Offshore Tower Installation Using Concrete Substructures
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Solution Overview
Problem
Current offshore wind turbine substructures face high costs, durability issues due to marine corrosion, sensitivity to fatigue, collisions, and complex geotechnical uncertainties, with limited tower capacity and height due to metal materials, and high dependence on specialized transportation and maintenance in deep water environments.
Innovation Solution
The use of structural concrete for both tower shafts and foundations, allowing for self-floating installation with ballast control and modular section assembly, providing increased durability, adaptability, and cost-effectiveness, with the ability to support larger turbines and facilitate repowering without full substructure replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal structures are used for offshore towers, then strength and structural integrity are improved, but durability deteriorates due to marine corrosion and fatigue
Solution Approach 1:
The patent changes the material parameter from metal to concrete, fundamentally altering the material properties to achieve both strength and durability. Concrete provides inherent corrosion resistance while maintaining structural integrity through its compressive strength properties, eliminating the durability issues associated with metal in marine environments.
Solution Approach 2:
The patent employs composite construction by combining concrete with steel reinforcement bars (rebar) to create a composite material system. This composite structure leverages the compressive strength of concrete and the tensile strength of steel, achieving both structural integrity and durability against marine corrosion.
2Reliability
If concrete is used for tower shafts, then durability and corrosion resistance are improved, but manufacturing complexity increases due to modular assembly requirements
Solution Approach 1:
The patent divides the tower shaft into multiple modular concrete sections that can be manufactured separately and then assembled on-site. Each section is pre-cast with standardized dimensions and connection interfaces, simplifying the manufacturing process while enabling the use of durable concrete material throughout the structure.
Solution Approach 2:
The patent implements preliminary manufacturing of concrete sections in controlled factory environments before transport and assembly at the offshore site. This preliminary action allows for quality control, corrosion protection measures, and connection detail preparation to be completed beforehand, reducing on-site complexity.
3Ease of operation
If self-floating installation method is used, then transportation cost and complexity are reduced, but control over installation position and orientation becomes more difficult
Solution Approach 1:
The patent incorporates feedback mechanisms through GPS positioning, depth sensors, and orientation sensors that continuously monitor the floating tower's position and attitude during transport and installation. This real-time data feeds back to the control system, allowing operators to make precise adjustments to achieve the desired installation position and orientation.
Solution Approach 2:
The patent uses auxiliary floating platforms or barges as intermediaries to assist in positioning and orienting the self-floating tower during installation. These intermediary elements provide additional control points and mechanical means for adjusting the tower's position and orientation without compromising the benefits of self-floating transport.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces maintenance needs, extends the lifespan of substructures, allows for larger and more efficient wind turbines, and lowers initial and repowering costs by leveraging concrete's durability and resistance to marine environments, while enabling flexible and cost-effective installation and future upgrades.
Implementation Method 1
a foundation block basically made of concrete, said foundation block being essentially hollow and watertight
Implementation Method 2
introduce ballast in said foundation block through said passage in such a manner that said starting unit sinks until resting on the bottom of the body of water
Data Source
AI summary
Process for installing an offshore tower, specifically a substructure, which basically comprises the following steps: a) dry manufacturing a foundation comprising a block (1, 1') basically made of concrete and dry manufacturing a base section (25) of a shaft (2); b) applying said base section to said foundation block, forming a unit called the "starting unit"; c) moving said starting unit to the installation point of said substructure; and d) actuating in a controlled manner, first ballast valve means in such a manner that said starting unit sinks until resting on the seabed; having placed said foundation block or said starting unit in the body of water where the installation point said substructure is located.