Shared carrier for the installation of tools intended for the mass production of metal structures, in particular fixed or floating foundations for offshore wind turbines

Abstract

The invention relates to a shared carrier (30) for the installation of tools intended for the mass production of metal structures, each structure being formed by the assembly of at least two different unitary blocks, the carrier comprising a guide (32) intended to be positioned on one of the blocks (32) to be assembled in the vicinity of the junction with another block to be assembled, a tool carrier (34) intended to receive without distinction one or more tools (38), means for moving the tool carrier along the guide, and means for knowing the position of the tool carrier.

Description

Description Title of the invention: Shared carrier for the installation of tools intended for the mass production of metal structures, in particular fixed or floating foundations for offshore wind turbines Technical Field

[0001] The invention relates to the general field of mass production of metal structures, in particular fixed or floating foundations for offshore wind turbines or metal structures used in the oil sector.

[0002] More specifically, it concerns a shared carrier for the installation of tools intended for the mass production of such metal structures. Prior art

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

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

[0005] The lower end of the mast is mounted on a support structure (called the "foundation"). For floating foundations, there are different types of floats, namely semi-submersible floats (with or without a pendulum counterweight), submerged floats with tensioned cables (or "TLP" platforms for "Tension-Leg Platform" in English), floats “SPAR” type (for “Single Point Anchor Reservoir”), semi-submersible floats of the “barge” type, etc. For example, we can refer to publication WO 2019 / 106283 which describes a floating support structure whose main structure has a toric or polygonal shape. As for the fixed foundations, they can be made of steel, concrete or a combination of these two materials.

[0006] Offshore wind turbines are most often grouped together in a "wind park" or "wind farm" generally comprising between 20 and 100 wind turbines with a unit power of several megawatts.

[0007] In floating offshore wind farm development projects, the floater delivery schedule is a key parameter for the successful delivery of large offshore wind farms within tight installation windows. Furthermore, the ability to ensure local floater production is of utmost importance, but land space available for floater assembly is usually a major obstacle.

[0008] Patent application FR 23 02023 filed on March 3, 2023 discloses a method for the mass production of floats for offshore wind turbines, each consisting of the assembly of at least two different unit blocks of floats. This method is remarkable in that it allows floats for offshore wind turbines to be manufactured in series on a very limited land area.

[0009] The implementation of such a production process requires reducing as much as possible the time required for setting up and removing the various tools involved in the manufacturing process (welding tools, control tools, etc.). In addition, it is necessary to try to reduce the number of spare parts and optimize tool maintenance (with a view to reducing maintenance personnel and training sessions).

[0010] Furthermore, in the oil sector, it is known to use installations to carry out various operations during the mass production of metal structures, in particular during the assembly of steel pipe sections. Examples include publications WO2016026969, W02018073511, and W02018073511 which describe different installations dedicated to each receiving a specific tool (for example welding equipment, or weld seam inspection equipment, or sandblasting equipment, etc.). The main disadvantage of these installations is that they have no flexibility in terms of use and it is necessary to change the installation as a whole when moving from one operation to another. Statement of the invention

[0011] The invention therefore aims to propose a multi-tool carrier for the installation of tools intended for the mass production of metal structures, in particular fixed or floating foundations for offshore wind turbines, this carrier being shared to allow one or more tools to be used indifferently during the same pass.

[0012] According to the invention, this aim is achieved by means of a shared carrier for the installation of tools intended for the mass production of metal structures, in particular fixed or floating foundations for offshore wind turbines, each structure being formed by the assembly of at least two different unit blocks, the installation comprising: - a guide intended to be positioned on one of the blocks to be assembled near the junction with another block to be assembled; - a tool carrier intended to receive one or more tools; - means for moving the tool carrier along the guide; and - means of knowing the position of the tool carrier.

[0013] The carrier according to the invention is remarkable in that it allows the use of the same installation for the use of tools with different functionalities involved in the mass production of metal structures such as foundations for offshore wind turbines. It is thus possible to maximize activities in hidden time and to reduce as much as possible the time required for the implementation installation and removal of various tools. In addition, the number of spare parts is reduced and maintenance is optimized, which reduces the number of personnel responsible for maintenance.

[0014] The guide may support one or more rails on which the tool carrier moves. The guide may consist of a structure independent of the two foundation blocks capable of being moved relative to them.

[0015] The means for moving the tool carrier may comprise a motor powered by an independent power source. Alternatively, the means for moving the tool carrier may comprise a motor powered by an external power source connected to the motor by an umbilical cable.

[0016] The means for knowing the position of the tool carrier may comprise a three-dimensional positioning system relative to the blocks to be assembled. Alternatively, these means may comprise an encoder and / or an orbital inclinometer.

[0017] The installation may further comprise means for remotely controlling the tool carrier. The tools may be chosen from the following tools: chamfer control tool, welding and weld control tool, profilometry control tool, non-destructive testing tool, preheating tool, profiling tool, surface preparation tool for depositing an anti-corrosion coating, hammering tool, grinding tool, etc.

[0018] The invention also relates to a method for the mass production of semi-submersible floats for offshore wind turbines, each consisting of the assembly of at least two different unit blocks, the method comprising: - the transport and storage in different storage areas of a production area of a plurality of different blocks of floats, the same blocks of floats being stored in the same storage area of the production area; - the production line of floats comprising successively for each float, a step of preparing the blocks, a step of assembling and primary welding of the float blocks together at a zone primary assembly and welding separate from and adjacent to the storage areas, followed by a final welding step of the blocks together at a final welding area separate from the other areas of the production surface, followed by a float completion step at a completion area separate from the other areas of the production surface; - the float blocks and floats being manufactured being moved on the production surface between the different zones thereof mainly according to translational movements; and - the assembly and primary welding, final welding and completion stages being carried out using a carrier as defined previously.

[0019] During the assembly stage and before starting the primary welding phase, a chamfer control tool can be installed on the tool holder in order to control the chamfers and the variation in altitude of the respective ends of the two blocks to be assembled.

[0020] In this case, once the chamfers have been checked and validated, a preheating, welding and weld control tool can be installed on the tool holder.

[0021] Additionally, during the final welding and completion stage, once the welding operations have been finalized, a profilometry control tool can be installed on the tool holder to control the profile of the welds made. Brief description of the drawings

[0022] [Fig. 1] Figure 1 shows an example of different unit blocks of a semi-submersible float to which the invention applies.

[0023] [Fig. 2] Figure 2 is a schematic and perspective view of an example of an arrangement in which the carrier according to the invention can be implemented.

[0024] [Fig. 3] Figure 3 is a perspective view showing the carrier according to the invention configured for scanning float blocks to be assembled.

[0025] [Fig. 4] Figure 4 is a perspective view showing the carrier according to the invention configured for welding float blocks to be assembled.

[0026] [Fig. 5] Figure 5 is a perspective view showing the carrier according to the invention configured for profilometry of welds between float blocks.

[0027] [Fig. 6] Figure 6 is a perspective view showing the carrier according to the invention configured for non-destructive testing of welding of float blocks to be assembled.

[0028] [Fig. 7] Figure 7 is a perspective view showing the installation according to the invention configured for hammering float blocks to be assembled

[0029] [Fig. 8] Figure 8 is a perspective view showing the installation according to the invention configured for working the surface condition of welds between float blocks to be assembled.

[0030] [Fig. 9] Figure 9 is a perspective view showing the installation according to an alternative embodiment of the invention. Description of the embodiments

[0031] The invention relates to the general field of mass production and the chain of metal structures, in particular fixed or floating foundations for offshore wind turbines, in particular semi-submersible type floats, but also metal structures used in the oil field, such as suction anchors, riser buoyancy tanks, etc.).

[0032] The floats to which the present invention applies in particular have the particularity of being able to be manufactured by assembling a plurality of different unit blocks (or elements).

[0033] In the embodiment described below relating to the manufacture of a semi-submersible float for an offshore wind turbine, each float 2 comprises, as shown in FIG. 1, four columns including a central column 4 which is intended to receive a wind turbine mast and three external columns 6 which are connected to the central column by lower pontoons 8.

[0034] In practice, such floats 2 can each be formed by assembling three blocks: a first block B1 comprising the central column 4, an outer column 6 and a lower pontoon 8, and two second identical blocks B-2 each comprising an outer column 6 and a lower pontoon 8.

[0035] Of course, the invention applies to other types and other forms of semi-submersible floats, the latter having to be formed by the assembly of at least two different unit blocks of floats.

[0036] Furthermore, at least the lower pontoons 8 of each block B1, B-2 are formed by an assembly of flat panels. For example, as shown in Figures 3 and 4, these lower pontoons are each formed by the assembly of four flat panels 8i to 84 forming a rectangular parallelepiped (only the flat panels 81 and 84 are visible in Figures 3 and 4).

[0037] In addition, the lower pontoons 8 of each float block may be reinforced by longitudinal internal stiffeners 9a and / or transverse internal stiffeners 9b (see Figure 4).

[0038] Reference may be made to patent application FR 23 01328 filed on February 13, 2023, which describes an example of a float structure with flat panels.

[0039] As shown in Figure 2, these floats 2 can be manufactured on a relatively compact production land area 10 capable of accommodating the various elements and equipment necessary for the manufacture of the floats.

[0040] This production area 10 is divided into different zones Z1 to Z6, namely: a first storage zone Z1 on which the blocks B-1 are stored, a second storage zone Z-2 on which the blocks B-2 are stored, an assembly and primary welding zone Z-3 on which the different blocks B1, B-2 constituting the same float are assembled together and subjected to primary welding, a final welding zone Z-4 on which the different blocks constituting the float undergo a new welding pass, a zone Z-5 completion zone on which the float is inspected and equipped with various equipment, and a Z-6 buffer zone on which a 2' float with manufacturing defects can be withdrawn for repair.

[0041] A transport barge 20 is moored at the loading dock of the production area. Float 2 located in the Z-5 completion zone is then loaded onto the transport barge by means of transport.

[0042] It should be noted that the float blocks and floats being manufactured are moved between the different areas of the construction surface by multi-wheeled transport vehicles or by skidding, i.e. mainly by following translational movements.

[0043] The invention provides for the use of a single multi-tool carrier 30 which is shared to assist in the practical implementation of each of the stages of the mass production process of the floats.

[0044] As shown in Figure 3, this carrier 30 comprises a guide (or strip) 36 which is, in this embodiment, pre-installed on a block 32 to be assembled in the vicinity of the junction between two blocks while being slightly set back from this junction.

[0045] The installation also includes a tool carrier which is intended to receive one or more tools indifferently. This tool carrier is for example a carriage 34 on which the tool(s) is / are installed.

[0046] Of course, the belt can accommodate several tool carriers whose tools work simultaneously.

[0047] The carriage 34 is capable of moving, for example, on a system of rails (not shown in the figures) which are mounted both on the upper face 32a and on the two lateral faces 32b of the block 32 to be assembled on which the strip 36 is pre-installed. The rail system can be modular, with manual gripping and installation, and with magnetic or mechanical or suction cup type fixing.

[0048] The movement of the carriage 34 can be carried out by a motor powered by an autonomous energy source or by a motor powered by a source external energy connected to the motor by an umbilical cable (motors not shown in the figures). [0049)11 Means are also provided for knowing the position of the carriage 34 on the strip 36. For example, such means may comprise a three-dimensional positioning system relative to the blocks to be assembled in order to guarantee the position of the weld within the assembly tolerances of the two blocks. This system may be supplemented by an orbital inclinometer.

[0050] Advantageously, the installation further comprises means for remotely controlling the tool carrier. For example, such means may comprise a device for controlling the speed depending on the weld to be made, a device for controlling the welding parameters, etc.

[0051] The invention is remarkable in particular in that the same tool carrier (or carriage) is capable of accommodating a plurality of different tools indifferently.

[0052] These different tools are mounted on the trolley 34 according to requirements, in particular according to the areas of the production surface used in the mass production of semi-submersible offshore wind turbine floats.

[0053] Thus, as shown in Figure 3, the tool 38 mounted on the carriage 34 may be a system for scanning the ends of the float blocks that are to be assembled. Such a tool 38 is notably used on the first and second storage areas Z1, Z-2 to check the surfaces of the ends of the blocks to be assembled.

[0054] At these first and second storage areas Zl, Z-2, other tools may be used, including: a block end beveling tool (milling the faces according to the metrology performed upon block reception, a strip positioning / alignment tool on all faces at a correct distance from the joint planes (inside / outside or both), a bevel control tool (angle control against the qualified procedure), a weldable primer spray tool (to avoid surface corrosion between block beveling and block transfer), etc.

[0055] At the Z-3 primary assembly and welding area where the various constituent blocks of the same float are assembled together and subjected to primary welding, a chamfer control tool is installed on the installation trolley in order to control the chamfers and the variation in altitude of the respective ends of the two blocks to be assembled.

[0056] Once the chamfers have been checked and validated, as shown in FIG. 4, a welding tool 40 is installed on the carriage 34. This welding tool 40 can be coupled to a heating device positioned upstream of the welding tool and a tool for automatic and real-time inspection of the weld beads positioned downstream of the welding tool as described in the publication WO 2018 / 073511.

[0057] Once the welds are completed, a weld profilometry control tool is installed on the installation trolley to check the quality of the welds.

[0058] If a welding defect has to be corrected, a milling tool 42 can be installed on the installation carriage as shown in Figure 5. This operation is for example carried out at the final welding zone Z-4 on which the different constituent blocks of the float undergo a new welding pass.

[0059] When the welds are completed, a profilometry inspection tool can be installed, as well as a non-destructive weld inspection tool 44 as shown in Figure 6.

[0060] Of course, other tools can be installed on the installation trolley. For example, as shown in Figure 7, a pinning tool can be used. Typically, pinning is intended to improve the fatigue resistance of a structure in preparation for the welding process (for example, reference may be made to publication WO 2009 / 024406 which describes an example of a pinning tool).

[0061] As shown in Figure 8, a sandblasting and painting tool 46 may also be mounted on the installation carriage in order to prepare the surface conditions before the deposition of the weld beads.

[0062] Furthermore, as shown in Figure 9, the strip on which the tool-carrying carriage 34 is able to move can be constituted by a junction plate 48 which is mounted against the end to be connected of one of the two blocks B1, B-2 to be assembled.

[0063] More specifically, in this alternative embodiment, the carriage 34 moves on a rack 50 formed on the projecting portion of the junction plate 48.

Claims

Claims

1. Method for mass production of semi-submersible floats for offshore wind turbines each consisting of the assembly of at least two different unit blocks (B1, B-2), the method comprising: - the transport and storage on different storage areas (Zl, Z-2) of a production surface (10) of a plurality of different blocks of floats, the same blocks of floats being stored on the same storage area of the production surface; - the production line manufacture of floats comprising successively for each float, a step of preparing the blocks, a step of assembling and primary welding the float blocks together at a primary assembly and welding zone (Z-3) separate from the storage zones and adjacent to them, followed by a step of final welding of the blocks together at a final welding zone (Z-4) separate from the other zones of the production area, followed by a step of completing the float at a completion zone (Z-5) separate from the other zones of the production area; - the float blocks and floats being manufactured being moved on the production surface between the different zones thereof mainly according to translational movements, and - the assembly and primary welding, final welding and completion stages being implemented using a shared carrier (30) for the installation of tools comprising: - a guide (36; 48) intended to be positioned on one of the blocks to be assembled in the vicinity of the junction with another block to be assembled; - a tool carrier (34) intended to receive one or more tools; - means for moving the tool carrier along the guide; and - means of knowing the position of the tool carrier.

2. The method of claim 1, wherein the carrier guide (30) supports one or more rails on which the tool carrier (34) rides.

3. Method according to one of claims 1 and 2, in which the means for moving the tool carrier comprise a motor powered by an autonomous energy source.

4. Method according to one of claims 1 and 2, in which the means for moving the tool carrier comprise a motor powered by an external energy source connected to the motor by an umbilical cable.

5. Method according to any one of claims 1 to 4, in which the means for knowing the position of the tool carrier comprise a three-dimensional positioning system relative to the blocks to be assembled.

6. Method according to any one of claims 1 to 4, in which the means for knowing the position of the tool carrier comprise an encoder and / or an orbital inclinometer.

7. Method according to any one of claims 1 to 6, further comprising means for remotely controlling the tool carrier.

8. Method according to any one of claims 1 to 7, in which the carrier guide is constituted by a structure (32) independent of the two foundation blocks capable of being moved relative to them.

9. Method according to any one of claims 1 to 7, in which the carrier guide is constituted by a junction plate (48) mounted against the end to be connected of one of the two foundation blocks.

10. A method according to any one of claims 1 to 9, wherein the tools are selected from the following tools: chamfer control tool, welding (40) and weld control tool, profilometry control tool, non-destructive control tool (44), preheating tool, profiling tool, surface preparation tool for depositing an anti-corrosion coating, hammering tool, and grinding tool.

11. A method according to any one of claims 1 to 10, wherein, during the assembly step and before starting the primary welding phase, a chamfer control tool is installed on the tool holder of the installation in order to control the chamfers and the variation in altitude of the respective ends of the two blocks to be assembled.

12. Method according to claim 11, wherein, once the chamfers have been checked and validated, a preheating, welding and welding control tool is installed on the tool carrier (34).

13. A method according to any one of claims 1 to 12, wherein, during the final welding and completion step, once the welding operations have been finalized, a profilometry control tool is installed on the tool carrier to control the profile of the welds made.

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