Semi-submersible float for an offshore wind turbine and method for constructing such a float

Abstract

The invention relates to a semi-submersible float (2-1), in particular for an offshore wind turbine comprising four columns including one central column (4) intended to receive a wind turbine tower (6) and at least three outer columns (8) which are connected to the central column by arms forming lower pontoons (10). The float is free of upper arms connecting the central column to the outer columns and the outer columns and the lower pontoons are each formed by an assembly of planar panels (81 to 86, 101 to 104) each having a polyhedral cross-section. The invention also relates to a method for constructing such a float.

Description

Description Title of the invention: Semi-submersible float for offshore wind turbine and method of constructing such a float Technical Field

[0001] The present invention relates to the general field of semi-submersible floats used for offshore wind turbines.

[0002] More specifically, it concerns a new semi-submersible float architecture and a method of constructing such a float. Prior art

[0003] An offshore wind turbine uses wind energy to generate electricity using a turbine and an electric generator. There are two main types of offshore wind turbines: fixed wind turbines, which are installed on the seabed (at shallow depths, typically less than 50m), and floating wind turbines, which offer the advantage of being able to be built on land and installed in areas where the seabed depth typically exceeds 50m.

[0004] The floating wind turbines to which the present invention relates comprise a turbine generally formed by a motor with several horizontal-axis rotating blades and an electric generator coupled to the motor, the motor and the generator being fixed to an upper end of a vertical mast (or pylon). The lower end of the mast is mounted on a floating support structure (hereinafter referred to as a float).

[0005] There are several main families of floats for offshore wind turbines: semi-submersible floats, submerged floats with tensioned cables (or "TLP" platforms for "Tension-Leg Platform" in English), "SPAR" type floats (for "Single Point Anchor Reservoir"), semi-submersible "barge" type floats, and floats with a pendulum counterweight.

[0006] The invention relates more specifically to semi-submersible floats, i.e. steel or concrete foundations which generally take the form of a tripod with three (or four) cylindrical columns connected to each other by metal structures. The stability of the structure is ensured by a ballasting system which allows part of the foundation to be submerged. This structure is characterized by its large size and reduced draft.

[0007] For example, we can refer to publication FR 3,064,973 which describes a semi-submersible hybrid float structure comprising a central column and three external columns connected to the central column by pontoon-shaped branches.

[0008] Although relatively simple in design, this hybrid float has the disadvantage of a relatively long assembly time and potentially high manufacturing costs. Statement of the invention

[0009] The invention therefore aims to propose a semi-submersible float structure which has an extremely short construction and delivery time for low costs.

[0010] This aim is achieved by means of a semi-submersible float, in particular for an offshore wind turbine, comprising four columns including a central column intended to receive a wind turbine mast, and at least three external columns which are connected to the central column by branches forming lower pontoons, and in which, in accordance with the invention, it is devoid of upper branches connecting the central column to the external columns and the external columns and the lower pontoons are each formed by an assembly of flat panels and each have a polyhedral cross section.

[0011] The float according to the invention is remarkable in that the main elements which compose it (external columns and lower pontoons) result from an assembly of a plurality of flat panels, which greatly facilitates the float manufacturing. Due to this feature, float construction and delivery times can be greatly reduced due to a more abundant supply chain than that of the large diameter cylindrical columns of the prior art (because it opens up to global capacities in the field of shipbuilding).

[0012] This makes it possible to offer a robust and qualified float that meets the operating conditions of the installation site and the required performance with an attractive cost / performance ratio. The associated risks are also contained due to the simplicity of construction.

[0013] Preferably, the central column is formed by an assembly of flat panels and has a polyhedral cross-section. This arrangement further reduces the construction time and costs of the float.

[0014] The central column can advantageously end with a transition piece having the shape of a truncated cone widening downwards.

[0015] Alternatively, the central column may advantageously have a truncated cone shape that tapers downwards. The presence of a truncated cone that tapers downwards is particularly advantageous for the overall design of the wind turbine.

[0016] The outer columns can have the same height and the central column can have a different height than the outer columns.

[0017] Preferably, the central column comprises an access door to a tower supporting the wind turbine which is located below the interface with the tower and internal reinforcements of the interface with the tower. This access door allows operators to enter the structure to access equipment positioned inside the tower. Compared to the prior art in which the access door is generally positioned a few meters above the interface with the tower, the position of the access door is here advantageously lowered by several meters to remove it from the area of ​​the internal reinforcements of the interface with the tower.

[0018] Also preferably, the flat panels forming the external columns are assembled together by at least one rounded rod so as to improve their hydrodynamic behavior and reduce stress concentrations.

[0019] The flat panels forming the external columns and the lower pontoons can advantageously be reinforced by longitudinal internal stiffeners and / or transverse internal stiffeners.

[0020] The flat panels forming the outer columns and lower pontoons can also be reinforced by longitudinal external stiffeners and / or transverse external stiffeners. Compared to internal stiffeners, external stiffeners have the advantage of facilitating the welding operations required to install such stiffeners.

[0021] Preferably, the external columns are connected to each other by pre-stressed cables. These pre-stressed cables have the advantage of absorbing some of the out-of-plane forces and thus reducing the stress on the structure, and therefore its mass.

[0022] The float may further comprise members each extending between the central column and one of the lower pontoons to partially transfer the loads in the plane of the central column to the lower pontoons. Such members may have a tubular or polyhedral shape.

[0023] The lower pontoons can be angularly spaced from each other by 120° to form a star structure.

[0024] The invention also relates to a method for the modular construction of a float as defined above, comprising: - the assembly of flat panels together to form, on the one hand, the lower pontoons and, on the other hand, the external columns - the assembly of the lower pontoons to a central structure with branches supporting the central column - the assembly of the outer columns on the lower branches, and - assembling the central column on the branched central structure.

[0025] The assembly of the lower pontoons on the branched central structure can be carried out by welding. In this case, the assembly welds of the lower pontoons on the branched central structure are advantageously external with the use of external stiffeners connected by welding so as to facilitate their installation.

[0026] Alternatively, the assembly of the lower pontoons on the branched central structure can be carried out by means of mechanical connectors.

[0027] Furthermore, the assembly of the lower pontoons on the branched central structure can be carried out at sea on a floating barge.

[0028] Yet alternatively, the assembly of the lower pontoons on the branched central structure can be carried out afloat at sea. Brief description of the drawings

[0029] [Fig. 1] Figure 1 is a perspective view of a float according to a first embodiment of the invention.

[0030] [Fig. 2] Figure 2 is a perspective view of a float according to a second embodiment of the invention.

[0031] [Fig. 3] Figure 3 is a perspective view of a float according to a third embodiment of the invention.

[0032] [Fig. 4] Figure 4 is a perspective view of a float according to a fourth embodiment of the invention.

[0033] [Fig. 5] Figure 5 is a perspective view of a float according to a fifth embodiment of the invention.

[0034] [Fig. 6] Figure 6 represents in perspective a float according to a sixth embodiment of the invention.

[0035] [Fig. 7] Figure 7 represents in perspective a float according to a seventh embodiment of the invention.

[0036] [Fig. 8] Figure 8 represents in perspective a float according to an eighth embodiment of the invention.

[0037] [Fig. 9] Figure 9 shows the presence of internal stiffeners equipping an external column and a lower pontoon of a float according to the invention.

[0038] [Fig. 10] Figure 10 shows the presence of external stiffeners equipping the lower pontoons of a float according to the invention.

[0039] [Fig. 11] to [Fig. 13] Figure 11, Figure 12 and Figure 13 show different variants of a method of constructing a float according to the invention. Description of the embodiments

[0040] Figure 1 shows in perspective a semi-submersible float 2-1 for an offshore wind turbine according to a first embodiment of the invention.

[0041] The float 2-1 comprises four columns including: a central column 4 intended to receive a wind turbine mast 6; and three external columns 8 which are connected to the central column 4 by branches forming lower pontoons 10.

[0042] More specifically, the lower pontoons 10 and the outer columns 8 are angularly spaced from each other by 120° to form a star structure.

[0043] The float 2-1 according to the invention has the characteristic of being devoid of upper branches connecting the central column 4 to the outer columns 8. In addition, at least the outer columns 8 and the lower pontoons 10 are each formed by an assembly of flat panels and each have a polyhedral cross section.

[0044] Thus, in the first embodiment illustrated by figure 1, each external column 8 is constituted by the assembly of six flat panels 8i to 8 6forming a right prism with a hexagonal base, and each lower pontoon 10 is made up of the assembly of four flat panels 10i to 10 4 forming a rectangular parallelepiped (only flat panels 101 and 10 4 are visible in Figure 1).

[0045] Of course, the polyhedron formed by the assembly of the flat panels of the external columns and the lower pontoons could be different: rectangular parallelepiped, right prism with a pentagonal base, etc.

[0046] Furthermore, according to an advantageous arrangement of the invention, the central column 4 is also formed by an assembly of flat panels and thus has a polyhedral cross section.

[0047] Furthermore, still in this first embodiment, the lower pontoons 10 of the float are each connected to an external column 8 at the same face thereof (namely at the level of the flat panel 83 in FIG. 1). Similarly, the lower pontoons 10 are also connected at the same face of the central column 4.

[0048] Figure 2 shows in perspective a 2-2 semi-submersible float for an offshore wind turbine according to a second embodiment of the invention.

[0049] This float 2-2 differs from that of the first embodiment in that the lower pontoons 10 of the float are each connected to an external column 8 at two adjacent faces thereof (namely at the level of the flat panel 83 in FIG. 1).

[0050] On the contrary, as for the first embodiment, the lower pontoons 10 are also connected at the same face of the central column 4.

[0051] Figure 3 represents in perspective a semi-submersible float 2-3 for an offshore wind turbine according to a third embodiment of the invention.

[0052] This float 2-3 differs from that of the second embodiment in that the flat panels 81 to 8e forming the external columns 8 are assembled together by rounded rods 12 so as to improve their hydrodynamic behavior and reduce stress concentrations.

[0053] Furthermore, it will be noted that in each of the embodiments of figures 1 to 3, the central column 4 ends (at its upper end) with a transition piece 14 with the wind turbine mast 6 which has a cylindrical shape.

[0054] Other forms are possible.

[0055] Thus, in the fourth embodiment represented by figure 4, the semi-submersible float 2-4 differs from that of the second embodiment in that the transition piece 14' between the central column 4 and the wind turbine mast 6 has the shape of a truncated cone widening downwards so as to limit the height of the transition zone between the central column and the wind turbine mast.

[0056] In the fifth embodiment shown in Figure 5, the central column 4 of the semi-submersible float 2-5 has a truncated cone shape that widens downwards.

[0057] In the sixth embodiment shown in Figure 6, the central column 4 of the semi-submersible float 2-6 has a cylinder shape.

[0058] Figure 7 shows in perspective a semi-submersible float 2-7 for an offshore wind turbine according to a seventh embodiment of the invention.

[0059] The float 2-7 differs from that of the second embodiment in that it further comprises members 16 each extending between the central column 4 and one of the lower pontoons 10 in order to partially transfer the loads in the plane of the central column to the lower pontoons.

[0060] Thus, the presence of these members 16 makes it possible to reduce the height of the lower pontoons 10. In addition, the draft of the float in operation can be reduced, which makes it possible to reduce the reinforcements for resistance to immersion pressure.

[0061] As shown in Figure 7, these members 16 may have a tubular shape. Alternatively, they could have a polyhedral shape.

[0062] Figure 8 shows in perspective a semi-submersible float 2-8 for an offshore wind turbine according to an eighth embodiment of the invention.

[0063] The float 2-8 differs from that of the second embodiment in that the outer columns 8 are connected to each other by prestressed cables 18. More precisely, these prestressed cables 18 are fixed to flat panels of the outer columns. The presence of these cables makes it possible to reduce the width of the lower pontoons 10 thanks to the out-of-plane moment loads transferred to the cables.

[0064] This results in a reduced float weight. Wave sensitivity can also be reduced, and therefore loads, which allows for fewer structural reinforcements. In addition, float assembly time is reduced because the lower pontoon connection dimension is reduced.

[0065] The prestress load of the cables 18 is defined so that they remain in tension throughout the life of the float.

[0066] Of course, it is possible to envisage that the float has both frames as illustrated in figure 7 and prestressed cables as illustrated in figure 8.

[0067] According to an advantageous arrangement shown in particular in Figure 9, the external columns 8 of the float according to the invention can be reinforced by longitudinal internal stiffeners 20a and / or transverse internal stiffeners 20b.

[0068] Likewise, the lower pontoons 10 of the float may be reinforced by longitudinal internal stiffeners 22a and / or transverse internal stiffeners 22b.

[0069] Alternatively, or in addition, the outer columns 8 of the float according to the invention may be reinforced by longitudinal external stiffeners and / or transverse external stiffeners.

[0070] Similarly, as shown in Figure 10, the lower pontoons 10 of the float may be reinforced by longitudinal external stiffeners 24a and / or transverse external stiffeners 24b.

[0071] Preferably, as shown in Figures 1 to 8, the outer columns 8 of the float have the same height and the central column 4 has a height different from that of the outer columns.

[0072] Advantageously, as shown in Figure 1, the central column 4 of the float according to the invention comprises an access door 28 to a tower supporting the turbine of the wind turbine which is located below the interface with the tower and internal reinforcements of the interface with the tower. This new position of the door results in the lowering of the external platform and a shortening of the access ladder for maintenance personnel from the support vessels.

[0073] In connection with Figures 11 to 13, a method of modular construction of a float according to the invention will now be described.

[0074] Generally, this method involves assembling flat panels together to form, on the one hand, the lower pontoons and, on the other hand, the outer columns. The lower pontoons thus formed are then assembled to a central structure with branches supporting the central column. Similarly, the outer columns thus formed are assembled on the lower branches. Finally, the central column can be assembled on the central structure with branches.

[0075] Different variations can be made.

[0076] Thus, in the variant represented by figure 11, four blocks are assembled together, namely: three identical external blocks B which are each constituted by the assembly of an external column 8 on a lower pontoon 10, and a central block C which is formed by the assembly of the central column 4 on a central structure with branches 30 for supporting the central column.

[0077] The three external blocks B are then assembled on the central block C by welding. This variant makes it possible to avoid welding in areas sensitive in terms of fatigue.

[0078] In order to limit the fatigue constraints linked to the welds, the central branch structure 30 is sized so as to space the weld zones of the central column.

[0079] In the variant represented by figure 12, three blocks are assembled together, namely: two identical external blocks B which are each constituted by the assembly of an external column 8 on a lower pontoon 10, and a main block D which is formed by the assembly of the central column 4 on a central branch structure 32 comprising a lower pontoon and an external column.

[0080] The two external blocks B are then assembled on the main block D by welding. Compared to the previous one, this variant limits the number of connections and therefore reduces the duration of the final assembly phase. It also avoids welding in areas sensitive to fatigue.

[0081] In the variant represented by figure 13, only two blocks are assembled together, namely: an external block B which is constituted by the assembly of an external column 8 on a lower pontoon 10, and a main block D' which is formed by the assembly of the central column 4 on a central branch structure 34 comprising two lower pontoons on each of which an external column is assembled.

[0082] The external block B is welded to the main block D'. Compared to the previous version, this variant further limits the number of connections. It also avoids welding in areas that are sensitive to fatigue.

[0083] It should be noted that the assembly welds of the lower pontoons of the external blocks on these different central branch structures can be external with the use of external stiffeners.

[0084] It should also be noted that as an alternative to welding, the assembly of the lower pontoons of the external blocks on these different central branch structures can be carried out using mechanical connectors.

[0085] Likewise, these assemblies can be made at sea on a floating barge or at sea afloat.

Claims

Claims 1. Semi-submersible float (2-1 to 2-8), in particular for offshore wind turbines, comprising four columns including a central column (4) intended to receive a wind turbine mast (6), and at least three external columns (8) which are connected to the central column by branches forming lower pontoons (10), the float being devoid of upper branches connecting the central column to the external columns and the external columns and the lower pontoons each being formed by an assembly of flat panels (8i to 8 6 , 101 to 10 4 ) and each having a polyhedral cross section, characterized in that the flat panels (81 to 8 6 ) forming the outer columns (8) are assembled together by at least one rounded rod (12) so as to improve their hydrodynamic behavior and reduce stress concentrations.

2. Float according to claim 1, characterized in that the central column (4) has the shape of a truncated cone widening downwards.

3. Float (2-4) according to one of claims 1 and 2, characterized in that the central column (4) ends with a transition piece (14') having the shape of a truncated cone widening downwards.

4. Float according to claim 1, characterized in that the central column (4) has the shape of a truncated cone widening downwards.

5. Float according to any one of claims 1 to 4, characterized in that the outer columns (8) have the same height and the central column (4) has a height different from that of the outer columns.

6. Float according to any one of claims 1 to 5, characterized in that the central column (4) comprises an access door (28) to a tower supporting the wind turbine which is located below the interface with the tower and internal reinforcements of the interface with the tower.

7. Float according to any one of claims 1 to 6, characterized in that the flat panels forming the outer columns (8) and the lower pontoons (10) are reinforced by longitudinal internal stiffeners (20a, 22a) and / or transverse internal stiffeners (20b, 22b).

8. Float according to any one of claims 1 to 7, characterized in that the flat panels forming the external columns (8) and the lower pontoons (10) are reinforced by longitudinal external stiffeners (24a) and / or transverse external stiffeners (24b).

9. Float (2-6) according to any one of claims 1 to 8, characterized in that the outer columns (8) are connected to each other by prestressed cables (18).

10. Floater (2-5) according to any one of claims 1 to 9, characterized in that it further comprises ribs (16) each extending between the central column (4) and one of the lower pontoons (10) in order to partly transfer the loads in the plane of the central column towards the lower pontoons.

11. Floater according to claim 10, characterized in that the ribs (16) have a tubular or polyhedral shape.

12. Floater according to any one of claims 1 to 11, characterized in that the lower pontoons (10) are angularly spaced from each other by 120° to form a star-shaped structure.

13. Modular construction method of a floater according to any one of claims 1 to 12, characterized in that it comprises: - the assembly of flat panels with each other to form, on the one hand the lower pontoons (10) and, on the other hand the outer columns (4), - the assembly of the lower pontoons to a central branch structure (30-34) supporting the central column, - the assembly of the exterior columns on the lower pontoons, and - the assembly of the central column (4) on the central branch structure.

14. Method according to claim 13, characterized in that the assembly of the lower pontoons on the central branch structure is carried out by welding.

15. Method according to claim 14, characterized in that the assembly welds of the lower pontoons on the central branch structure are external with the use of external stiffeners connected by welds.

16. Method according to claim 13, characterized in that the assembly of the lower pontoons on the central branch structure is carried out by means of mechanical connectors.

17. Method according to any one of claims 13 to 15, characterized in that the assembly of the lower pontoons on the central branch structure is carried out at sea on a floating barge.

18. Method according to any one of claims 13 to 15, characterized in that the assembly of the lower pontoons on the central branch structure is carried out at sea while afloat.

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