FLOATING MANUFACTURING ARRANGEMENT AND METHOD FOR MANUFACTURING FLOATING STRUCTURES

Description

Technical Field

[0001] The present invention relates to a floating fabrication arrangement for building of floating structures, such as wind turbine foundations, as well as a method of building such structures.Background Art

[0002] It is convenient to build floating structures either on shore or close to a quay. If the structure is built on shore, there must be a either a crane present that can lift the structure into the water or a slip to launch the structure into the water after the structure has been built.

[0003] Alternatively, the structure can be built while it is floating. This can be done in a dry dock or on top of an already built floating sub-structure. If a dry dock is used, this has to have a sufficient size to accommodate the finished structure. For large structures there are a limited number of such docks available.

[0004] These techniques generally require a sufficient water depth next to the quay to allow for the launch of the structure without the structure hitting the seabed. The only exception is if the structure is built in a dry dock, as it is then possible to tow the dock to a place with sufficient water depth.

[0005] EP3170730 shows a vessel that can be ballasted so that one end thereof is below the water surface. This is, however, done when the vessel is mid-ocean. It is in no way connected to a quay, or any other land side for that matter. When the vessel is at the quay side it is not possible to lower that end of the vessel to launch a structure. The launch end of the vessel extends into and above the quay, and a lowering would only cause the vessel to hit the top of the quay.

[0006] Moreover, while the components of the floating structure are temporarily stored on the deck of the vessel, the building takes place on an arm shaped structure extending outside the deck aft of the vessel.

[0007] KR102192116B1 shows several floating elements interconnected to a barge-like support structure. This barge-like structure can receive a load to be transported to a site of installation. When the site of installation has been reached, the barge-like structure is de-ballasted to bring one end thereof below the water surface and the load slides into the sea. The barge-like structure lacks any facilities to enable assembly of large components on the deck thereof.

[0008] The above constraints put great limits on where a floating structure can be built. The limitations increase with the size and draught of the floating structure.

[0009] It is therefore often necessary to tow the floating structure from a place suitable for building the structure to the place where it is to be deployed. The distance can be considerable. This does not only take time and is costly. It is also risky, as the tow will have to be done during good weather conditions. Last, but not least, it is not very environmentally friendly to tow the structure over large distances. Especially, when building wind turbines, which are supposed to reduce the carbon emission footprint, it is desirable to make the production as environmentally friendly as possible.

[0010] The obvious solution to this would be to increase the water depth either by excavating the seabed close to an existing quay, or by building a quay, or extending an existing quay, into deeper waters. This is, however, not desirable both from an environmental perspective and due to the high costs.

[0011] Prior art references include WO 2016 / 138088, JP S5583678 and SE 443962. None of these meets the requirements of the present invention.

[0012] There is consequently a great need for a new solution that makes it possible to build large floating structures at an existing facility close to where the structures are to be deployed, even though the water depth close to the existing facility is too shallow for the floating structure to float.Summary of invention

[0013] The invention solves the above problem by the arrangement defined in the subsequent claim 1 and the method of the subsequent claim 10. Convenient embodiments are defined in the depending claims.Brief description of drawings

[0014] Figure 1 shows a set of barges with cranes being towed to the building site, Figure 2 shows the set of barges assembled at the building site, Figure 3 shows a structure being erected on the set of barges, Figure 4 shows the finished structure on top of the set of barges, Figure 5 shows the structure about to be launched from the set of barges, Figure 6 shows the structure during launch, Figure 7 shows the structure floating outside of the set of barges, and Figure 8 illustrates the disassembly and towing away of the set of barges. Detailed description of the invention

[0015] Figure 1 shows a set of barges 1 - 4 being towed to the construction site. The barges may be of a standard type or standard barges that are modified to be able to connect with each other. In the drawings are shown four barges, but depending on the size of deck area and the buoyancy required, the number of barges may be smaller or greater.

[0016] Two cranes 5, 6, which are attached on top of a respective barge 1, 4 are also present. During the tow, the boom of the cranes is resting in a respective boom rest 7, 8.

[0017] The barges can conveniently be towed by a single tow vessel 9 with tow lines extending between the barges 1-4. However, it would be safer to have at least two tow vessels, one at each end of the tow.

[0018] When the barges 1-4 have reached their destination, i.e. a quay 10, the barges are lined up side-by-side and moored with one short side of the barges 1-4 next to the quay side. Preferably, the barges 1-4 abut the quay 10. Fenders may be placed between the barges and the quay. The mooring may comprise hawsers extending between the barges and the quay.

[0019] Then the barges 1-4 are fixedly connected, such as by welding, to make up a single floating unit where the barges are unable to move or flex relative to each other. This process may also take place before the barges are moored.

[0020] Instead of welding, the barges may also be firmly connected by devices that are attached between the barges. The connection should be made in such a way that the decks of the barges 1-4 are flush and that there are no obstacles protruding above the surface of the decks.

[0021] The barges are arranged so that the two cranes 5, 6 are situated on a respective outer barge 1 and 4, and preferably close to the outer side of those barges as well as close to the inner end, i.e. the end next to the quay 10, of the barges 1, 4. For the building of smaller floating structures, one crane 5 may be sufficient.

[0022] Due to tidal differences, the deck of the barges 1-4, i.e. the floating unit will be at different altitudes relative to the quay 10. This can be at least partially compensated for by varying the ballast of the barges. Nevertheless, a ramp (not shown) may be arranged between the barges 1-4 and the quay 10. The ramp may be a small ramp solely for persons and small carry-on goods but may also be a larger ramp that can be crossed by vehicles.

[0023] The barges may also have moorings lines, such as ropes or chains, attached to their sides distal from the quay side at one end and attached to anchors at another end, such as suction anchors, placed at the seabed distant from the quay side.

[0024] With the barges 1-4 thus moored, the building of the sub-structure may commence. The elements from which the sub-structure is to be built are brought to the quay either by lorry or by boat. The elements are conveniently hoisted onto the deck of the barges 1-4 by the cranes 5, 6.

[0025] In an alternative embodiment, the floating unit may be purpose-built as a single or multi hull structure instead of assembling it from barges.

[0026] Figure 3 shows two columns 11, 12 of the sub-structure having been installed and interconnected by struts 13. The connections are conveniently made by welding the pipes of the struts together.

[0027] In figure 4 a third column 14 has been installed and connected to the two first columns 11, 12. The sub-structure 15 is now completed.

[0028] Figure 5 shows a first step of the launching process. The booms of the cranes 5, 6 have been lowered onto the boom rests 7, 8 and secured thereto. The barges are ballasted by letting water flow into ballast chambers at the distal end of the barges 1-4. This ballasting causes the distal ends of the barges 1-4 to sink into the water. The flow of water into the ballasting chambers continues until the two columns 12, 14 closest to the outer edge of the barges 1-4 are partially submerged under water, and preferably floats off from the deck of the barges 1-4.

[0029] When the barges 1-4 have reached a sufficient inclination for the sub-structure 15 to slide off the deck and into the water, any ties between the sub-structure and the barges 1-4 are released. A winch or similar may also be activated to pull the sub-structure along the deck if it will not slide due to gravity.

[0030] In figure 6 the sub-structure 15 has almost completely slid off the deck, and the innermost column 11 has started to float.

[0031] In figure 7 the sub-structure 15 is floating outside of the barges 1-4. At this distance from the quayside, the water depth is sufficient for the sub-structure 15 to float without touching the seabed. It can now be towed to a convenient nearby site for installation of the super-structure such as a wind turbine.

[0032] After the launch of the sub-structure 15, the barges 1-4 are de-ballasted by pumping the water in the ballasting chambers out, so that the barges 1-4 are brought up to float with the deck in a horizontal plane. Building of the next sub-structure can then be started.

[0033] When the planned number of sub-structures have been built and launched as described above, the barges 1-4 are disconnected from each other and towed away. Alternatively, the barges 1-4 may also be towed as one unit if the next use of the barges is as a single unit, such as at another location.

Claims

1. A floating fabrication arrangement (1-4, 5, 6, 10) for building of floating structures (15), comprising a floating unit (1-4) having a continuous deck, at least one crane (5; 6), suitable to hoist elements of the floating structure from a quay to the continuous deck, attached to said floating unit (1-4) and a mooring arrangement capable of mooring the floating unit in a floating state on a body of water, the floating unit having ballast chambers capable of ballasting and de-ballasting the floating unit between a first building position where the floating unit floats with the deck above water in a substantially horizontal position and a second inclined launch position, in which a first part of the deck is submerged and a second part of the deck is above water, wherein said arrangement is adapted to be moored next to a quay-side (10), said first part of the deck is next to a distal side of the floating unit, facing away from said quay-side (10), and said second part of the deck is next to a proximal side of the floating unit, facing towards the quay-side, wherein when the floating unit has reached a sufficient inclination, the floating structure (15) slides off the continuous deck and into the body of water on the distal side of the floating unit.

2. The arrangement of claim 1, wherein the floating unit is assembled from a plurality of barges (1-4) that are firmly interconnected.

3. The arrangement according to claim 2, wherein the barges (1-4) are interconnected with their long sides facing each other.

4. The arrangement of any of the preceding claims, wherein it comprises two cranes (5, 6) arranged on the deck of the outermost barges (1, 4).

5. The arrangement according to claim 2 or 4, wherein the barges (1-4) are connected to each other by welding.

6. The arrangement according to claim 2 or 4, wherein the barges (1-4) are connected to each other by devices attached between the barges.

7. The arrangement of any of the claims 3-6, wherein it comprises a ramp extending between the quay (10) and the floating unit (1-4).

8. The arrangement of any of the claims 3-7, wherein said mooring comprises hawsers attaching the floating unit (1-4) to the quay (10).

9. The arrangement of claim 8, wherein the mooring also comprises mooring lines attached between said floating unit (1-4) and one or more anchors at the seabed.

10. A method of building a floating structure using the floating fabrication arrangement of any of the claims 1-9, characterised in the following steps: a. mooring a proximal side of the floating unit (1-4) by hawsers to a quay (10) while said floating unit (1-4) is floating on a body of water, b. while said continuous deck is in a horizontal building position, lifting said elements with the at least one crane (5; 6) of the floating unit (1-4) onto said deck and interconnecting said elements to erect said floating structure (15) on said deck, c. ballasting said floating unit (1-4) into an inclined launch position, to bring a first part of said deck, next to a distal side of said floating unit (1-4), facing away from said quay (10), below the surface of the water, d. sliding said completed floating structure (15) off of said floating unit (1-4) and into said water, and e. de-ballasting said floating unit (1-4) to bring the deck completely out of the water; f. said proximal side of said floating unit (1-4) being maintained in a moored state to the quay (10) during steps a-e.

11. The method of claim 10, further comprising firmly interconnecting a plurality of barges (1-4) to form a single floating unit having a continuous deck.

12. The method of claim 11, further comprising interconnecting said barges (1-4) with their long sides facing each other.

13. The method of claim 10, 11 or 12, further comprising bringing elements to build said floating structure (15) to said quay (10) prior to lifting said elements onto said deck.

14. The method of any of the claims 10-13, further comprising arranging a ramp between said quay (10) and said deck of said floating unit (1-4).

15. The method of any of the claims 10-14, further comprising attaching mooring lines between said floating unit (1-4) and one or more anchors at the seabed.