, the vessel 201 comprising a first crane 203a and a second crane 203b, the first crane 203a and the second crane 203b hoisting a top structure 24 onto the storage deck 204 of the vessel 201 using a routine, more in particular a hoisting routine to control the movements of the cranes 203a, 203b.

Claims

1. Offshore wind turbine installation vessel (1) comprising: - a hull (2) having a storage deck (4), wherein the storage deck is configured for storage thereon of one or more wind turbine foundation piles (5), e.g. monopiles, in horizontal orientation thereof, said foundation piles (5) each having a lower end (6) configured to be driven into the seabed and a top end (7); - a crane (8) comprising: - a crane base (9) secured to the hull, - a slewable superstructure (10) mounted on the crane base (9) and slewable about a vertical slew axis relative to the crane base, - a slew drive (11) configured to cause slew motion of the superstructure (10) about the slew axis, - a boom structure (12) comprising a boom (16) that is pivotally connected to the superstructure (10) about an inner pivot axis, - a luffing mechanism (13) comprising a luffing drive (17) and configured to cause luffing motion of the boom structure, - a hoisting assembly (14) comprising a hoisting winch (18) and a hoisting winch driven cable (19), - a load connector (15), wherein the winch driven cable extends (19) in a multi-fall arrangement between a sheave set on the boom structure (12) and a sheave set on the load connector (15), characterized, in that the vessel furthermore comprises: - a pile holder having an upending cradle (22), and in that the crane furthermore comprises: - a computerized crane control system linked to the slew drive (11), the luffing drive (17), and the hoisting winch (18), which computerized crane control system is programmed to perform a routine providing a coordinated pattern of slew motion of the superstructure (10) and of luffing motion of the boom structure (12), as well as operation of the hoisting winch (18), so that the load connector (15) moves along a predefined trajectory (27), and wherein the computerized crane control system is programmed to perform a foundation pile installation routine providing the coordinated pattern of slew motion of the superstructure (10) and of luffing motion of the boom structure (12), as well as operation of the hoisting winch (18) so that the load connector (15) moves from a foundation pile pick up position thereof where the load connector is connected to the top end (7) of a horizontally oriented foundation pile (5) stored on the deck (4) to a foundation pile overboarding position thereof wherein the foundation pile (5) is vertical suspended from the load connector (15), outside of the hull, wherein the upending cradle (22) is configured to support the lower end (6) or a lower section of the foundation pile (5) during upending of the foundation pile during the foundation pile installation routine, and wherein the predefined trajectory (27) is predefined relative to a pivot axis of the upending cradle of the pile holder, and, preferably, a curved trajectory of movement of the load connector (15) lies within a plane that is perpendicular to the pivot axis of the upending cradle (22).

2. Vessel according to claim 1, wherein the upending cradle comprises a pivotably supported clamp, to secure the bottom section of the pile relative to an upending pivot axis, and wherein the computerized crane control system is configured to measure the angle of the clamp and use this information in controlling the trajectory of the load connector, and is provided with one or more sensors, and / or is linked to one or more sensors provided on the pivotable support clamp, which sensors monitor the angle of the pivotable support clamp, and thus monitor the angle relative to the horizontal of the pile supported by the clamp.

3. Vessel according to claim 1 or claim 2, wherein the foundation pile, when in the overboarding position, is aligned with a pile gripper configured to maintain the wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed.

4. Vessel according to any of the preceding claims, wherein the vessel further comprises a pile gripper configured to maintain a wind turbine foundation pile in vertical orientation during a pile driving operation wherein the foundation pile is driven into the seabed.

5. Vessel according to claim 3 or claim 4, wherein the pile gripper is moveably supported by the hull of the vessel, and is provided with a pile gripper control system configured to position the pile gripper relative to the vessel, such that it is aligned with a foundation side installation site adjacent the vessel, and the pile gripper control system is provided to compensate for movement of the vessel relative to the installation site.

6. Vessel according to claim 5, wherein the computerized crane control system is linked with the pile gripper control system, to enable the computerized crane control system to take into account the movement of the pile gripper, and thus keep a foundation pile received in the pile gripper and supported by the load connector substantially vertical while the pile gripper is moved relative to the vessel, and thus relative to the crane mounted on the vessel.

7. Vessel according to one or more of the preceding claims, wherein the upending cradle is mounted on that cradle track and is configured to move along a track, during the upending of the foundation pile.

8. Vessel according to one or more of the preceding claims, wherein the upending cradle is configured to guide the foundation pile, while the pile, in an upended position, is lowered towards the sea floor.

9. Vessel according to one or more of the preceding claims, wherein the vessel, preferably the crane, further comprises an observation system linked to the computerized crane control system, for tracking movement of the load connector and / or the top end of the wind turbine foundation piles during the foundation pile installation routine, which observation system comprises: - at least one camera, preferably mounted to the boom, to register a crane working area view, preferably a crane working area top view, of the working area of the crane, - an augmentation system, linked with the at least one camera and with the crane control system, and configured to combine graphic crane information, e.g. hoisting speed, wind direction, with the real time view registered by the camera into an augmented crane working area view; and - a display, e.g. a monitor or a head up display, linked to the augmentation system to present the augmented working area view to a crane driver.

10. Vessel according to one or more of the preceding claims, wherein the computerized crane control system comprises an input device, e.g. a key pad, a slot for connecting an information carrier, that is configured to receive a foundation pile installation routine, to enable the computerized crane control system to perform said foundation pile installation routine.

11. Vessel according to one or more of the preceding claims, wherein the crane further comprises - a collision prevention system, comprising multiple proximity detectors, e.g. camera's with object recognition software or laser scanners, which proximity detectors are located along at least a top section of the boom structure to scan a collision safety zone extending adjacent at least the top section of the boom structure, to detect an object entering the collision safety zone during a slew motion and / or a luffing motion and to subsequently present a crane driver with a warning signal and / or stop the slew motion and / or luffing motion of the boom to prevent a collision with the detected object.

12. Vessel according to one or more of the preceding claims, wherein the crane is a first crane and wherein the vessel further comprises a second crane, which second crane is similar to the first crane, for in addition to the first crane support a foundation pile, wherein the computerized crane control system is linked to a slew drive, a luffing drive, and a hoisting winch of the second crane, and wherein the computerized crane control system is programmed to perform the foundation pile installation routine providing a coordinated pattern of slew motion of the superstructure and of luffing motion of the boom structure, as well as operation of the hoisting winch of both the first crane and the second crane so that the load connector of the first crane and the load connector of the second crane each move from a foundation pile pick up position thereof where the load connector is connected to a horizontally oriented foundation pile stored on the deck to a foundation pile upended position thereof wherein the foundation pile is in vertical position and is suspended from at least the load connector of the first crane.

13. Method for installation of a pile adapted to support an offshore wind turbine, using a vessel according to one or more of the preceding claims, the method comprising the following steps: a. transporting a pile in a horizontal orientation to an offshore installation site; b. positioning the pile in a pile holder on an installation vessel while being in a horizontal orientation parallel to a longitudinal axis of the vessel, wherein the pile holder engages with a circumference of the pile at a lower side thereof to hold the pile in order to limit movement of the lower side of the pile in a direction perpendicular to a longitudinal axis of the pile, and wherein the pile holder engages with a lower end of the pile in order to limit movement of the pile in a direction parallel to the longitudinal axis of the pile; c. lifting an upper end portion of the pile, preferably with the lower side in the pile holder, thereby rotating the pile from a horizontal orientation to a vertical orientation about a substantially horizontal rotation axis perpendicular to the longitudinal axis of the vessel, preferably wherein, after rotating the pile from the horizontal orientation to the vertical orientation, the pile is located outside the contour of the vessel seen from above to be lowered into the water; d. lowering the pile into the water while being held by the pile holder, e. wherein step c, and preferably also step d, is / are performed by a computerized crane control system of the vessel according to one or more of the claims 1-12, and wherein the vessel preferably also carries out step a and step b.

14. Method according to claim 13, wherein step d. further comprises: lowering the pile until the pile reaches the sea bottom and until passive lowering of the pile, due to gravity sinking the pile into the sea bed, stops.