Facility and method for manufacturing offshore wind turbine platforms
Patent Information
- Application Number
- EP2024785911
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-04-05
- Filing Date
- 2024-04-05
- Publication Date
- 2026-02-11
AI Technical Summary
Current manufacturing facilities for offshore wind turbine platforms face challenges in economics and logistics due to smaller revenue per platform and the need for a larger number of platforms, with existing designs being inefficient in transporting and deploying these structures effectively.
A movable manufacturing facility on a barge integrating robotic compartment manufacturing and a floodable or floating dry dock allows for the assembly and completion of offshore wind turbine platform floaters before lowering them into the water, enabling efficient transport to deployment sites using buoyancy, with retractable beams and modular dry dock modules for versatility.
This solution enables cost-effective and efficient manufacturing and transport of offshore wind turbine platforms by allowing assembly and completion on-site, reducing transportation costs and increasing deployment efficiency by utilizing buoyancy and modular dry dock systems.
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Abstract
Description
FACILITY AND METHOD FOR MANUFACTURINGOFFSHORE WIND TURBINE PLATFORMSCROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to US provisional application serial no. 63 / 457,354 filed on April 5, 2023, which is incorporated herein by reference in its entirety for all and any purposes.BACKGROUND
[0002] This disclosure relates generally to facilities and methods for manufacturing offshore wind turbine platforms. This disclosure relates more particularly to a facility and method in which the offshore wind turbine platforms that are constructed can then be easily lowered into the water and then transported to their deployment site.
[0003] Some current designs of facilities for economically manufacturing offshore wind turbine platforms plan on building on the known designs of facilities for manufacturing offshore platforms for the oil and gas business. For example, a known design of a facility for manufacturing offshore platforms for the oil and gas business is described in IA pub. no. WO 2010 / 030901. The economics and logistics required for manufacturing offshore wind turbine platforms, however, are quite different from offshore platforms for the oil and gas business due to the fact that revenues per platform are significantly smaller for offshore wind turbine platforms and a larger number of platforms is required.
[0004] Examples of current designs of facilities for manufacturing offshore wind turbine platforms are described in US pub. no. 2022 / 0260058, and IA pub. no. WO 2023 / 244607. The facility designs described in these later references demonstrate how offshore wind turbine platforms can be built using robotic automation to make standard components, such as compartments (e g., “cans,” or “cells” attached to bulkhead decks). These facility designs are more efficient than standard ship-type stiffened plate construction and achieves attractive cost and schedule.
[0005] Nevertheless, significant challenges to the economically manufacturing of offshore wind turbine platforms still remain, including providing a facility that is not excessively far from thedeployment site of the offshore wind turbine platforms, and then, providing the transport of the offshore wind turbine platforms to their deployment site.BRIEF DESCRIPTION OF THE DRAWINGS
[0006] For a more detailed description of the embodiments of the disclosure, reference will now be made to the accompanying drawings, wherein:
[0007] FIG. 1 is a plan view of a facility for manufacturing at least the floater of offshore wind turbine platforms, wherein the facility is provided on a manufacturing barge that combines a robotic line to manufacture compartments (e g., “cans,” or “cells” attached to bulkhead decks), and a floodable dry dock into which the compartments are assembled to make the floater of wind turbine platforms;
[0008] FIG. 2 is a perspective view of a portion of the facility shown in FIG. 1 illustrating retractable beams with rollers that support the floater of a wind turbine platform;
[0009] FIG. 3 is a perspective view of a portion of the facility shown in FIG. 1 illustrating the retractable beams with rollers that are moved out of position when the floater of the wind turbine platform is lifted so that the floater can be lowered into the water and transported to a deployment site;
[0010] FIG. 4 is a perspective view of the retractable beams with rollers shown in FIGs. 2 and 3;
[0011] FIG. 5 is a perspective view of the retractable beams with rollers shown in FIGs. 2 and 3 illustrated supporting a compartment;
[0012] FIG. 6 is a side view of a modular facility for manufacturing at least the floater of offshore wind turbine platforms, wherein the facility is provided on a manufacturing barge that provides a robotic line to manufacture compartments (e g., “cans,” or “cells” attached to bulkhead decks), and a floating dry dock module into which the compartments are assembled to make the floater of a wind turbine platform, wherein the floating dry dock module has an adjustable buoyancy so that its waterline can be raised or lowered, and wherein the floating dry dock module includes a jack up structure;
[0013] FIG. 7 is a side view of the modular facility shown in FIG. 6 illustrating the floating dry dock module with a high waterline so that the floater of the wind turbine platform can be lowered into the water and transported to a deployment site;
[0014] FIGs. 8A-8E are views of different floating dry dock modules that can be connected to the same manufacturing barge shown in FIG. 6, wherein the different floating dry dock modules are adapted for the assembly of different types of floaters of wind turbine platforms; and
[0015] FIG. 9 is a plan view of a modular facility for manufacturing offshore wind turbine platforms, wherein the facility is provided on a manufacturing barge that provides a robotic line to manufacture compartments (e.g., “cans,” or “cells” attached to bulkhead decks), and a floating dry dock module that includes a water lock for welding a turbine tower to the floater of the wind turbine platform in the dry.DETAILED DESCRIPTION
[0016] FIGs. 1-9 describe preferred embodiments of a movable facility for manufacturing at least the floater of offshore wind turbine platforms. Thus, the facility can be relocated close to the deployment site of the offshore wind turbine platforms.
[0017] The manufacturing facility is designed to integrate the aspects of compartment manufacturing and a dry dock.
[0018] The compartment manufacturing is performed on a barge that includes a robotic line to manufacture compartments. The manufacture of compartments may be achieved using: a production line involving known rolling and welding techniques combined with special-purpose T-Beam fabrication, so that structural “cans” or “cells,” can be made of rolled standard plates with one or two T-Beam stiffeners welded to them; a separate production line to build a series of bulkhead decks that provide compartmentations as well as attachment structures: for example, a single bulkhead deck can be combined with a series of one or more “cans” or “cells” to make a component in the form of a compartment which can be pre-outfitted with attachment structures for assembly.
[0019] The integration of a compartment with other compartments to form a complete floater of an offshore wind turbine platform (e.g., a spar, a buoyant tower structure or column, a pontoon of a semi-submersible) is performed in the dry dock, which allows the floater to be completed beforeit is lowered into water in order to transport the floater to the deployment site of the offshore wind turbine platforms using its own buoyancy.
[0020] In some embodiments, the dry dock is a floodable dry dock fixedly integrated to the barge.
[0021] In some embodiments, the dry dock is a floating dry dock module which can be raised or lowered relative to a main portion of the barge.
[0022] FIG. 1 illustrates a facility 10 for manufacturing at least the floater of offshore wind turbine platforms. In this example, the floater is a spar / buoyant tower column 18.
[0023] The facility 10 is provided on a manufacturing barge 12 that combines a robotic line 14 to manufacture compartments (e.g., “cans,” or “cells” attached to bulkhead decks), and a floodable dry dock 16 into which the compartments are assembled to make the floater of a wind turbine platform. For example, the dry dock portion 16 of the manufacturing barge 12 can be built separately and permanently integrated with the main portion of the manufacturing barge 12.
[0024] The robotic line 14 combines rolling / welding line 20 to create “cans” or “cells” with a panel line 22 to create bulkhead decks. These components are assembled into compartments, such as compartment 24. The different compartments are then connected (e.g., welded together) to form floaters (e.g., the spar / buoyant tower column 18) for wind turbine platforms.
[0025] As shown in the example of FIG. 1, the dry dock 16 can be incorporated or integrated to the barge 12. The dry dock 16 allows the platform floater to be completed before floating the floater off the facility 10 under its own buoyancy. As shows, the dry dock 16 may be permanently flooded when it does not have a gate. However, when using a gate, the dry dock 16 could be flooded only after the platform floater is completed.
[0026] FIGs. 2 and 3 show that the dry dock 16 includes retractable beams 26 with rollers 30 that support a floater in the form of the spar / buoyant tower column 18 during final integration and outfitting. The retractable beams 26 with rollers 30 are moved out of position after the floater is lifted using a series of lifting devices (e.g., the pantry or overhead cranes 28).
[0027] FIGs. 4 and 5 illustrate that some rollers 30a facilitate the longitudinal travel of the “cans” or “cells,” or a group thereof forming a compartment (e.g., the compartment 24 as specifically shown in FIG. 5), or even a portion of the floater. Some rollers 30b facilitate the rotation of the“cans” or “cells,” or a group thereof forming a compartment (e.g., the compartment 24 as specifically shown in FIG. 5), or even a portion of the floater. Some rollers 30c can be displaced to facilitate the alignment of the “cans” or “cells,” or a group thereof forming a compartment (e.g., the compartment 24 as specifically shown in FIG. 5), or even a portion of the floater.
[0028] In another embodiment of the facility 10 shown in FIGs. 6 and 7, the dry dock can be built separately as a module 16 and connected to a main portion 12 of the manufacturing barge. This modular structure of the facility 10 would allow the dry dock 16 to be replaced, for example, if a different type of floater will be constructed. The manufacturing facility 10 therefore becomes a producer of standardized components (the compartments 24) that can be integrated / stacked in various ways to form different floater types for different designs of offshore wind turbine platforms.
[0029] The module 16 can be a floating dry dock that includes floodable buoyancy chambers. When valves are opened, the chambers fill with water, causing the dry dock to float lower in the water. The deck of the dry dock becomes submerged and this allow floating off the floater of an offshore wind turbine platform after it has been completed. A floating dry dock may not always be necessary but is preferred to float off platform floaters of the type of semi-submersibles.
[0030] The module 16 forming the dry dock portion can be connected to the main portion 12 of the manufacturing barge using a sliding interface 34. A jack up structure 32 can be used together with the sliding interface 34. However, other types of mechanical connections, such as described in KRpat. no. 10-1584571 may also be used to connect the module 16 forming the dry dock portion to the main portion 12 of the manufacturing barge.
[0031] In this example, the floater is again a spar / buoyant tower column 18. As shown in FIG. 7, the module 16 includes rollers 30 that remain in place and have sufficient clearance when lowered in water to allow the spar / buoyant tower column 18 to float free after flooding.
[0032] FIGs. 8A is a schematic of a module 16a, similar to the module 16 shown in FIGs. 6 and 7. Like the module 16, the module 16a can be connected to the main portion 12 of the manufacturing barge shown in FIGs. 6 and 7. The module 16a is specifically adapted for the assembly of compartments into a spar 18a.
[0033] The module 16a can be disconnected from the main portion 12 of the manufacturing barge shown in FIGs. 6 and 7, and replaced by either the module 16b shown in FIG. 8B or the module 16c shown in FIG. 8C. The modules 16b and / or 16c are specifically adapted for the assembly of compartments into buoyant tower structures 18b and / or 18c, respectively.
[0034] Similarly, any of modules 16a, 16b, 16c can be disconnected from the main portion 12 of the manufacturing barge shown in FIGs. 6 and 7, and replaced by either the module 16d shown in FIG. 8D or the module 16e shown in FIG. 8D. The modules 16d and / or 16e are specifically adapted for the assembly of compartments into semi-submersibles 18d and / or 18e, respectively. To float off the semi-submersibles 18d and / or 18e, the modules 16d and / or 16e are partially lowered and the waterline raised, or if provided, a gate 36 may also be opened to allow the semisubmersibles 18d and / or 18e to float off. The main portion 12 of the manufacturing barge shown in FIGs. 6 and 7 may be first disconnected from the modules 16d and / or 16e and displaced to make way for the semi-submersibles 18d and / or 18e to float off.
[0035] Optionally, in the case of floaters of the type of a spar / buoyant tower column, it may be convenient to be able to install the tower 38 of the offshore wind turbine platform on the spar / buoyant tower column 18 in the horizontal position prior to tow the tower 38 and the spar / buoyant tower column 18 to the deployment location in the upended position. In this case, the components of the tower 38 can be pre-assembled, either using a similar construction method on a barge or using flanged connections. As shown in FIG. 9, the tower 38 can then be towed into position with its base facing into the dry dock 16 to be mated to the spar / buoyant tower column 18 and a specialized water lock can be used to allow welding of the two together in the dry.
[0036] In order to implement a water lock, the dry dock 16 can include a main outside gate 40 shaped to accept the tower 38 into the end of the dry dock 16. The main outside gate 40 is provided with sealing surfaces that can be engaged onto the base of the tower 38. The dry dock 16 can also include at least one internal, adjustable (e.g., axially movable) gate 42 which has elastomers that are able to engage with the outside of the top the spar / buoyant tower column 18 and seal.
[0037] During installation of the tower 38 on the spar / buoyant tower column 18, it may be advantageous to support to the top of the tower 38 using a tensioned cable 44 that can also be used to position the tower 38.
Claims
What is claimed is:
1. A facility for manufacturing at least a floater of an offshore wind turbine platform, comprising: a movable barge carrying a robotic line configured to manufacture components of cylindrical compartments; and a first dry dock configured for assembly of the cylindrical compartments into the floater of the wind turbine platform; wherein the first dry dock is either a floodable dry dock integrated to the movable barge or a floating dry dock module releasably connected to a main portion of the movable barge.
2. The facility of claim 1, wherein the first dry dock is a floating dry dock module releasably disconnectable from the main portion of the movable barge, wherein the facility further comprises a second dry dock, wherein the second dry dock is a floating dry dock module releasably connectable to the main portion of the movable barge in place of the first dry dock, wherein the first dry dock is adapted for assembly of the cylindrical compartments into one of a spar, a buoyant tower structure, or a semi-submersible, and wherein the second dry dock is adapted for assembly of the cylindrical compartments into another one of a spar, a buoyant tower structure, or a semi-submersible.
3. The facility of claim 1 or 2, wherein the first dry dock is a floating dry dock module that includes rollers, wherein the rollers are configured to support the floater of the offshore wind turbine platform in a first position of a waterline of the floating dry dock module, wherein the floating dry dock module can be sunk into water to raise the waterline of the floating dry dock module to a second position, wherein the rollers do not support the floater of the offshore wind turbine platform in the second position of the waterline of the floating dry dock module, andwherein the floater of the offshore wind turbine platform floats by its own buoyancy in the second position of the waterline of the floating dry dock module.
4. The facility of claim 3, wherein some rollers are configured to facilitate longitudinal travel of the floater, some rollers are configured to facilitate rotation of the floater, and some rollers are configured to facilitate alignment of the floater.
5. The facility of claim 1 or 2, wherein the first dry dock is connected to the main portion of the movable barge via sliding interfaces.
6. The facility of claim 5, wherein the first dry dock includes a jack up structure.
7. The facility of claim 1 or 2, wherein the first dry dock includes a water lock, and wherein the water lock includes an outside gate and an internal gate that have sealing surfaces that are shaped to engage the floater of the offshore wind turbine platform and a turbine tower.
8. The facility of claim 1, wherein the first dry dock is a floodable dry dock integrated to the movable barge that includes retractable beams with rollers, wherein the rollers are configured to support the floater of the offshore wind turbine platform in a first position of the retractable beams, and wherein the retractable beams are movable out of the first position after the floater is lifted using a lifting device.
9. The facility of claim 8, wherein some rollers are configured to facilitate longitudinal travel of the floater, some rollers are configured to facilitate rotation of the floater, and some rollers are configured to facilitate alignment of the floater.
10. The facility of any of claim 8 or 9, wherein the first dry dock includes a water lock, and wherein the water lock includes an outside gate and an internal gate that have sealing surfaces that are shaped to engage the floater of the offshore wind turbine platform and a turbine tower.
9. A method for manufacturing at least a floater of an offshore wind turbine platform, comprising: providing a movable barge carrying a robotic line; using the robotic line to manufacture components of cylindrical compartments; providing a first dry dock, wherein the first dry dock is either a floodable dry dock integrated to the movable barge or a floating dry dock module releasably connected to a main portion of the movable barge; and assembling of the cylindrical compartments into the floater of the wind turbine platform.
10. The method of claim 9, further comprising: disconnecting the first dry dock from the main portion of the movable barge, connecting a second dry dock to the main portion of the movable barge in place of the first dry dock, wherein the first dry dock is a floating dry dock module, wherein the first dry dock is adapted for assembly of the cylindrical compartments into one of a spar, a buoyant tower structure, or a semi-submersible, wherein the facility further comprises the second dry dock, wherein the second dry dock is a floating dry dock module, andwherein the second dry dock is adapted for assembly of the cylindrical compartments into another one of a spar, a buoyant tower structure, or a semi-submersible.
11. The method of claim 9 or 10, wherein the first dry dock is a floating dry dock module that includes rollers, the method further comprising: supporting the floater of the offshore wind turbine platform in a first position of a waterline of the floating dry dock module with the rollers; sinking the floating dry dock module into water to raise the waterline of the floating dry dock module to a second position, wherein the rollers do not support the floater of the offshore wind turbine platform in the second position of the waterline of the floating dry dock module; and causing the floater of the offshore wind turbine platform to float by its own buoyancy in the second position of the waterline of the floating dry dock module.
12. The method of claim 9, wherein the first dry dock is a floodable dry dock integrated to the movable barge that includes retractable beams with rollers, the method further comprising: supporting the floater of the offshore wind turbine platform in a first position of the retractable beams with the rollers; and moving the retractable beams are out of the first position after the floater is lifted using a lifting device.