Adjustable lifting and installation device
The adjustable lifting and installation device addresses the inefficiencies in installing auxiliary components on offshore wind turbine monopiles by using an exchangeable interface body to adapt to different diameters, allowing for the reuse of the handling tool and reducing installation time and costs.
Patent Information
- Application Number
- PCT/EP2024/071204
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-07-26
- Filing Date
- 2024-07-25
- Publication Date
- 2025-01-30
AI Technical Summary
The installation of auxiliary components on offshore wind turbine monopiles is time-consuming and requires custom-made tools, which are often project-specific and lead to engineering time, cost, and waste inefficiencies due to variations in monopile diameters and construction details.
An adjustable lifting and installation device that can fit different offshore foundation structures, including monopiles with varying diameters, by using an exchangeable interface body that adapts to specific diameters, allowing the handling tool to be reused across different projects.
The device significantly reduces installation time and costs by enabling the reuse of the handling tool across various projects, eliminating the need for custom-made tools and minimizing engineering time and resources.
Smart Images

Figure EP2024071204_30012025_PF_FP_ABST
Abstract
Description
[0001] Adjustable lifting and installation device
[0002] The present invention relates to an adjustable lifting and installation device for installing at least a first auxiliary component in, and / or onto, an offshore foundation structure, a kit of parts comprising a pair of adjustable lifting and installation devices, a method of providing such an adjustable lifting and installation device and a method of installing the first auxiliary component using such an adjustable lifting and installation device.
[0003] In order to position wind turbines offshore, offshore foundations are required for anchoring the wind turbines to the seabed and for raising the towers of such wind turbines sufficiently high to not be impacted by sea waves. Although various types of offshore foundation structures exist, the monopile is still the most common type. A monopile is essentially a large tubular member that is hammered into the seabed. In the early days of offshore wind energy, it was not possible to achieve the verticality tolerances of such a hammered monopile, as was specified by the wind turbine suppliers. To compensate this, a grouted transition piece (TP), sitting between the monopile and tower, was included. The required verticality tolerance was achieved by aligning the transition piece vertically and to allow the grout to take up the misalignment in the connection between the monopile to transition piece interface.
[0004] In addition to solving the alignment problem, the transition piece became a very useful piece of structure to connect all manner of auxiliary components (or structures) onto, particularly as it was not being hammer driven and were as such not experienced to high installation accelerations. Consequently, the transition piece was typically provided with a number of auxiliary components, for instance, a boat landing, anode cage, internal platforms and an external platform, also commonly known as “secondary steel”.
[0005] As the industry has developed, continuous improvements in offshore installation procedures, techniques, and technology have made it possible to achieve the verticality tolerance during installation of the monopile. Additionally, the traditional grouted connections also came with their specific issues, such as cracking and / or premature failures.
[0006] In recent times, monopiles not requiring a transition piece, so-called “TP-less monopiles” have become more popular. A TP-less monopile is provided, at its upper outer end, with a connecting section, typically a bolted-flange connection, for connecting to a bottom section of the wind turbine tower. As the auxiliary structures will not survive the monopile hammer driving installation process, they need to be mounted to the monopile after installation. Typically, a number of mounting sections are prepared on the monopile for mounting these auxiliary structures after installation of the monopile. Nonetheless, subsequently mounting the various auxiliary structures requires a lot of installation time, which can thereby prove to be a bottleneck in the overall installation process for an offshore wind turbine.
[0007] Recently, a number of lifting and installation tools have been introduced that aid in the mounting of these auxiliary structures. However, installing the various auxiliary structures requires a number of custom- made installation tools that are typically only usable for a single project only and thereby add to the overall engineering time, costs and waste. Variations in monopile-diameters and other project specific construction details prevent from making a single, universal installation tool for installing the auxiliary structures.
[0008] The goal of the current invention is to provide for an improved lifting and installation device for installing at least a first auxiliary component wherein at least one of the previously described problems is solved, or at least alleviated, in particular to provide for an improved lifting and installation device that can be used for installing at least one auxiliary component on monopiles having different dimension, in particular having different diameters.
[0009] This goal is achieved by providing an adjustable lifting and installation device for installing at least a first auxiliary component, such as a corrosion protection system, a boat landing, an external ladder, a cable entry and / or support system, an internal platform(s), an external platform, in, and / or onto, an offshore foundation structure, in particular a monopile that does not require a transition piece, wherein said adjustable lifting and installation device is arranged to be adjustable to fit different offshore foundation structures, said offshore foundation structures having respective tubular upper end sections having different outer and / or inner diameters, wherein said adjustable lifting and installation device is arranged to be lifted, preferably by means of a crane, onto the offshore foundation structure, wherein said lifting and installation device comprises: a handling tool, wherein said handling tool comprises at least one auxiliary component holding section for releasably holding the first auxiliary component, wherein the at least one auxiliary component holding section is adjustable in at least a radial direction extending from a central longitudinal axis to be adjustable to the different outer and / or inner diameters; an exchangeable offshore foundation structure interface body that is arranged to specifically fit the tubular upper end section having a predefined outer and / or inner diameter, wherein said offshore foundation structure interface body comprises an offshore foundation structure interface section comprising at least one alignment member and at least one supporting surface for supporting and aligning said offshore foundation structure interface body onto, and / or into, the tubular upper end section having the predefined outer and / or inner diameter thereof; wherein said exchangeable offshore foundation structure interface body is releasably connected to the handling tool by means of a releasable interface body connection. In the adjustable lifting and installation device according to the present disclosure, the exchangeable offshore foundation structure interface body is the only part that is dependent on the dimensioning of the offshore foundation structure, in particular of the inner and / or outer diameter of a top section of the TP-less monopile. Hence, the adjustable lifting and installation device is easily re-usable and adaptable to a different monopile having, for instance, a different diameter, by simply removing the former exchangeable offshore foundation structure interface body by releasing the releasable interface body connection between the exchangeable offshore foundation structure interface body and the handling tool and by connecting a new exchangeable offshore foundation structure interface body that is specifically adapted to the different monopile. The handling tool, that comprises the interfaces with the auxiliary component and the lifting cable of the crane can simply be re-used, as the one auxiliary component holding section, whereby the installed auxiliary is held in order to hold it during installation, is adjustable such that it is able to be used on a range of different outer and / or inner diameters of the tubular upper end sections. In other words, the handling tool can be used for different projects having differently sized offshore foundations structures, e.g. TP-less monopiles, this eliminates the need to design and build a new tool for each project, such that valuable engineering time and resources can be saved and the overall efficiency of installing wind turbines offshore is increased.
[0010] The exchangeable offshore foundation structure interface body is preferably arranged that the only part of the adjustable lifting and installation device that directly engages (i.e. abuts, contacts and the like) the offshore foundation structure, such that the handling tool, when the lifting and installation device is positioned on the offshore foundation structure, is spaced apart from the offshore foundation structure, or in other words does not directly engage the offshore foundation structure. Any offshore foundation structure dependent interfaces are thus not required for the handling tool, such that it is easily re-usable in combination with a different offshore foundation structure interface body. Hereby, it is noted that, at least in case of a circular cross section of the tubular upper end section, two alignment members (when aligning on the basis of the inner circumference of the tubular upper end section) or three alignment members (when aligning on the basis of the outer circumference of the tubular upper end section) allow for aligning the exchangeable offshore foundation structure interface body in the plane perpendicular to the longitudinal axis.
[0011] For the support to be fully, or over-, determined, three discrete contact points between the exchangeable offshore foundation structure interface body and an upper surface of the tubular upper end section are sufficient. A single large contact surface may suffice for this, or a plurality (i.e. at least three) separate supporting surface may also suffice.
[0012] It is further noted that the term “to fit for different offshore foundation structures” has to be interpreted in such a way that it should fit in a geometric sense, i.e. it has to match the geometry of at least the tubular upper end section of the offshore foundation structure such that it is properly aligned with, and supported by, said offshore foundation structure after placing said device on the offshore foundation structure. Additionally, it should also fit in a functional sense, such that it is able to perform its intended function of enabling the installation of at least a first auxiliary component onto, preferably at a predefined location at, the respective offshore foundation structure.
[0013] Furthermore, the releasable connection between the handling tool and exchangeable offshore foundation structure interface body is standardized in size, such that also only an offshore foundation structure interface section, which comprises the at least one alignment member and at least one supporting surface, needs to be adapted to fit a different monopile.
[0014] Alternatively, an adjustable offshore foundation structure interface body can be provided, which can even be integrated with the handling tool, having at least one adjustable alignment member and at least one adjustable supporting surface, wherein said adjustable alignment member and supporting surfaces are movable in at least the radial direction for being adaptable to tubular upper end sections having different inner and / or outer diameters. Such an adjustable offshore foundation structure interface body eliminates the need for providing different exchangeable offshore foundation structure interface bodies that are made specifically for a certain type of tubular upper end section. However, as the auxiliary components often need to fit exactly into, or around, the tubular upper end section, the supporting surfaces and / or adjustment members often may not extend in either the inwardly extending radial direction (for instance in case of mounting an internal platform), and / or in the outwardly extending radial direction (for instance in case of mounting anode cages, an external platform, a boat landing and / or external ladder to the tubular upper end section). Even though, an adjustable offshore foundation structure interface body would render a single, fully adaptable tool, it would inevitably lead to a complicated installation tool in order to fulfill the above noted requirements. As the exchangeable offshore foundation structure interface body can be a relatively simple structure, as is shown in the following sections, an adjustable lifting and installation tool is obtainable that is highly adaptable and for the most part re-usable to be useable with offshore foundation structures, in particular TP-less monopiles, with different inner and / or outer diameters, while not becoming technically overcomplicated.
[0015] Preferably, the releasable interface body connection has a predefined size that is, in particular, not adjustable to the different outer and / or inner diameters of the tubular upper end section. The releasable interface body connection thereby forms a standard connection that is arranged between the handling tool and the exchangeable offshore foundation structure interface body, such that, when needing to provide for an exchangeable offshore foundation structure interface body that is arranged to fit a tubular upper end section having a predefined geometry (e.g. inner diameter, outer diameter and / or flange specific geometrical details of a flange arranged at the top of the tubular upper end section), only the part of the exchangeable offshore foundation structure interface body that is arranged to contact and / or engage with the tubular upper end section needs to be customized, whereas the connection to the handling tool is standardized. This enables that that valuable engineering time and (material) resources can be saved.
[0016] In a preferred embodiment, the releasable interface body connection is formed by a releasable handling tool connecting section of the exchangeable offshore foundation structure interface body and the therewith cooperating releasable offshore foundation structure interface body connecting section of the handling tool, in particular wherein the respective connecting sections are formed by respective flanges, preferably comprising a plurality of bolt holes for receiving bolts therein, having an equal size and geometry. This enables a reliable connection between said parts of the adjustable lifting and installation device. Additionally, as the bolted flange connections are commonly used for offshore wind turbines, the tools and skilled labor required for uncoupling and coupling of said connection are widely available on the installation vessels that are used for installing said wind turbines. No additional training, tools and / or staff is required for exchanging an exchangeable offshore foundation structure interface body when at sea.
[0017] It is preferred that a respective inner and / or outer diameter of the releasable interface body connection is equal, or larger than, respectively, the predefined outer and / or inner diameter of the tubular upper end section. The inner and / or outer diameter of the releasable interface body connection thereby effectively set an upper limit for sizes of outer and / or inner diameter of the tubular upper end sections that the adjustable lifting and installation device can be used on, nonetheless, this results in a device that is easily adaptable for diameters below this respective upper limit.
[0018] Preferably, the at least one alignment member, or each of the alignment members, is arranged to fit an outer, or inner, circumference of the offshore foundation structure and wherein the at least one supporting surface, or each of the supporting surfaces, is arranged to fit an upper surface, in particular an upper surface of a flange, of the tubular upper end section, such that the respective supporting surface is arranged to extend inwardly with respect to an outer circumference of the upper surface and / or extend outwardly with respect to an inner circumference of the upper surface. This allows to obtain an exchangeable offshore foundation structure interface body having a relatively simple and robust construction that is able to fit the offshore foundation structure and thereby allows to easily adapt the adjustable lifting and installation device.
[0019] The alignment members may be formed by bumper members that extend outwardly (with respect to the supporting surface) from the exchangeable offshore foundation structure interface body in a downward direction (i.e. in the direction of the offshore foundation structure, when positioned on top of said structure). A circumference that is defined by respective internal (i.e. facing inwardly in the radial direction) surfaces and / or edges of said respective bumper members may than be dimensioned to fit substantially exactly (i.e. having a clearance of less than 3%, preferably less than 1,5%, of the outer diameter of said tubular upper end section) around the outer circumference of the tubular upper end section. Alternatively, a circumference that is defined by respective external (i.e. facing outwardly in the radial direction) surfaces and / or edges of said respective bumper members may than be dimensioned to fit, e.g. exactly fit, (i.e. having a clearance of less than 3%, preferably less than 1,5%, of the outer diameter of said tubular upper end section) within the inner circumference of the tubular upper end section. A reliable and precise fit of the adjustable lifting and installation device is thereby obtained, as was also described above.
[0020] By arranging a plurality, e.g. three or more, alignment members, in particular the downwardly extending bumper elements, that enclose an outer circumference, or engage in inner circumference, of the offshore foundation structure, the relative position the offshore foundation structure interface body with respect to the offshore foundation structure can be fixed in at least the horizontal plane, that is substantially perpendicular to the central longitudinal axis. The supporting surface, which may be a single continuous abutment surface, or be formed from a plurality of smaller, spaced apart, abutment surfaces, extends in the horizontal plane, such that it locks, at least in the downward direction, the offshore foundation structure interface body the with respect to the offshore foundation structure in the vertical direction. A reliable positioning of the lifting and installation device on the offshore support structure is obtainable by providing a supporting surface that is specifically arranged to engage the upper surface of the offshore foundation structure, and a (plurality of) alignment member(s) that is / are arranged to closely engage with the outer circumference, or the inner circumference, of the tubular upper end section.
[0021] Preferably, the adjustable lifting and installation device, in particular the handling tool, is arranged to be releasably coupled to at least one lifting and / or handling cable; preferably, wherein the handling tool comprises one or more lifting cable coupling points for releasably coupling the at least one lifting and / or handling cable to the handling tool. This allows said adjustable lifting and installation device to be lifted from deck of an installation vessel, to said offshore foundation structure, whereby, after placement, said lifting cable(s) can be detached allowing the device to install the auxiliary component(s).
[0022] It is preferred that, in a lifting state wherein said adjustable lifting and installation device is suspended from the at least one lifting cable of the crane, the exchangeable offshore foundation structure interface body is only in direct contact with the handling tool and / or wherein in a deployed state, wherein the adjustable lifting and installation device is positioned and supported on the offshore foundation structure, the exchangeable offshore foundation structure interface body is arranged in between the offshore foundation structure and handling tool, such that, preferably, the adjustable lifting and installation tool is only supported onto, and aligned with respect to, the offshore support structure through the exchangeable offshore foundation structure interface body. In other words, the adjustable lifting and installation device can be arranged such that only the exchangeable offshore foundation structure interface body contacts the offshore support structure, such that only the exchangeable offshore foundation structure interface body needs to be made specifically for the respective offshore foundation structure. In combination with the adjustable handling tool, this leads to a device that can be adapted to any offshore foundation structure within the range of sizes that the adjustable lifting and installation device is intended for.
[0023] Preferably, the releasable handling tool connecting section is arranged at a first end section of said offshore foundation structure interface body and wherein said at least one supporting surface is arranged at a second, substantially opposite, end section of the offshore foundation structure interface body, such that, when in the deployed state, the handling tool is spaced apart from said offshore foundation structure. The handling tool thereby does not need to sized to exactly fit the offshore foundation structure, but can be provided with adjustable installation subsystems to allow it to function on different sizes of offshore foundation structures, in particular TP-less monopiles, without requiring any structural changes to the handling tool.
[0024] Preferably, the handling tool comprises a structural base body and a rotatable structural body, wherein said structural base body is releasably connected with the exchangeable offshore foundation structure interface body, wherein said rotatable structural body is rotatably arranged with respect to the structural base body around the central longitudinal axis of the adjustable lifting and installation tool and wherein said at least one auxiliary component holding section is mounted to, and arranged to rotate with, the rotatable structural body. The rotatable structural body allows to rotate the auxiliary component holding section around the central longitudinal axis of the tubular upper section, this allows to disregard the azimuth-orientation of the adjustable lifting and installation tool during the process of placing it onto the tubular upper end section, while it also allows to have, in case of having multiple different auxiliary component holding sections for installing multiple different auxiliary components, the freedom to install the various different auxiliary components at different azimuth directions into, or onto, the offshore foundation structure. Such that the tool is not only able to cope with tubular upper end sections having different (inner and / or outer) diameters, but also being adaptable to offshore foundation structures having a variation in the relative positioning between the respective auxiliary components that are to be installed onto the offshore foundation structure.
[0025] In a preferred embodiment, the handling tool, in particular said rotatable structural body, comprises at least a one auxiliary component positioning subsystem for moving the auxiliary component holding section, with respect to the handling tool, from a lifting position, wherein, at least when in a lifting state, the auxiliary component holding section is spaced apart from the offshore foundation structure at a first distance, to an installation position, wherein, when the auxiliary component is brought into position for mounting to a predefined location at the offshore support structure, the auxiliary component holding section is positioned closer to the offshore foundation structure at a second distance, wherein said first distance is greater than said second distance, such that the first auxiliary component can be mounted to a predefined mounting position at the offshore foundation structure. During the lifting phase, the auxiliary component(s) can thereby be held at a position that is spaced apart for the alignment member(s) and support surface(s) of the exchangeable offshore foundation structure interface body, such that the adjustable lifting and installation tool can be positioned onto the offshore foundation structure with minimum risk of damages to the auxiliary component(s) that is / are held by the respective auxiliary component holding section(s). In short, when the lifting and installation device is used for installing a respective auxiliary component, the respective auxiliary component can be moved with respect to the offshore foundation structure by the respective positioning subsystem.
[0026] Preferably, said handling tool, in particular said rotatable structural body, comprises an adjustable boat landing installation subsystem, wherein said adjustable boat landing installation subsystem is arranged to be adjusted to allow installing the boat landing to the tubular end section having the predefined outer diameter, wherein adjustable boat landing installation subsystem comprises a boat landing holding section for releasably connecting said boat landing, preferably, wherein said boat landing holding section is, by means of a respective positioning system, translationally movable with respect to the handling tool in at least a direction parallel to the central longitudinal axis, translationally movable from, and towards, the central longitudinal axis, movable in a tilting direction with respect to the central longitudinal axis for, when a boat landing in connected to the boat landing holding section, tilting a first end section of the boat landing in a direction from, and towards, the central longitudinal axis, and / or in any combination of said movements. The positioning system thereby allows to move boat landing from the lifting to the installation position. Additionally, the translational movements from, and towards, the central longitudinal axis and / or movements in a tilting direction with respect to the central longitudinal axis allow to adjust the one boat landing holding section in at least a radial direction, such that they enables the adjustability of the adjustable boat lading installation subsystem.
[0027] The boat landing holding section may comprise one or more adjustable holding members that can be adjusted for holding different boat landings having various geometries, such as different center to center distances between longitudinal bumper elements of said boat landing, different diameters of the longitudinal bumper elements. The boat landing holding section may further comprise separate external ladder holding members, for holding a separate external ladder that is to be mounted to the offshore foundation structure, which may will typically be smaller than the boat landing holding members, but may be adjustable in the same manner as the external ladder holding members. An embodiment of the boat landing holding member may for instance comprise two open ended gripper-members, which may be substantially U- or V-shaped to receive a respective longitudinal bumper element therein. The open ended gripper-members may be movable from, and towards, each other in order to be adjusted to receive different boat landings having different center to center distances therein. An internal size of, for instance, a U-shaped gripper member, may be adjustable by mounting different filler pads for decreasing a space between the legs of said U-shape, such that open ended gripper-members are adjustable to different diameters of the longitudinal bumper elements.
[0028] It is preferred that said handling tool, in particular said rotatable structural body, comprises a corrosion protection installation subsystem for installing a corrosion protection system, such as an anode cage or Impressed Current Cathodic Protection (ICCP) system, wherein said corrosion protection installation subsystem comprises a corrosion protection system holding section for releasably connecting said corrosion protection system, wherein said corrosion protection subsystem holding section is translationally movable, by means of a respective positioning system, with respect to the handling tool in at least a direction parallel to the central longitudinal axis. The corrosion protection system can thereby be lowered along the offshore foundation structure, in particular along the monopile, to a predefined location under the water lever in order to be installed onto the offshore foundation structure.
[0029] Preferably, the corrosion protection system holding section comprises a plurality of holding members arranged for holding a corrosion protection system, wherein said holding members are arranged in a circular arrangement with respect to each other and wherein, preferably, said holding members are adjustable in the radial direction for adjusting a diameter of the circular arrangement. Anode cages, for instance, comprise a plurality of sacrificial anodes that are assembled onto a relatively fragile frame that is to be arranged below sea level around the offshore foundation structure, in particular around the outer circumference of a monopile. Due to the fragility, these require a careful handling during installation. They are therefore typically suspended from lifting slings, or cables during installation. In order to prevent tensional forces in the fragile frame during this process, the slings, or cables, need to be arranged substantially vertical, such that the holding members need to be arranged in a circular arrangement that corresponds to the diameter of the anode cage. By arranging the holding members to be adjustable, i.e. movable, in the radial direction, the circular arranged can be adjusted to correspond to the diameter of the anode cage, thereby reducing forces on, and minimizing the risk of damaging, the anode cages during the installation process.
[0030] In a preferred embodiment, said handling tool comprises an internal platform installation subsystem for installing an internal platform in a space enclosed by a circumferential wall of the tubular upper end section, wherein said internal platform installation subsystem comprises an internal platform holding section for releasably connecting said internal platform, wherein said internal platform holding section is translationally movable, by means of a respective positioning system, with respect to the handling tool in at least a direction parallel to the central longitudinal axis for moving the internal platform holding section through, and out of, an internal space that is enclosed by the handling tool and the exchangeable offshore foundation structure interface body. The positioning system thereby allows to move boat landing from the lifting position, wherein the internal platform is held within the adjustable lifting and installation device, to the installation position, wherein the internal platform is lowered into, or through, the tubular upper end section in order to be installed in an interior section of said offshore foundation structure. As the internal platform will typically only have a relatively small clearance with respect to an internal circumferential wall of the tubular upper end section, the exchangeable offshore foundation structure interface body and / or handling tool may need to be fit with an internal space having an inner diameter that may not be significantly smaller than an inner diameter of said tubular upper end section in order for the internal platform to fit.
[0031] Preferably, said internal platform holding section comprises a plurality of internal platform holding members arranged for holding lifting means, such as a lifting cable and / or sling, wherein said holding members are each arranged to be movable, preferably in at least two directions, in a plane that is perpendicular to the central longitudinal axis, preferably, wherein said holding members are, preferably individually and / or collectively, movable in the radial direction and / or the azimuth direction. Typically, for each offshore wind project, the foundations are a project specific design, such that the internal platform(s), which may be a single platform, but is typically an assembly of a plurality of different platforms forming different stories inside of the monopile, are also project specific designed. For the installation thereof, the platform(s) are typically provided with a number of (i.e. 3, 4 or more) lifting points, e.g. lifting eyes or lifting anchors, for connecting lifting cables, or lifting slings thereto. These lifting points can thereby also be arranged at different positions in the platform. By providing that the holding members, which may be lifting hooks or eyes comprised at the lower end of the lifting cables / slings, are also adjustable in the plane perpendicular to the central longitudinal axis, the holding section is adjustable to fit the different lay-outs of lifting points, such that the lifting and installation device is adjustable to be able to install internal platform in offshore foundations of different projects.
[0032] Preferably, said handling tool comprises an external platform installation subsystem for installing an external platform to an outer circumferential wall of the tubular end section, wherein said external platform installation subsystem comprises an external platform holding section for releasably connecting said external platform, wherein said external platform holding section is, by means of a respective positioning system, translationally movable with respect to the handling tool in at least a direction parallel to the central longitudinal axis for moving the external platform holding section along an outer circumference of the offshore foundation structure interface body. An outer platform is typically provided with a circular through hole for receiving the foundation structure therein, typically a monopile foundation, which is then mounted to a number of supports that are arranged on the exterior circumferential wall of the foundation. Therefore, there is typically only a small clearance between the outer edge of the through hole and the exterior circumferential wall. In order to install the platform, it needs to be lifted and lowered around the exterior circumferential wall. The positioning system allows to lower the platform around the offshore foundation in order to allow it to be installed.
[0033] The external platform holding section preferably comprises a plurality of external platform holding members arranged for holding lifting means, such as a lifting cable and / or sling, wherein the positions of said holding members are adjustable, preferably in two directions, in a plane that is perpendicular to the central longitudinal axis and wherein, preferably, said holding members are adjustably arranged in the radial direction and / or the azimuth direction, for adjusting the respective positions. Similar to the internal platform(s), the external platform is customized for each project, such that the lifting points may also be arranged at different positions. The adjustable holding members thereby allow to adjust the external platform holding section in such a manner that it is able to be modified to install a large range of different external platforms having different arrangements of lifting points.
[0034] It is preferred that the respective positioning systems, as described above, comprise a driving mechanism for driving a respective movement, wherein a movement in the radial and / or a direction parallel to the central longitudinal axis is arranged to be driving by a respective linear driving mechanism, such as a linear motor and / or actuator for driving movement in the radial direction and a winch-driven mechanism for driving a movement in the direction parallel to the central longitudinal axis, and / or wherein a movement along the azimuth angle is arranged to be driving by an angular and / or rotational motor, wherein said motors and / or actuators are preferably electrically powered motors and / or actuators and / or hydraulically powered motors and / or actuators, such as hydraulic motors and / or hydraulic cylinders. The (powered) drive mechanisms allow for efficiently handling the relatively heavy auxiliary components and, furthermore, enable that the driving mechanism can be remotely operated from the installation vessel (i.e. the vessel comprising the crane, crews and components to be installed), thereby further increasing the safety and efficiency of the operation.
[0035] Preferably, said handling tool comprises a plurality of auxiliary component positioning subsystems for positioning at least two of a corrosion protection system, a boat landing, external ladder, a cable entry and / or support system, internal platform(s), an external platform. By allowing a plurality of auxiliary components to be installed using the same adjustable lifting and installation tool, it further reduces the amount of lifting and installation devices needed, thereby saving valuable material resources and engineering time. Additionally, installation time is reduced and the efficiency of the installation operation is increased as the amount of lifts from the vessel towards the offshore foundation structure can be reduced.
[0036] In a preferred embodiment, the exchangeable offshore foundation structure interface body is substantially rigid structure, preferably wherein the exchangeable offshore foundation structure interface body does not comprise a positioning subsystem for positioning any of the auxiliary components, and / or wherein the positioning subsystems do not engage with the exchangeable offshore foundation structure interface body. The exchangeable offshore foundation structure interface body can thereby be a relatively simple structure, such as a welded steel frame that can be constructed from off-the-shelve steel beams that are cut to size. This further reduces the time of adapting the adjustable lifting and installation tool to a different size and / or type of offshore foundation, such that the efficiency of the overall turbine installation process in improved. This enables that the offshore foundation structure interface body can be a relatively simple structure having, at one end thereof, a standardized interface to the handling tool. An offshore specific offshore foundation structure interface body can thereby easily be designed on the basis of the specifications of the respective offshore foundation structure it needs to sit on.
[0037] In a preferred embodiment, the adjustable lifting and installation device is adjustable to fit at least on tubular upper end sections having an outer diameter in the range of 7 to 7.5, preferably 6 to 8, more preferably 5.5 to 8.5 meters, even more preferably in the range of 5 to 9 meters. These ranges allow the tool to be usable on the majority of offshore wind projects that are to be installing the coming years.
[0038] In second aspect, the invention relates to a kit comprising two adjustable lifting and installation devices according to any of the preceding claims, wherein a first of said adjustable lifting and installation devices is arranged for installing a corrosion protection system, a boat landing, external ladder, a cable entry and / or support system and / or internal platform(s) and a second of said adjustable lifting and installation devices is arranged for installing an external platform. As was described above, the internal and external platforms each require a small clearance with respect to the offshore foundation structure, and thereby with the respective inner, or outer, edges of the adjustable lifting and installation device, in particular the exchangeable offshore foundation structure interface body. In practice it is thereby very difficult to combine both platforms on a single lifting and installation device, as the device also requires at least one alignment member, i.e. bumper member, for aligning it on the inside, or outside, of the tubular upper end section. Ensuring that the alignment member do not block the movement of one of the respective platforms, would require very small and fragile alignment members that are not practical to work with.
[0039] In a third aspect, the invention relates to a method of providing an adjustable lifting and installation device for installing at least a first auxiliary component, such as a corrosion protection system, a boat landing, an external ladder, a cable entry and / or support system, internal platform(s), an external platform, in, and / or onto, a tubular upper end section of an offshore foundation structure, such as a monopile that does not require a transition piece, wherein said adjustable lifting an installation device is arranged to be adjustable to fit different offshore foundation structures having tubular upper end sections having different outer and / or inner diameters, wherein said adjustable lifting and installation device is arranged to be coupled to at least one lifting cable of a crane, wherein the method comprises the steps, in any suitable order, of:
[0040] - providing a handling tool, wherein said handling tool comprises at least one auxiliary component holding section for releasably connecting the first auxiliary component thereto, wherein the at least one auxiliary component holding section is adjustable in at least a radial direction extending from a central longitudinal axis to be adjustable to a different outer and / or inner diameters;
[0041] - determining an inner and / or outer diameter of the tubular upper end section of the offshore foundation structure;
[0042] - adjusting, on the basis of the determined inner and / or outer diameter of the tubular upper end section, a position of the at least one auxiliary component holding section in at least the radial direction;
[0043] - providing an exchangeable offshore foundation structure interface body, wherein said exchangeable offshore foundation interface body comprises at least one alignment member and at least one supporting surface for supporting and aligning and supporting said exchangeable offshore foundation structure interface body onto, and / or into, the offshore foundation structure, comprising the steps of:
[0044] - providing the at least one alignment member to fit in, or around, the respective inner and / or outer diameter of the tubular end section thereof; and
[0045] - providing the at least one supporting surface to fit an upper surface, in particular an upper surface of a flange, of the tubular upper end section, in particular of the tubular end section thereof;
[0046] - preferably, connecting the handling tool and the exchangeable offshore foundation structure interface body by means of a releasable interface body connection.
[0047] The enables to obtain the above described embodiments of the adjustable lifting and installation device and its associated technical advantages.
[0048] In a fourth aspect, the invention relates to a method of installing at least a first auxiliary component in, and / or onto, an offshore foundation structure, such as a monopile that does not require a transition piece, comprising the steps of:
[0049] - providing an adjustable lifting and installation device according to any of the embodiment of the adjustable lifting and installation device, or an adjustable lifting and installation device obtained using the method according to the third aspect;
[0050] - connecting the first auxiliary component, such as a corrosion protection system, a boat landing, external ladder, a cable entry and / or support system, internal platform(s), an external platform, to a respective auxiliary component connections section;
[0051] - placing, in particular lifting, the adjustable lifting and installation device on the tubular upper end section of the offshore foundation structure;
[0052] - installing the first auxiliary component in, or onto, the offshore foundation structure using the adjustable lifting and installation device. Preferably, the installation method further comprising the steps of:
[0053] - moving the auxiliary component, by means of an auxiliary component positioning subsystem, from a lifting position to an installation position, wherein the auxiliary component is brought into position for mounting to a predefined location on the offshore support structure;
[0054] - fixedly mounting said auxiliary component to a predefined mounting position on the offshore foundation structure.
[0055] The present invention is further illustrated by the following figures, which show preferred embodiments of the adjustable lifting and installation device according to the present disclosure, and are not intended to limit the scope of the invention in any way, wherein:
[0056] - Figure 1A schematically shows a first embodiment of the adjustable lifting and installation device, wherein the device is set up for installing auxiliary components on a monopile having a first outer diameter.
[0057] - Figure IB schematically shows a cross-sectional view of the first embodiment;
[0058] - Figure 2 schematically shows a second embodiment of the adjustable lifting and installation device, wherein the device is set up for installing auxiliary components on a monopile having a second outer diameter that is smaller than said first outer diameter.
[0059] - Figure 3A schematically shows the first embodiment of the adjustable lifting and installation device, wherein the handling tool is separated from a first exchangeable offshore foundation structure interface body.
[0060] - Figure 3B schematically shows the second embodiment of the adjustable lifting and installation device, wherein the handling tool is separated from a second exchangeable offshore foundation structure interface body.
[0061] - Figures 4A and 4B schematically show different steps of installing an anode cage using an adjustable corrosion protection installation subsystem of the adjustable lifting and installation device according to the first embodiment on a monopile having the first outer diameter.
[0062] - Figures 5A and 5B schematically show different steps of installing an anode cage using the adjustable corrosion protection installation subsystem of the adjustable lifting and installation device according to the second embodiment on a monopile having the second outer diameter.
[0063] - Figures 6A and 6B schematically show different steps of installing a boat landing using an adjustable boat landing installation subsystem of the adjustable lifting and installation device according to the first embodiment on a monopile having the first outer diameter.
[0064] - Figures 7A and 7B schematically show the step of adjusting the boat landing holding member of the adjustable boat landing installation subsystem to the geometry of a first boat landing.
[0065] - Figures 8A and 8B schematically show the step of adjusting the boat landing holding member of the adjustable boat landing installation subsystem to the geometry of a second boat landing having a different geometry than the first boat landing. - Figures 9A - 9C schematically show the internal platform holding section of the adjustable internal platform installation subsystem that comprises a plurality of internal platform holding members which can be moved in a plane perpendicular to the central longitudinal axis.
[0066] - Figure 10A schematically shows a third embodiment of the adjustable lifting and installation device, wherein the device is set up for installing an external platform on a monopile having a first outer diameter.
[0067] - Figure 10B schematically shows a fourth embodiment of the adjustable lifting and installation device, wherein the device is set up for installing an external platform on a monopile having a second outer diameter that is smaller than said first outer diameter.
[0068] - Figure 11 A and 1 IB schematically shows cross section top views of the embodiments of, respectively, figures lOA and 10B.
[0069] - Figures 12A and 12B schematically show a fifth embodiment of the adjustable lifting and installation device, wherein the device is set up for installing an external platform on a monopile, wherein said external platform is arranged with a different arrangement of the lifting points.
[0070] Figures 1A and IB schematically shows a first embodiment of the adjustable lifting and installation device 1000, wherein the device is set up for installing auxiliary components on a monopile 10 having a first outer diameter di . Monopile 10, in particular a TP-less monopile, comprises a tubular upper end section 11, which is thus formed as a hollow cylinder, having a first diameter di and a conical section 12 that tapers outwardly to a secondary diameter dn that is larger than the first diameter di .
[0071] The adjustable lifting and installation device 1000 comprises an exchangeable offshore foundation structure interface body 1010 (i.e. exchangeable interface body 1010) that comprises a number of alignment members, or bumpers 1011, 1012, that are arranged to fit around the outer circumference 13 of the tubular upper end section 11 with only a small clearance (i.e. in the range as described above), and a supporting surface 1013 that is arranged to be positioned on the upper surface 14 of the monopile 10, in particular of its flange 15. The inner diameter diois is seen to be larger than the inner diameter dis of the monopile flange 15, such that the internal platform assembly 40 can be lowered into the monopile 1, as is explained in more detail below.
[0072] The exchangeable interface body 1010 is made specifically to fit monopile 10. The adjustable lifting and installation device 1000 further comprises a re-usable handling tool 1 comprising a plurality of adjustable auxiliary component installation subsystems. The handling tool 1 comprises a structural base body 101 that is releasably connected to the exchangeable interface body 1010 by means of a releasable interface body connection 120 that is, in the current example, formed by a pair of flanges 121, 1016 having an equal size and geometry, wherein a first of said flanges 121 is arranged on the lower end of the structural base body 101 and the second of said flanges 1016 is arranged at the upper end of the exchangeable interface body 1010, preferably comprising a plurality of bolt holes for receiving bolts therein, although a form -closable, clampable, or any other suitably releasable connection would also be possible. A rotatable structural body 102 is rotatably arranged onto the structural base body 101, in particular on an upper end thereof, for instance by means of a suitable bearing member, to be rotatable in an azimuth direction around a central longitudinal axis I that is seen to extend along the longitudinal direction through the center of the monopile 1 and adjustable lifting and installation device 1.
[0073] Firstly, an adjustable boat landing installation subsystem 200 for installing a boat landing 20 is arranged at the side of the rotatable structural body 102, rotatable structural body 102 further comprises a corrosion protection installation subsystem 300 for installing the anode cage 30 and (as best seen in figure IB) an internal platform installation subsystem 400 for installing an internal platform assembly 40 comprising a plurality of interconnected internal platforms 41, 42, 43. The azimuth position of the adjustable auxiliary component installation subsystems 200, 300, 400 with respect to the monopile 1 can be varied by rotating said rotatable structural body 102 around the central longitudinal axis I, preferably by means of a rotational (electric or hydraulic) drive mechanism (not shown) that is remotely operable.
[0074] Figure 2 schematically shows a second embodiment of the adjustable lifting and installation device 2000, wherein the device is set up for installing auxiliary components on a monopile 10’ having a first outer diameter d2. Monopile 10’ is similar to monopile 10 and comprises a tubular upper end section 11 ’ having a second diameter d2 and a conical section 12’ that tapers outwardly to a second secondary diameter d22 that is larger than the second diameter d2. The difference being that the first diameter di is larger than the second diameter d2. In the current example, first diameter di is 8 m and the second diameter d2 is 7 m. The adjustable lifting and installation devices 1000 and 2000 thereby only differ in that they are arranged with different exchangeable interface bodies 1010, 2010. The geometries and / or arrangements of the supporting surface 2013, and alignment members 2011, 2012 are therefore also different from the geometries and / or arrangements of supporting surface 1013, and alignment members 1011, 1012.
[0075] In order for the second exchangeable interface bodies 2010 to be connectable to the handling tool 1, the second exchangeable interface bodies 2010 is fitted with an interface body conical section 2017 that tapers (as seen in an upward direction) outwardly to fit the second flange 1016 that is connected to first flange 121 for forming the releasable interface body connection 120.
[0076] As the first and second monopiles 10, 10’ are different, the boat landings 20, 20’ and anode cages 30, 30’ are also slightly different. As is, for instance, seen, the anode cage 30’ is arranged to fit to a smaller monopile (when compared to anode cage 30). Thereby, the arrangement for lifting said anode cages 30, 30’ is also different and the corrosion protection installation subsystem 300 is therefore adjusted, as is explained in more detail below. Figures 3A and 3B show, side by side, the first and second embodiments of the adjustable lifting and installation device 1000, 2000 having alternatively formed exchangeable interface bodies 1020, 2020, whereby said exchangeable interface bodies 1020, 2020 are disconnected from the handling tool 1. Whereas the exchangeable interface bodies 1010, 2010, as shown in figures 1A - 2, are formed from tubular sections having a continuous circumferential wall, the alternatively formed exchangeable interface bodies 1020, 2020 are formed as a cylindrical framework having open circumferential walls. Vertically arranged members, i.e. beams, couple, respectively, the second flange 1016 or the interface body conical section 2017 with a respective bottom section 1022, 2022, wherein said bottom section comprises the respective supporting surface 1013, 2013. Figures 3A and 3B clearly show, that in order to be able to position the adjustable lifting and installation devices 1000, 2000 onto an respective monopile 10, 10’ in such a way that it sufficiently supported and aligned, only requires to mount different exchangeable interface bodies 1010, 1020, 2010, 2020 to the bottom of the handling tool 1.
[0077] However, in order to ensure that the device 1000, 2000 also functions properly, i.e. is able to allow (i.e. aid in) installing the respective auxiliary components 20, 20’, 30, 30’, 40, the respective auxiliary component installation subsystems 200, 300, 400 also need to have some sort of adjustability in order to be able to cope with varying sizes, geometries and / or arrangements of the different auxiliary components that are to be installed on the different monopile 10, 10’. The adjustability of the different installation subsystems is discussed using, amongst others, figures 4A - 9C.
[0078] The functionality and adjustability of the adjustable corrosion protection installation subsystem 300 is visualized in figures 4A - 5B, showing steps of the installation process on the first monopile 10 (i.e. having the larger outer diameter di) in figures 4A and 4B and the same steps on the second monopile 10’ (i.e. having the smaller diameter d2) in figures 5A and 5B. The monopiles 10, 10’ are seen to comprise, following (from above to below) the tubular upper end section 11, 11’, the conical section 12, 12’ and a further straight tubular section 16, 16’ having a larger outer diameter than the tubular upper end section 11, 11’. Corrosion protection systems 30, 30’, in particular anode cages 30, 30’, are substantially similar, with the difference that the first anode cage 30 has a larger diameter when compared to the second anode cage 30’, as the first is arranged to fit the larger monopile 10. Both anode cages 30, 30’ comprise a plurality of sacrificial anodes 31 that are arranged in a circular arrangement having a diameter larger than the outer diameter of the monopile (i.e. the diameter at the position where the anode cage 30, 30’ needs to be mounted). The plurality of anodes 31 is interconnected by means of a cage framework 32, 32’ for holding the anodes 31 together and forming a so called anode cage 30, 30’. Corrosion protection systems, such as anode cage 30, 30’, are relatively fragile components, as over the lifetime, they are not exposed to large forces. Care must therefore be taken during the installation of these components. During lifting and installation, the anode cage 30, 30’ is typically held by a plurality of lifting slings (and / or cable and / or the like) 311. These slings 311 are coupled to a ring-shaped body 301 that is arranged to be moved up and down along the monopile 10, 10’ in a direction substantially parallel to the central longitudinal axis I. The ring-shaped body 301 is coupled to a plurality of ring lifting cables 302, which are arranged to run in, and out of, respective winches 303 that are arranged on the rotatable structural body 102 for moving the ring-shaped body 301 in the up and down directions. For guiding the ringshaped body 301 along the outer circumferential wall of the monopile 10, 10’, an adjustable guiding mechanism 320 is provided. The adjustable guiding mechanism 320 comprises a plurality of adjustable guiding members 321, in the current example provide with guide rollers 322 arranged at the outer end thereof, that are arranged to contact the outer circumference of the monopile 10, 10’. The guiding members 321 are arranged on the ring-shaped member 301 and are arranged to be moveable in at least a radial direction II from and towards the central longitudinal axis I, such that they can be brought in, and out of, contact with the outer circumferential wall of the monopile 10, 10’. By moving the guiding members 321, in particular the guide rollers 322, into contact with the outer circumferential wall, they thereby allow to guide the ring-shaped body 301 at a predefined (i.e. pre-set) distance from the outer circumferential wall. This can for instance be achieved by arranging a biasing mechanism to the guiding members 321, such that they are urged to move in the direction of the circumferential wall and are pushed with a certain pre-load to the outer circumferential wall. The anode cage 30, 30’ can thereby also be spaced apart from the outer circumferential wall with a predefined distance. Once the ring-shaped member 301 arrives at a conical section 12, the guiding members 321 may be moved in the radial outward direction for guiding the ring-shaped member 301 over the conical section 12. In case biasing mechanism is arranged, the weight of the ring-shaped member 301 and the anode cage 30, 30’ can result in an automatic movement of the guiding members 321 in case the pre-load can be exceeded. The guiding members 321 may thus be movable from a fully retracted position, in which the outer ends, e.g. guide rollers 322, thereof define a circle having a maximum diameter, to a fully extended position, in which the outer ends, e.g. guide rollers 322, thereof define a circle having a minimum diameter. The ring-shaped member 301 can thereby be guided on monopiles having an outer diameter that fall within the range of between the above noted minimum and maximum diameters.
[0079] The lifting slings 311 need to be arranged substantially vertically (i.e. parallel to the central longitudinal axis I) in order to prevent introducing tensile forces in the relatively fragile cage framework 32, 32’ . The adjustable corrosion protection installation subsystem 300, in particular the ring-shaped member 301, can therefore comprise an adjustable holding section, that is formed by an adjustable lifting system 310 which may comprise a plurality of adjustable sling connectors 312. The adjustable sling connectors 312 comprise of a pivotable arm 313 that is pivotally connected to a sling connector base 315 at a pivoting point 314. The sling connector base 315 and pivotable arm 313 may have means, such as a mutually cooperating pin and a plurality of pin holes, to releasably fix the pivoting angle of the pivotable 313 in a predefined angle. The different sling connection points 317, which are the point at the pivotable arms 313 where the sling 311 is held by, is thereby movable in at least the radial direction II. The sling connection points 317 (or generically speaking: holding members) are arranged thereby arranged in a circular arrangement with respect to each other and wherein, preferably, said holding members are adjustable in the radial direction for adjusting a diameter of the circular arrangement. The diameter of the circular arrangement can thereby be matched with the diameter of the cage framework 32, 32’, such that the slings 311 can be arranged substantially vertically.
[0080] In figures 4A and 4B, the size of the smaller monopile 10’ is indicated with dashed lines, wherein in figures 5A and 5B the size of the larger monopile is indicated with dashed lines. By comparing figures 4A with 5 A and 4B with 5B is can be seen that the adjustable lifting system 310 is adjusted in order to correspond to the size of the anode cage 30, 30’ that is suitable for the respective monopile 10, 10’. More specifically, to accommodate the smaller anode cage 30’, the pivotable arms 313 have been pivoted inwards (i.e. towards the central longitudinal axis) to result in a smaller diameter of the circular arrangement of sling connection points, such that the slings 311 are arranged substantially vertical. Additionally, in figure 5B the guiding members 321 can be seen to extend further inwardly (i.e. towards the central longitudinal axis) in order to provide the desired guiding of the ring-shaped member 301 along the outer circumference of monopile 10’. It is noted that the number of guiding members 321 provided on the ring-shaped member 301 may differ from the number of adjustable sling connectors 312 and that their respective position on the ring-shaped member 301 may also differ and be adjustable, such that the respective guiding members 321 and adjustable sling connectors 312 may be adjustably positioned along the circumference of the ring-shaped member 301.
[0081] Figures 6A and 6B schematically show different steps in the installation process for installing a boat landing 20 using the adjustable boat landing installation subsystem 200, wherein figure 6A shows the boat landing 20 in, or close to, the lifting position and figure 6B shows the boat landing 20 in, or close to, the installation position. The boat landing 20, which is formed in the current example from a pair of interconnected longitudinal bumper elements 21, an external ladder 22, a plurality of beam elements 23 interconnecting the external ladder to the longitudinal bumper elements 21 and mounting members 24 for mounting said boat landing to the monopile 10’. It is noted that in the current example, the boat landing is mounted to a monopile having the smaller outer diameter d2.
[0082] The boat landing 20 is held by a plurality, e.g. a pair, adjustable holding members 210, in the current example gripper units 210, the gripper units 210, as is explained later in relation to figures 7A- 8B, are preferably arranged for merely providing a form-closed coupling with the boat landing. Due to the relative fragility of the boat landing 20, in particular of its anti -corrosion coating, it is preferred not to clamp the boat landing by the gripper units 210. The gripper units 210 are arranged to a boom member body 102. The gripper units 210 may therefore be arranged at a lower boom section 202, that is pivotally connected (at second pivot point 203) to the upper boom section 204, which is in turn coupled to the rotatable structural body 102. Second pivot point 203 may be arranged such as to allow for a pivoting movement around a second pivoting axis A203 that is substantially perpendicular to the central longitudinal axis I and / or wherein the second pivoting axis A203 is defined as the tangent with respect to a virtual circle, around the central longitudinal axis I as its center, running through said second pivot point 203, wherein said tangent is taken at the second pivot point 203.
[0083] The boom member 201, in particular the upper boom section 204, may be translationally moveable with respect to the rotatable structural body 102 in an up-and-down direction Z2oothat is substantially parallel to the central longitudinal axis I, an side-ways direction X2oo that is substantially parallel to the radial direction II and / or pivotally movable, along the titling direction (X200, around a first pivot axis A205 that is substantially perpendicular to the central longitudinal axis I and / or wherein the first pivoting axis A205 is defined as the tangent with respect to a virtual circle, around the central longitudinal axis I as its center, running through said first pivot point 205, wherein said tangent is taken at the first pivot point 205. In order to ensure the lower boom section 202 to remain parallel to the central longitudinal axis I and thereby simplifying position boat landing 20 to the installation position, pivot point 203 may be provided with a suitable mechanism, such as a gear mechanism, four-bar linkage, or controlled driving mechanism. The respective motions of the boom member 201 may be driven by a respective driving mechanism, wherein the movements in the up-and-down Z200 and side-ways X200 may be driven by respective linear drives, such as a linear motor and / or actuator and / or wherein the movement along the titling direction (X200 may be driven by an angular and / or rotational motor. These may be electrically powered motors and / or actuators and / or hydraulically powered motors and / or actuators, such as hydraulic motors and / or hydraulic cylinders, that can preferably be remotely controlled.
[0084] Figures 7 - 8B schematically show, in a cross-sectional top view along plane VII (i.e. in a downward direction parallel to the central longitudinal axis I), the adjustable boat landing holding members, or gripper unis 210, that can be adjusted to accommodate different boat landings 20, 20’ having different geometries. Figures 7A and 7B show a first boat landing 20 having a first outer width W20, determined as the distance between the outermost sides of the pair of first longitudinal bumper elements 21, said first longitudinal bumper elements 21 having a first outer diameter d2i . Figures 8A and 8B show a second boat landing 20’ having a second outer width W20’, determined as the distance between the outermost sides of the pair of second longitudinal bumper elements 21’, said second longitudinal bumper elements 21’ having a first outer diameter d2r, wherein, respectively, the first outer width W20 and first outer diameter d2i are larger than, respectively, the second outer width W20’ and second outer diameter d2r . The arrangement for both boat landings 20, 20’ is the same in the current example and was already partly described above. The pairs of mounting members 24, 24’ are coupled by means of interconnecting beam members 25, 25’ and are connected to the respective longitudinal bumper members 21, 21’ by means of secondary interconnecting beam members 26, 26’.
[0085] In the current example the gripper units 201 may comprise two open ended gripper-members 211, which may be substantially U- or V-shaped to receive a respective longitudinal bumper element 21, 21’ therein. The open ended gripper-members 211 are translationally movable from, and towards, each other in order to be adjusted to receive different boat landings 20,20’. The internal size of the U-shaped gripper member 211 is adjustable by mounting different fdler pads 212 for decreasing a space between the legs of said U- shape, such that open ended gripper-members 211 are adjustable to different diameters d2i , d2r of the longitudinal bumper elements 21, 21’. The movable open ended gripper-members 211 are slidably arranged onto a central longitudinal member 213 that is part of a stationary base part 214 that is fixedly connected to the lower boom section 202. By providing respective linear actuators, such as hydraulic cylinders 215, between the respective the movable open ended gripper-members 211 and the stationary base part 214, or a single linear actuator between the two movable open ended gripper-members 211, the open ended gripper-members 211 can be controlled to move closely around the longitudinal bumper element 21, 21’ for enclosing said longitudinal bumper element 21, 21’. It is then preferred that no clamping force is applied, but that the secondary interconnecting beam members 26, 26’ rather rest on the outer leg 216 of the U- (or V-) shaped member 211 for securely holding the boat landing 20, 20’ in the gripper unit 210. A protection pad 217, such as a plastic, or rubber, pad may be provided for minimizing any damage to the anti -corrosion coating applied to the boat landing 20, 20’.
[0086] As is clearly shown, a distance W211 between the open ended gripper-members 211 (in figure 7B) is larger than a distance W2ir between the open ended gripper-members 211 (in figure 8B). Additionally, additional filler pads 212 are applied in the situation shown in figure 8B in order to ensure a sufficient fit between the open ended gripper-members 211 and longitudinal bumper elements 21’.
[0087] Figures 9A - 9C schematically show the internal platform holding section 410 of the adjustable internal platform installation subsystem 400 that comprises a plurality of, in the current example four, internal platform holding members 411 which can be moved in a plane perpendicular to the central longitudinal axis I, wherein said plane is spanned by respective X and Y directions X4Oo, Y4Oo. The holding members 411 comprise primary lifting eyes 412 arranged for coupling a lifting cable or sling 402 thereto which can in turn be coupled to the respective lifting points, or eyes, 45 of the internal platform assembly 40 for suspending the internal platform assembly 40 from the internal platform holding section 410. The internal platform holding section 410 is, in turn, suspended from a number of cables 401 that are coupled to the rotatable structural body 102 of the handling tool 1. The cables 401 can be part of a winch-system (not shown, but similar to winches 303) that is arranged on the rotatable structural body 102, or be part of any generic lifting system, for lowering (i.e. moving along vertical direction Z400) the internal platform holding section 410, and thereby the thereto connected internal platform assembly 40, with respect to the handling tool 1, such that they can be lowered into the monopile 10, 10’ for installing said internal platform assembly 40 therein. The internal platform holding section 410 may therefore be provide with secondary lifting eyes 413.
[0088] As was noted earlier, different sized monopiles 10, 10’ will require different sized internal platform assemblies, which may also be provided with varying positions of the respective lifting points 45. In order to properly handle the internal platform assembly 40, it is preferred that the primary lifting eyes 412 of the holding member 411 align with the lifting points 45, such that the lifting slings 402 run substantially vertical (i.e. substantially parallel to the vertical direction Z400). The holding members 411 are therefore preferably moveable in the X and Y directions X4Oo, Y4Oo, which may be achieved by providing the holding members 411 to be movably connected to a base body 414 whereon the secondary lifting eyes 413 are arranged. In the current embodiment, the holding members 411 are arranged at the outer end of a telescopic arm 415 that cantilevers outwardly from the base body 414, wherein a change of the length of the telescopic arm 415 leads to a movement in the longitudinal direction IV of the telescopic arm 415. The telescopic arm 415 may be arranged with a linear motor and / or actuator, such as an hydraulic cylinder that may be remotely operable. In order to further improve the adjustability of the internal platform holding section 410, and thereby of the adjustable internal platform installation subsystem 400, or alternatively, the holding members 411 may be arranged at the end of a pivotable arm member, in the current example corresponding to the telescopic arm 415, that is pivotally connected to the base body 414 allowing for a pivoting movement around an pivoting axis 3400 substantially parallel to vertical direction Z400 along the local azimuth direction P400, thereby enabling a holding member 411 that is moveable in said plane. The pivoting movement may be arranged to be driven by a rotational motor that may be remotely operable. As such, the adjustable internal platform installation subsystem 400 can be adjusted to be operable on different monopiles 10, 10’ having different internal platform assemblies 40, requiring a different arrangement of the holding members 411.
[0089] Figure 10A and 10B schematically shows a third and fourth embodiment of the adjustable lifting and installation device 3000, 4000, wherein the respective device 3000, 4000 are set up for installing an external platform 50, 50’ on respective monopiles 10, 10’ having a respective first and second outer diameter di, d2.
[0090] The adjustable lifting and installation devices 3000, 4000 again comprises respective exchangeable interface bodies 1030, 2030 that comprises a number of alignment members, or bumpers 1031, 1032, 2031, 2032 that are arranged to fit within the inner circumference of the respective tubular upper end sections 11, 11’, in particular of their respective flanges 15, 15’, with only a small clearance (i.e. in the range as described above), and respective supporting surface 1033, 2033 that are arranged to be positioned on the respective upper surfaces of the respective monopiles 10, 10’, in particular of their respective flanges 15, 15’.
[0091] The adjustable lifting and installation devices 3000, 4000 comprise a re-useable handling tool 1’, wherein said handling tool 1’ is arranged specifically for installing external platforms 50, 50’ on different monopileslO, 10’ having different outer diameters. The handling tool 1’, like handling tool 1, comprises a structural base body 101 that is releasably connected to the respective exchangeable interface body 1030, 2030 at its lower end and rotatably coupled to a rotatable base body 102 that is arranged to rotate around the central longitudinal axis I. Handling tool 1’ comprises an adjustable external platform installation subsystem 500 for enabling to install the respective external platform 50, 50’ to the respective monopile 10, 10’.
[0092] In the current example, the adjustable external platform installation subsystem 500 comprises a ringshaped structural member 501 that is guided along the circumference of the exchangeable interface body 1030, 2030 and the monopile 10, 10’ by a second adjustable guiding mechanism 520 that comprises a plurality of adjustable second guiding members 521, in the current example provide with second guide rollers 522 arranged at the outer end thereof, that are arranged to contact the outer circumference of the monopile 10, 10’. The second adjustable guiding mechanism 520 may be substantially similar to the adjustable guiding mechanism 320. The adjustable external platform installation subsystem 500 further comprises an adjustable holding section, that is formed by a second adjustable lifting system 510 that comprises a plurality of second adjustable sling connectors 512 that are arranged on the ring-shaped structural member 501. The second adjustable lifting system 510 may be substantially similar to the adjustable lifting system 310. However, as the external platform 50, 50’ is significantly heavier than a corrosion protection system, such as an anode cage 30, 30’, a pivoting arm mechanism, as is comprised in adjustable lifting system 310 may become too technically complex in order to cope with the large forces. The ring-shaped structural member 501 is also for this reason preferably significantly stiffer than the ring- shaped structural member 301, for instance by heaving a larger cross-sectional area of the ring-shaped structural member 501.
[0093] A plurality of plurality of second adjustable sling connectors 512 are arranged around the circumference of the ring-shaped structural member 501, whereby a second adjustable sling connectors 512 comprises a plurality of sling attachment points 512a - 512c for attaching a lifting sling or cable 511 thereto that extend in a substantially linear direction with respect to the radial direction II. The respective sling attachment points 512a - 512c of the plurality of adjustable sling connectors 512 thereby form various circular arrangements of lifting points, each having a different diameter. Similar to the internal platform assembly 40, the external platform 50, 50’ is customized for each project, such that its lifting points 51, 51’ may also be arranged at different positions on the external platform 50, 50’ . The second adjustable sling connectors 512 thereby allow to adjust the external platform holding section 510 in such a manner that it is able to be modified to install a large range of different external platforms 50, 50’ having different arrangements of lifting points 51, 51’. For this reason the respective position of the second adjustable sling connectors 512 on the ring-shaped structural member 501 may also differ and be adjustable, such that the respective second guiding members 521 and second adjustable sling connectors 512 may be adjustably positioned along the circumference of the ring-shaped structural member 501, as is seen in figures 11A and 11B that are cross-sectional top view taken in respective cross- sectional lines XIA and XIB. The arrows indicated in the ring-shaped structural member 501 indicate that second adjustable sling connectors 512 may be slid over the ring 501 and refixed, or may even be taken from the ring and refixed at a different azimuth location on the ring-shaped structural member 501.
[0094] The ring-shaped structural member 501 is suspended from a number of lifting cables 502 that are coupled to the respective cable coupling members 530 that are arranged at the ring-shaped structural member 501. The lifting cables 502 can be winched in, and out, by respective winches 303’ (which may comprise a motor that can be remotely operable) thereby moving the ring-shaped structural member 501 respectively upwards or downwards. By moving the ring-shaped structural member 501 downwards along the exchangeable interface body 1030, 2030, the respective external platform 50, 50’ can be moved to an installation position wherein the external platform 50, 50’ can be mounted to a predefined location at the monopile 10, 10’.
[0095] Finally, figures 12A and 12B schematically show a fifth embodiment of the adjustable lifting and installation device 5000, wherein the device is set up for installing an external platform 50” on a monopile 10, wherein said external platform 50” is arranged with a different arrangement of the lifting points 51,’ 51”. A secondary lifting point 51” is set further from the circumference of the monopile 10, and thereby further outwardly in the radial direction II than an outer perimeter of the ring-shaped structural member 501. The adjustable external platform installation subsystem 500 can then be adjusted by mounting a cantilevered beam member 503 having at its end a holding member, i.e. a sling attachment point 504, thereto, such that a sling 512 can be arranged between the sling attachment point 504 and the secondary lifting point 51”. In order to prevent excessive torsional forces in the ring-shaped structural member 501, the handling tool 1” may then also be adjusted by arranging secondary winches 303” at primary cantilevered beam member 104 extending outwardly in a radially direction II from the rotatable structural base 102, such that the respective lifting cables 502 provide sufficient support for the cantilevered beam member 503, thereby reducing the torsional forces in the ring-shaped structural member 501. Adjustable lifting and installation device 5000 functions in the same manner as adjustable lifting and installation devices 3000, 4000. All possible suitable combination of the above described embodiments are also part of the current disclosure. Additionally, the present invention is not limited to the embodiments shown, but also extends to other embodiments falling within the scope of the appended claims.
Claims
Claims1. Adjustable lifting and installation device for installing at least a first auxiliary component, such as a corrosion protection system, a boat landing, an external ladder, a cable entry and / or support system, an internal platform(s), an external platform, in, and / or onto, an offshore foundation structure, in particular a monopile that does not require a transition piece, wherein said adjustable lifting and installation device is arranged to be adjustable to fit different offshore foundation structures, said offshore foundation structures having respective tubular upper end sections having different outer and / or inner diameters, wherein said adjustable lifting and installation device is arranged to be lifted by means of a crane onto the offshore foundation structure, wherein said lifting and installation device comprises: a handling tool, wherein said handling tool comprises at least one auxiliary component holding section for releasably holding the first auxiliary component, wherein the at least one auxiliary component holding section is adjustable in at least a radial direction extending from a central longitudinal axis to be adjustable to the different outer and / or inner diameters; an exchangeable offshore foundation structure interface body that is arranged to specifically fit the tubular upper end section having a predefined outer and / or inner diameter, wherein said offshore foundation structure interface body comprises an offshore foundation structure interface section comprising at least one alignment member and at least one supporting surface for supporting and aligning said offshore foundation structure interface body onto, and / or into, the tubular upper end section having the predefined outer and / or inner diameter thereof; wherein said exchangeable offshore foundation structure interface body is releasably connected to the handling tool by means of a releasable interface body connection.
2. Adjustable lifting and installation device according to claim 1, wherein said releasable interface body connection has a predefined size that is, in particular, not adjustable to the different outer and / or inner diameters of the tubular upper end section.
3. Adjustable lifting and installation device according to claim 1 or 2, wherein the releasable interface body connection is formed by a releasable handling tool connecting section of the exchangeable offshore foundation structure interface body and the therewith cooperating releasable offshore foundation structure interface body connecting section of the handling tool, in particular wherein the respective connecting sections are formed by respective flanges, preferably comprising a plurality of bolt holes for receiving bolts therein, having an equal size and geometry.
4. Adjustable lifting and installation device according to any of the preceding claims, wherein a respective inner and / or outer diameter of the releasable interface body connection is equal, or larger than, respectively, the predefined outer and / or inner diameter of the tubular upper end section.
5. Adjustable lifting and installation device according to any of the preceding claims, wherein the at least one alignment member is arranged to fit an outer, or inner, circumference of the offshore foundation structure and wherein the at least one supporting surface is arranged to fit an upper surface, in particular an upper surface of a flange, of the tubular upper end section, such that the respective supporting surface is arranged to extend inwardly with respect to an outer circumference of the upper surface and / or extend outwardly with respect to an inner circumference of the upper surface.
6. Adjustable lifting and installation device according to any of the preceding claims, wherein the adjustable lifting and installation device, in particular the handling tool, is arranged to be releasably coupled to at least one lifting and / or handling cable; preferably, wherein the handling tool comprises one or more lifting cable coupling points for releasably coupling the at least one lifting and / or handling cable to the handling tool.
7. Adjustable lifting and installation device according to any of the preceding claims, wherein, in a lifting state wherein said adjustable lifting and installation device is suspended from the at least one lifting cable of the crane, the exchangeable offshore foundation structure interface body is only in direct contact with the handling tool and / or wherein in a deployed state, wherein the adjustable lifting and installation device is positioned and supported on the offshore foundation structure, the exchangeable offshore foundation structure interface body is arranged in between the offshore foundation structure and handling tool, such that, preferably, the adjustable lifting and installation tool is only supported onto, and aligned with respect to, the offshore support structure through the exchangeable offshore foundation structure interface body.
8. Adjustable lifting and installation device according to any of the preceding claims, wherein the releasable handling tool connecting section is arranged at a first end section of said offshore foundation structure interface body and wherein said at least one supporting surface is arranged at a second, substantially opposite, end section of the offshore foundation structure interface body, such that, when in the deployed state, the handling tool is spaced apart from said offshore foundation structure.
9. Adjustable lifting and installation device according to any of the preceding claims, wherein the handling tool comprises a structural base body and a rotatable structural body, wherein said structural base body is releasably connected with the exchangeable offshore foundation structure interface body, wherein said rotatable structural body is rotatably arranged with respect to the structural base body aroundthe central longitudinal axis of the adjustable lifting and installation tool and wherein said at least one auxiliary component holding section is mounted to, and arranged to rotate with, the rotatable structural body.
10. Adjustable lifting and installation device according to any of the preceding claims, wherein the handling tool, in particular said rotatable structural body, comprises at least one auxiliary component positioning subsystem for moving the auxiliary component holding section, with respect to the handling tool, from a lifting position, wherein, at least when in a lifting state, the auxiliary component holding section is spaced apart from the offshore foundation structure at a first distance, to an installation position, wherein, when the auxiliary component is brought into position for mounting to a predefined location at the offshore support structure, the auxiliary component holding section is positioned closer to the offshore foundation structure at a second distance, wherein said first distance is greater than said second distance, such that the first auxiliary component can be mounted at a predefined mounting position on the offshore foundation structure.
11. Adjustable lifting and installation device according to any of the preceding claims, wherein said handling tool, in particular said rotatable structural body, comprises an adjustable boat landing installation subsystem, wherein said adjustable boat landing installation subsystem is arranged to be adjusted to allow installing the boat landing to the tubular end section having the predefined outer diameter, wherein adjustable boat landing installation subsystem comprises a boat landing holding section for releasably connecting said boat landing, preferably, wherein said boat landing holding section is, by means of a respective positioning system, translationally movable with respect to the handling tool in at least a direction parallel to the central longitudinal axis, translationally movable from, and towards, the central longitudinal axis, movable in a tilting direction with respect to the central longitudinal axis for, when a boat landing in connected to the boat landing holding section, tilting a first end section of the boat landing in a direction from, and towards, the central longitudinal axis, and / or in any combination of said movements.
12. Adjustable lifting and installation device according to any of the preceding claims, wherein said handling tool, in particular said rotatable structural body, comprises a corrosion protection installation subsystem for installing a corrosion protection system, such as an anode cage or Impressed Current Cathodic Protection (ICCP) system, wherein said corrosion protection installation subsystem comprises a corrosion protection system holding section for releasably connecting said corrosion protection system, wherein said corrosion protection subsystem holding section is translationally movable, by means of a respective positioning system, with respect to the handling tool in at least a direction parallel to the central longitudinal axis.
13. Adjustable lifting and installation device according to claim 12, wherein said corrosion protection system holding section comprises a plurality of holding members arranged for holding a corrosion protection system, wherein said holding members are arranged in a circular arrangement with respect to each other and wherein, preferably, said holding members are adjustable in the radial direction for adjusting a diameter of the circular arrangement.
14. Adjustable lifting and installation device according to any of the preceding claims, wherein said handling tool comprises an internal platform installation subsystem for installing an internal platform in a space enclosed by a circumferential wall of the tubular upper end section, wherein said internal platform installation subsystem comprises an internal platform holding section for releasably connecting said internal platform, wherein said internal platform holding section is translationally movable, by means of a respective positioning system, with respect to the handling tool in at least a direction parallel to the central longitudinal axis for moving the internal platform holding section through, and out of, an internal space that is enclosed by the handling tool and the exchangeable offshore foundation structure interface body.
15. Adjustable lifting and installation device according to claim 14, wherein said internal platform holding section comprises a plurality of internal platform holding members arranged for holding lifting means, such as a lifting cable and / or sling, wherein said holding members are each arranged to be movable, preferably in at least two directions, in a plane that is perpendicular to the central longitudinal axis, preferably, wherein said holding members are, preferably individually and / or collectively, movable in the radial direction and / or the azimuth direction.
16. Adjustable lifting and installation device according to any of the preceding claims, wherein said handling tool comprises an external platform installation subsystem for installing an external platform to an outer circumferential wall of the tubular end section, wherein said external platform installation subsystem comprises an external platform holding section for releasably connecting said external platform, wherein said external platform holding section is, by means of a respective positioning system, translationally movable with respect to the handling tool in at least a direction parallel to the central longitudinal axis for moving the external platform holding section along an outer circumference of the offshore foundation structure interface body.
17. Adjustable lifting and installation device according to claim 16, wherein said external platform holding section comprises a plurality of external platform holding members arranged for holding lifting means, such as a lifting cable and / or sling, wherein the positions of said holding members are adjustable, preferably in two directions, in a plane that is perpendicular to the central longitudinal axis and wherein,preferably, said holding members are adjustably arranged in the radial direction and / or the azimuth direction, for adjusting the respective positions.
18. Adjustable lifting and installation device according to any of the preceding claims 10 - 17, wherein respective positioning systems comprise a driving mechanism for driving a respective movement, wherein a movement in the radial and / or a direction parallel to the central longitudinal axis is arranged to be driving by a respective linear driving mechanism, such as a linear motor and / or actuator for driving movement in the radial direction and a winch-driven mechanism for driving a movement in the direction parallel to the central longitudinal axis, and / or wherein a movement along the azimuth angle is arranged to be driving by an angular and / or rotational motor, wherein said motors and / or actuators are preferably electrically powered motors and / or actuators and / or hydraulically powered motors and / or actuators, such as hydraulic motors and / or hydraulic cylinders.
19. Adjustable lifting and installation device according to any of the preceding claims, wherein said handling tool comprises a plurality of auxiliary component positioning subsystems for positioning at least two of a corrosion protection system, a boat landing, external ladder, a cable entry and / or support system, internal platform(s), an external platform.
20. Adjustable lifting and installation device according to any of the preceding claims, wherein the exchangeable offshore foundation structure interface body is substantially rigid structure, preferably wherein the exchangeable offshore foundation structure interface body does not comprise a positioning subsystem for positioning any of the auxiliary components, and / or wherein the positioning subsystems do not engage with the exchangeable offshore foundation structure interface body.
21. Adjustable lifting and installation device according to any of the preceding claims, wherein the adjustable lifting and installation device is adjustable to fit at least on tubular upper end sections having an outer diameter in the range of 6 to 7.5, preferably 5.5 to 8 meters, more preferably in the range of 5 to 9 meters.
22. Kit comprising two adjustable lifting and installation devices according to any of the preceding claims, wherein a first of said adjustable lifting and installation devices is arranged for installing a corrosion protection system, a boat landing, external ladder, a cable entry and / or support system and / or internal platform(s) and a second of said adjustable lifting and installation devices is arranged for installing an external platform.
23. Method of providing an adjustable lifting and installation device for installing at least a first auxiliary component, such as a corrosion protection system, a boat landing, an external ladder, a cable entry and / or support system, internal platform(s), an external platform, in, and / or onto, a tubular upper end section of an offshore foundation structure, such as a monopile that does not require a transition piece, wherein said adjustable lifting an installation device is arranged to be adjustable to fit different offshore foundation structures having tubular upper end sections having different outer and / or inner diameters, wherein said adjustable lifting and installation device is arranged to be coupled to at least one lifting cable of a crane, wherein the method comprises the steps, in any suitable order, of: providing a handling tool, wherein said handling tool comprises at least one auxiliary component holding section for releasably connecting the first auxiliary component thereto, wherein the at least one auxiliary component holding section is adjustable in at least a radial direction extending from a central longitudinal axis to be adjustable to a different outer and / or inner diameters;- determining an inner and / or outer diameter of the tubular upper end section of the offshore foundation structure;- adjusting, on the basis of the determined inner and / or outer diameter of the tubular upper end section, a position of the at least one auxiliary component holding section in at least the radial direction;- providing an exchangeable offshore foundation structure interface body, wherein said exchangeable offshore foundation interface body comprises at least one alignment member and at least one supporting surface for supporting and aligning and supporting said exchangeable offshore foundation structure interface body onto, and / or into, the offshore foundation structure, comprising the steps of:- providing the at least one alignment member to fit in, or around, the respective inner and / or outer diameter of the tubular end section thereof; and providing the at least one supporting surface to fit an upper surface, in particular an upper surface of a flange, of the tubular upper end section, in particular of the tubular end section thereof; preferably, connecting the handling tool and the exchangeable offshore foundation structure interface body by means of a releasable interface body connection.
24. Method of installing at least a first auxiliary component in, and / or onto, an offshore foundation structure, such as a monopile that does not require a transition piece, comprising the steps of: providing an adjustable lifting and installation device according to any of the preceding claims 1 - 21, or an adjustable lifting and installation device obtained using the method of claim 23; connecting the first auxiliary component, such as a corrosion protection system, a boat landing, external ladder, a cable entry and / or support system, internal platform(s), an external platform, to a respective auxiliary component connections section; placing, in particular lifting, the adjustable lifting and installation device on the tubular upper end section of the offshore foundation structure;installing the first auxiliary component in, or onto, the offshore foundation structure using the adjustable lifting and installation device.
25. Method of installing according to claim 24, further comprising the steps of: - moving the auxiliary component, by means of an auxiliary component positioning subsystem, from a lifting position to an installation position, wherein the auxiliary component is brought into position for mounting to a predefined location on the offshore support structure; fixedly mounting said auxiliary component to a predefined mounting position on the offshore foundation structure.
Citation Information
Patent Citations
A method of installing a crane on a portion of an offshore wind turbine generator and a vessel therefor
DK201800518A1
Device and method for arranging a secondary construction on an offshore primary construction
EP3483342A1
Cable installation apparatus for mounting on a flanged structure
US20140374679A1
Installing equipment in offshore monopile foundations
WO2022118015A2
Cited By
Systems and methods for a rack structure for a transport vessel adapted for use with an offshore self-elevating vessel
US12420894B2
Systems and methods for assembling and installing offshore wind turbines
US12692837B2