On-site Fabricated Composite Spar Platforms for Offshore Wind
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Solution Overview
Problem
Current steel-spar technology for offshore wind-power installations requires upending and assembly in protected deep waters, limiting the number of suitable locations for wind turbine installations due to stringent depth and weather conditions.
Innovation Solution
The use of continuous-fiber composite tubes fabricated via a modified vacuum-assisted resin-transfer molding (VARTM) process, allowing on-site fabrication in either vertical or horizontal orientations, eliminating the need for upending and enabling installation in a wider range of locations, with reduced capital costs compared to conventional steel spar platforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steel-spar platforms are fabricated using conventional methods, then structural strength and stability are achieved, but installation requires protected deep waters and upending operations, limiting suitable locations
Solution Approach 1:
The patent changes the material parameter from steel to fiber-reinforced polymer composite, which fundamentally alters the fabrication and installation parameters. The composite material allows for direct water-based fabrication without requiring protected deep waters or complex upending operations, thus expanding location suitability while maintaining structural stability through the high strength-to-weight ratio of the composite materials.
Solution Approach 2:
The invention uses fiber-reinforced polymer composite materials to fabricate the spar platform directly in water. This composite material approach enables the platform to be constructed in a horizontal position using modular sections that are joined underwater, eliminating the need for protected deep-water locations and upending operations required by conventional steel-spar fabrication methods.
2Strength
If conventional steel-spar fabrication methods are used, then proven structural integrity is achieved, but capital investment and installation costs increase due to towing and deploying requirements
Solution Approach 1:
The spar platform is divided into multiple modular composite sections that can be fabricated separately and then joined together underwater. This segmentation allows each module to be manufactured more efficiently and transported more easily, reducing the capital investment and installation costs associated with moving and deploying large monolithic steel structures.
Solution Approach 2:
Changing from steel to composite materials fundamentally changes the manufacturing and installation parameters. The composite sections can be fabricated directly in water at the installation site, eliminating the need for expensive towing and heavy-lift deploying operations required for conventional steel-spar platforms, thus significantly reducing installation costs.
3Adaptability or versatility
If fiber-reinforced polymer composite sections are joined to form a complete spar platform, then on-site fabrication flexibility is achieved, but the joining process complexity increases
Solution Approach 1:
The composite spar sections are pre-fabricated with joining features and prepared in advance at the installation site before being assembled. This preliminary preparation simplifies the actual joining process by ensuring all components are ready for connection, reducing the complexity of the assembly operation while maintaining on-site fabrication flexibility.
Solution Approach 2:
The patent employs specialized joining mechanisms and intermediary components designed for underwater composite assembly. These intermediaries facilitate the connection between composite sections in a controlled manner, managing the complexity of the joining process while enabling flexible on-site fabrication of the complete spar platform.
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 expands the number of locations suitable for offshore wind farms, reduces installation costs by 40% or less, and provides a stable and durable spar platform for wind turbines, capable of withstanding harsh weather conditions.
Implementation Method 1
continuous-fiber composite tubes fabricated via a modified vacuum-assisted resin-transfer molding (VARTM) process
Data Source
AI summary
A spar platform comprises one or more continuous-fiber composite tubes fabricated at or near the intended site use of the platform. In some embodiments, the spar platform includes a relatively longer central tube and relatively shorter peripheral tubes. In some other embodiments, the spar platform is a single long tube. In some embodiments, the spar platform supports a wind turbine assembly. The continuous-fiber composite tubes are formed, in either a vertical or horizontal orientation, using a modified vacuum assisted resin transfer molding process.