Method for positioning and aligning semi-submersible float blocks for offshore wind turbines

Abstract

Method for positioning and aligning semi-submersible float blocks for offshore wind turbine The invention relates to a method for positioning and aligning semi-submersible float blocks (2) for offshore wind turbine relative to a reference block, the float being constituted by the assembly of at least two different unit blocks, the method comprising the positioning of each unit block on a plurality of positioning systems (30) each comprising a platform (32) on which the float block is intended to rest and which is mounted on a controlled horizontal and vertical translation mechanism, and the coordinated adjustment of the platforms of the positioning systems in order to position and align the unit blocks relative to each other. Figure for abstract: Fig. 2.

Description

Title of the invention: Method for positioning and aligning semi-submersible float blocks for offshore wind turbine Technical field

[0001] The invention relates to the general field of mass production of floats for offshore wind turbines. More specifically, it relates to a method for positioning and aligning unit blocks forming such floats. Prior art

[0002] The purpose of an offshore wind turbine is to use wind energy to produce 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 depth of the seabed typically exceeds 50m.

[0003] The floating wind turbines which are concerned by the present invention comprise a turbine generally formed by a motor with several rotating blades on a horizontal axis 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).

[0004] The lower end of the mast is mounted on a floating support structure (called a "float"). There are different types of floats, namely semi-submersible floats (with or without pendulum counterweight), 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, etc. For example, reference may be made to publication WO 2019 / 106283 which describes a floating support structure whose main structure has a toric or polygonal shape.

[0005] Offshore wind turbines are most often grouped together in a “wind park” or “wind farm” generally comprising between 20 and 50 wind turbines with a unit power of several megawatts.

[0006] In floating offshore wind farm development projects, the float delivery schedule is a key parameter for the successful delivery of large offshore wind farms within tight installation windows. In addition, the ability to secure local float production is of utmost importance, but the land areas available for float assembly are usually a major obstacle.

[0007] Patent application FR 23 02023 filed on March 3, 2023 discloses a method for mass production of floats for offshore wind turbines, each consisting of the assembly of at least two different unit blocks of floats. This method is remarkable in that it makes it possible to manufacture floats for offshore wind turbines in series on a very limited land area.

[0008] The implementation of such a production method poses a certain number of technical problems, in particular that of having to position the float blocks with great precision to allow their assembly. Statement of the invention

[0009] The object of the invention is therefore to propose a method for positioning and aligning semi-submersible float blocks making it possible to address this problem.

[0010] According to the invention, this aim is achieved by means of a method for positioning and aligning semi-submersible float blocks for offshore wind turbines relative to a reference block, the float being constituted by the assembly of at least two different unit blocks, the method comprising: - the positioning of each unit block on a plurality of positioning systems each comprising a platform on which the float block is intended to rest and which is mounted on a controlled horizontal and vertical translation mechanism, and - the coordinated adjustment of the platforms of the positioning systems in order to position and align the unit blocks relative to each other.

[0011] The method according to the invention is remarkable in that it uses a plurality of positioning systems on which the unit blocks rest and which are controlled in a coordinated manner in order to adjust the blocks relative to each other during the different stages of manufacturing the floats. This positioning method is thus carried out automatically with a minimum of human intervention.

[0012] Preferably, the coordinated adjustment of the platforms of the positioning systems comprises measuring the positioning and controlling the positioning systems associated with each unit block in accordance with a target block.

[0013] In this case, the measurement of the positioning of the positioning systems can be carried out by a topographic device. In addition, the measurement of the positioning and the control of the positioning systems can be carried out wired or wirelessly remotely.

[0014] The invention also relates to a positioning system for implementing the method as defined above, comprising a platform on which is intended to rest the float block and which is mounted on a horizontal and vertical translation mechanism.

[0015] The invention also relates to a method for the mass production of semi-submersible floats for offshore wind turbines, each consisting of the assembly of at least two different unit blocks of floats, the method comprising: - the transport and storage in different storage areas of a production dock of a plurality of different blocks of floats, the same blocks of floats being stored in the same storage area of ​​the production dock; - the production line manufacturing of floats comprising successively for each float, a step of preparing the blocks, a step of assembling and primary welding the float blocks together at an assembly and primary welding zone separate from the storage zones and adjacent to them, followed by a step of final welding of the blocks together at a final welding zone separate from the other zones of the production area, followed by a step of completing the float at a completion zone separate from the other zones of the production area; - the float blocks and floats being manufactured being moved on the production dock between the different areas of the latter mainly by translational movements; and - the float blocks and floats being manufactured being positioned and aligned in the primary assembly and welding, final welding, and completion areas using the process as defined above.

[0016] The positioning systems are advantageously sized so as to raise the float blocks and floats during manufacture to allow the passage of multi-wheeled transport vehicles.

[0017] Each float may be formed by assembling three blocks: a first block comprising a central column, an outer column and a lower pontoon, and two identical second blocks each comprising an outer column and a lower pontoon, in which case, at the primary assembly and welding area, the first block is static and constitutes a target block and the positioning of the two second blocks is adjusted according to the position of the first block.

[0018] Each float block can be positioned in the primary assembly and welding, final welding, and completion areas by means of two parallel rows of positioning systems. Brief description of the drawings

[0019] [Fig.l] [Fig.l] is a schematic and perspective view of an example of an installation for implementing the positioning method according to the invention.

[0020] [Fig.2] [Fig.2] is a top view of a float in the process of being manufactured showing the positioning systems according to the invention.

[0021] [Fig.3] [Fig.3] is a perspective view of an example of a positioning system according to the invention.

[0022] [Fig.4A-4D] Figures 4A to 4D show the different possible movements of the platform of the positioning system of [Fig.3]. Description of the embodiments

[0023] The invention relates to the general field of mass production and the chain of floats for offshore wind turbines, in particular semi-submersible type floats.

[0024] The floats to which the present invention applies have the particularity of being able to be manufactured by assembling a plurality of different unit blocks.

[0025] In the application example described below, each float 2 comprises, as shown in Figures 1 and 2, four columns including a central column 4 which is intended to receive a wind turbine mast and three external columns 6 which are connected to the central column by lower pontoons 8.

[0026] In practice, such floats 2 can each be formed by assembling three blocks: a first block B1 comprising the central column 4, an outer column 6 and a lower pontoon 8, and two second identical blocks B-2 each comprising an outer column 6 and a lower pontoon 8.

[0027] Of course, the invention applies to other types and other forms of floats, the latter having to be formed by the assembly of at least two different unit blocks of floats.

[0028] As shown in [Fig.l], these floats 2 can be manufactured on a relatively compact production land surface 10 capable of accommodating the various elements and equipment necessary for the manufacture of the floats.

[0029] This production area 10 is divided into different zones Z1 to Z6, namely: a first storage zone Z1 on which the blocks B1 are stored, a second storage zone Z-2 on which the blocks B-2 are stored, an assembly and primary welding zone Z-3 on which the different blocks B1, B-2 constituting the same float are assembled together and subjected to primary welding, a final welding zone Z-4 ​​on which the different blocks constituting the float undergo a new welding pass, a completion zone Z-5 on which the float is inspected and equipped with various equipment, and a buffer zone Z-6 on which a float 2' having manufacturing defects can be withdrawn to be repaired.

[0030] A transport barge 20 is moored at the loading dock of the production area. The float 2 located in the completion zone Z-5 is then loaded onto the transport barge by means of transport.

[0031] It will be noted that the float blocks and floats being manufactured are moved between the different areas of the construction surface by multi-wheeled transport vehicles or by skidding, i.e. mainly by following translational movements.

[0032] At the level of the assembly and primary welding zones Z-3, final welding Z-4, and completion Z-5, the blocks B1, B-2 and the floats being manufactured are positioned and aligned by means of a method according to the invention illustrated in particular by [Fig.2],

[0033] According to this positioning and alignment method, each block B1, B-2 is positioned at these zones on a plurality of positioning systems 30.

[0034] As shown in [Fig. 3], each positioning system 30 comprises in particular a platform 32 on which the float block is intended to rest and which is mounted on a controlled mechanism 34 for horizontal and vertical translation.

[0035] More precisely, the controlled mechanism 34 (for example with hydraulic or mechanical jacks) makes it possible to move the platform 32 in the two horizontal directions X, Y and the vertical direction Z. Figures 4A to 4D illustrate, in side view, these movements of the platform 32 in the directions X and Z.

[0036] It will be noted that the controlled mechanism 34 is sized to allow the platform to take up the full weight of the float block (greater than 100 tonnes).

[0037] It will also be noted that the positioning systems 30 are arranged on fixed foundations 36 forming supports. These foundations 36 make it possible to avoid collisions with multi-wheeled transport vehicles during transfers of float blocks. They also make it possible to minimize the deformation and stress of the float blocks during the assembly phases. They also make it possible to minimize the bearing pressure on the ground of the production surface.

[0038] Furthermore, the platforms 32 of the different positioning systems 30 on which the same float block B1, B-2 are positioned are adjusted relative to each other in order to position and align the blocks relative to each other with a view to their assembly and welding.

[0039] More specifically, at the primary assembly and welding zone Z-3, a first float block is brought and positioned on positioning systems. This first float block acts as a target block.

[0040] The other two float blocks are brought and positioned in turn on positioning systems. The platforms of the latter are adjusted so as to coordinate in order to position and align the two blocks in relation to the target block in particular.

[0041] This adjustment can be carried out within a minimum time constraint (typically less than 10 minutes) and with precision of the order of a millimeter to allow the execution of the butt joining and welding operations.

[0042] In addition, the adjustment is coordinated between the different positioning systems by measuring the positioning and controlling the positioning systems associated with each float block according to the target block.

[0043] As shown in [Fig.2], the measurement of the positioning of the different positioning systems 30 can be carried out by topographic devices 38 (of the laser, scanner, theodolite, etc. type) located angularly between the branches of the float. These topographic devices 38 are connected to the control mechanisms of the positioning systems 30 to send them the appropriate control orders.

[0044] The transmission of instructions between the topographic devices 38 and the control mechanisms of the positioning systems 30 can be wired or wireless (for example remotely by waves).

Claims

Claims

1. Method for positioning and aligning semi-submersible float blocks (2) for offshore wind turbines, the float being constituted by the assembly of at least two different unit blocks (B1, B-2), the method comprising: - the positioning of each unit block on a plurality of positioning systems (30) each comprising a platform (32) on which the float block is intended to rest and which is mounted on a controlled mechanism (34) for horizontal and vertical translation, and - the coordinated adjustment of the platforms of the positioning systems in order to position and align the unit blocks relative to each other.

2. The method of claim 1, wherein the coordinated adjustment of the platforms of the positioning systems comprises measuring the positioning and controlling the positioning systems associated with each unit block based on a target block.

3. A method according to claim 2, wherein the measurement of the positioning of the positioning systems is carried out by a topographical apparatus (38).

4. Method according to one of claims 2 and 3, in which the measurement of the positioning and the control of the positioning systems are carried out in a wired manner.

5. Method according to one of claims 2 and 3, in which the measurement of the positioning and the control of the positioning systems are carried out remotely.

6. Positioning system (30) for implementing the method according to any one of claims 1 to 5, comprising a platform (32) on which the float block (B1, B-2) is intended to rest and which is mounted on a horizontal and vertical translation mechanism (34).

7. Method for mass production of semi-submersible floats (2) for offshore wind turbines each consisting of the assembly of at least two different unit blocks (B1, B-2) of floats, the method comprising: - the transport and storage in different storage areas (Zl, Z-2) of a production dock of a plurality of different blocks of floats, the same blocks of floats being stored in the same storage area of the production dock; - the production line manufacture of floats comprising successively for each float, a step of preparation of the blocks, a step of assembly and primary welding of the float blocks together at an assembly and primary welding area (Z-3) separate from the storage areas and adjacent to them, followed by a step of final welding of the blocks together at a final welding area (Z-4) separate from the other areas of the production dock, followed by a step of completion of the float at a completion area (Z-5) separate from the other areas of the production dock;- the float blocks and the floats being manufactured being moved on the production dock between the different areas thereof mainly according to translational movements; and - the float blocks and the floats being manufactured being positioned and aligned in the assembly and primary welding, final welding, and completion areas by means of the method according to any one of claims 1 to 5.;

8. The method of claim 7, wherein the positioning systems (30) are sized to elevate the float blocks and floats being manufactured to allow passage of multi-wheeled transport vehicles.

9. Method according to one of claims 7 and 8, in which: - each float is formed by the assembly of three blocks: a first block (B-1) comprising a central column (4), an outer column (6) and a lower pontoon (8), and two second identical blocks (B-2) each comprising an outer column (6) and a lower pontoon (8), and in which

10. - at the primary assembly and welding area, the first block is static and constitutes a target block and the positioning of the two second blocks is adjusted according to the position of the first block. A method according to any one of claims 7 to 9, wherein each float block is positioned in the primary assembly and welding, final welding, and completion areas by means of two parallel rows of positioning systems.

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