Crane, vessel comprising such a crane, and a method for up-ending a longitudinal structure

Abstract

A method for up-ending a longitudinal structure, being one of a foundation of an offshore wind turbine or a wind turbine tower to be installed on top of a previously installed foundation, wherein use is made of a crane The method includes providing a longitudinal structure with an upper end and a lower end in a substantially horizontal orientation; connecting the middle hoisting block of three main hoisting systems and one outer hoisting block of the three main hoisting systems to the upper end of the longitudinal structure; connecting another other outer hoisting block of the three main hoisting systems to the lower end of the longitudinal structure; and operating respective winches of the three main hoisting systems until the longitudinal structure is in a substantially vertical orientation with the upper end above the lower end.

Claims

1. A method for up-ending a longitudinal structure, said longitudinal structure being one of a foundation of an offshore wind turbine or a wind turbine tower to be installed on top of a previously installed foundation, wherein use is made of a crane comprising: a base structure; a slew bearing; a crane housing moveably mounted to the base structure via the slew bearing to allow the crane housing to rotate relative to the base structure about a substantially vertical slewing axis; a boom moveably mounted to the crane housing to allow the boom to pivot relative to the crane housing about a substantially horizontal first pivot axis at one end of the boom, said boom having an opposite end remote from said one end; and three main hoisting systems, wherein each main hoisting system comprises: a hoisting cable; a sheave block with one or more sheaves that are rotatable about a sheave rotation axis, the sheave block being arranged on the opposite end of the boom; a hoisting block suspended from the sheave block by the hoisting cable; and a hoisting winch to lift and lower the hoisting block by hauling in or paying out the hoisting cable, wherein the sheave block of each main hoisting system is pivotable about a substantially horizontal second pivot axis that is perpendicular to the sheave rotation axis of the one or more sheaves of the sheave block, wherein the sheave blocks of the three main hoisting systems are arranged side-by-side, and wherein the method comprises the following steps: a) providing a longitudinal structure with an upper end and a lower end in a substantially horizontal orientation; b) connecting the middle hoisting block of the three main hoisting systems and one of the outer hoisting blocks of the three main hoisting systems to the upper end of the longitudinal structure; c) connecting the other outer hoisting block of the three main hoisting systems to the lower end of the longitudinal structure; and d) operating the respective winches of the three main hoisting systems until the longitudinal structure is in a substantially vertical orientation with the upper end above the lower end.

2. The method according to claim 1, wherein step c) comprises the following steps: c1) providing a gripping element; c2) providing the gripping element around the lower end or lower end portion of the longitudinal structure; and c3) connecting the other outer hoisting block of the three main hoisting systems to the gripping element.

3. The method according to claim 1, wherein the longitudinal structure is a monopile as a foundation of an offshore wind turbine.

4. The method according to claim 1, wherein the boom comprises an A-frame with two boom legs that are connected at said one end to the crane housing and at said opposite end to each other via a connection element.

5. The method according to claim 1, wherein the crane comprises a luffing system to set an angular orientation of the boom relative to the crane housing, and wherein the boom comprises an A-frame with two boom legs that are connected at said one end to the crane housing and at said opposite end to each other via a hammerhead structure, wherein the luffing system comprises: two luffing winches on the crane housing; and two luffing cables extending between the respective two luffing winches on the crane housing and the boom, and wherein the luffing cables are connected to respective outriggers of the hammerhead structure that extend beyond the boom legs of the A-frame seen in plan view.

6. The method according to claim 1, wherein use is made of a jack-up vessel, and wherein the base structure of the crane is mounted on the jack-up vessel, said jack-up vessel comprising: a hull with at least three openings in the hull, said openings extending vertically through the hull to receive a respective leg; a leg per opening in the hull; and a leg driving device per leg allowing to move the corresponding leg relative to the hull in a vertical direction to allow the hull to be lifted out of a water body.

Description

(1) The invention will now be described in more detail in a non-limiting way by reference to the accompanying drawings in which like parts are indicated by like reference symbols, and in which:

(2) FIG. 1 depicts a side view of a vessel according to an embodiment of the invention;

(3) FIG. 2 depicts a rear view of the vessel of FIG. 1;

(4) FIG. 3 depicts a top view of the vessel of FIG. 1;

(5) FIG. 4 depicts in more detail an end of the boom of the crane on the vessel of FIG. 1;

(6) FIG. 5 depicts in more detail the hammerhead structure on the boom of the crane of the vessel of FIG. 1;

(7) FIGS. 6A+6B depict respectively a side view and a front view of a first configuration of the three main hoisting systems of the crane of the vessel of FIG. 1;

(8) FIGS. 7A+7B depict respectively a side view and a front view of a second configuration of the three main hoisting systems of the crane of the vessel of FIG. 1;

(9) FIGS. 8A+8B depict respectively a side view and a front view of a third configuration of the three main hoisting systems of the crane of the vessel of FIG. 1;

(10) FIG. 9 depicts the rear side of the vessel of FIG. 1 in plan view;

(11) FIG. 10 depicts a rear view of the vessel of FIG. 1;

(12) FIG. 11 depicts a step in the method for up-ending a monopile;

(13) FIG. 12 depicts a further step in the method for up-ending a monopile;

(14) FIG. 13 depicts yet a further step in the method for up-ending a monopile;

(15) FIG. 14 depicts a preparatory step for driving a monopile into a sea bottom with the vessel of FIG. 1;

(16) FIG. 15 depicts the vessel of FIG. 1 during installation of a tower on a monopile foundation;

(17) FIG. 16 depicts the vessel of FIG. 1 during installation of a nacelle on the tower of FIG. 15 after installation of said tower;

(18) FIG. 17A depicts the vessel of FIG. 1 during installation of a platform on another type of foundation; and

(19) FIG. 17B depicts an example of connecting the three main hoisting systems.

(20) FIGS. 1 to 3 depict a vessel 1 according to an embodiment of the invention. FIG. 1 is a side view of the vessel 1, FIG. 2 is a rear view of the vessel 1, and FIG. 3 is a top view of the vessel 1.

(21) The vessel 1 comprises a hull 2 with four openings 2A, 2B, 2C, 2D in the hull 2, wherein the openings extend vertically through the hull 2 to receive a respective leg 3A, 3B, 3C, 3D.

(22) Each leg 3A, 3B, 3C, 3D is provided with a leg driving device 4A, 4B, 4C, 4D allowing to move the corresponding leg 3A, 3B, 3C, 3D up and down relative to the hull 2 in a vertical direction to allow the hull 2 to be lifted out of a water body 5 as shown in FIGS. 1 and 2. Hence, the vessel 1 is a jack-up vessel. The height of the legs 3A, 3B, 3C, 3D relative to the hull 2 when the legs are retracted for sailing with the vessel is indicated by dashed lines above the respective legs.

(23) Provided on the vessel 1 is a crane 10. The crane 10 comprises a base structure 11 mounted to the hull 2, a slew bearing 12 and a crane housing 13 moveably mounted to the base structure 11 via the slew bearing 12 to allow the crane housing 13 to slew relative to the base structure 11 about a substantially vertical slewing axis 14.

(24) The crane 10 further comprises a boom 15. The boom 15 is moveably mounted to the crane housing 13 to allow the boom 15 to pivot relative to the crane housing 13 about a substantially horizontal first pivot axis 16. In FIG. 1, the boom is depicted at two distinct angular orientations, a lower orientation in which the boom 15 is supported by the vessel at a distance from the horizontal first pivot axis 16, and an upright orientation in which the boom 15 is almost vertical.

(25) The boom 15 comprises an A-frame with two boom legs 15A, 15B that are connected at one end to the crane housing, thereby defining the first pivot axis 16, and are connected at the opposite end to each other via a hammerhead structure 17. In between the two ends, the boom legs are connected by intermediate connection members 15D to increase the stiffness of the A-frame.

(26) The boom legs in this embodiment are truss structures as are the intermediate members 15D. The hammerhead structure 17 may have a box structure. The box structure of the hammerhead structure may make it easier to mount components thereto while at the same time a torsion stiff structure is formed. The truss structures of the boom legs have the advantage that they provided a good stiffness to weight ratio.

(27) The crane further comprises a luffing system to set an angular orientation of the boom 15 relative to the crane housing 13. The luffing system comprises two luffing winches 20, 21 on the crane housing 13, and two respective luffing cables 22, 23 extending between the two luffing winches 20,21 on the crane housing 13 and the boom 15. One combination of luffing winch 20 and luffing cable 22 is arranged on one side of the crane 10, while the other combination of luffing winch 21 and luffing cable 23 is arranged on the opposite side of the crane 10 thereby passing the leg 3C on both sides.

(28) In this embodiment, the distance between the boom legs 15A, 15B of the A-frame at the legs 3B and 3C is not large enough to position the A-frame over the legs for storage or transport reasons. Hence, therefore the boom is supported from the hull 2 in between the two legs 3B, 3C as shown in FIGS. 1 and 3. However, it is also possible to position the boom on the opposite side of leg 3C as shown partially in FIG. 3, which has the advantage that more deck space is available for storage of other components.

(29) The hammerhead structure 17 at the end of the A-frame and nearby components of the boom 15 are depicted in more detail in FIGS. 4 and 5.

(30) In FIG. 4, the boom legs 15A, 15B of the A-frame are depicted and it can be clearly seen that the boom legs are connected to each other via the hammerhead structure 17. The hammerhead structure 17 comprises outriggers 17A, 17B extending beyond the boom legs 15A, 15B of the A-frame seen in plan view. Each outrigger 17A, 17B comprises a respective sheave block 24, 25 to which the respective luffing cables 22 and 23 are connected, thereby allowing to set the angular orientation of the boom relative to the crane housing by paying out or hauling in the luffing cables 22, 23 with the luffing winches 20,21. The sheave blocks 24, 25 are also schematically depicted in FIG. 5.

(31) The crane 10 further comprises three main hoisting systems. Components of the three main hoisting systems will be indicated using a similar reference numeral followed by a .X, where X will be 1, 2 or 3 to indicate one of the three main hoisting systems.

(32) Each main hoisting system comprises a hoisting cable 30.1, 30.2, 30.3, a sheave block 31.1, 31.2, 31.3, and a hoisting block 32.1, 32.2, 32.3. Each sheave block 31.1, 31.2, 31.3 comprises in this embodiment a plurality of sheaves that are rotatable about a respective sheave rotation axis 33.1, 33.2, 33.3. The sheave blocks 31.1, 31.2, 31.3 are arranged on the hammerhead structure, in this embodiment within the contour of the A-frame, i.e. not arranged on the outriggers 17A, 17B, in a side-by-side configuration, in this case in a row seen in plan view.

(33) The rotation axes 33.1, 33.2, 33.3 of the sheaves of the sheave blocks provide one degree of freedom for the hoisting cable, which degree of freedom is normally used in combination with gravity to keep the hoisting block below the corresponding sheave block independent of the angular orientation of the boom relative to the crane housing. In this embodiment, this degree of freedom is used to allow a sideways movement of the hoisting blocks as is for instance shown in FIG. 5 for the outer hoisting blocks. In FIG. 5, the outer hoisting blocks are moved sideways by an angle , which can be easily be 40 degrees.

(34) In order to keep the hoisting blocks 32.1, 32.2, 32.3 below the sheave blocks 31.1, 31.2, 31.3 independent of the angular orientation of the boom 15, each sheave block 31.1, 31.2, 31.3 is pivotable about a substantially horizontal second pivot axis 34.1, 34.2, 34.3 perpendicular to the sheave rotation axis 33.1, 33.2, 33.3 of the corresponding sheaves of the sheave block 31.1, 31.2, 31.3.

(35) The three main hoisting systems each further comprise a hoisting winch 35.1, 35.2, 35.3 (see FIG. 1) to lift and lower the hoisting block 32.1, 32.2, 32.3 by hauling in or paying out the hoisting cable 30.1, 30.2, 30.3.

(36) The boom 15 of the crane 10 further comprises a jib 15C extending from the A-frame, i.e. extending from the hammerhead structure 17 carrying, in this embodiment, two auxiliary hoisting systems, which are similar to a main hoisting system except that the loading capacity is usually smaller and that the additional degree of freedom for the sheave blocks is not provided. In FIG. 4, a sheave block 36 associated with a first auxiliary hoisting system and a sheave block 37 associated with a second auxiliary hoisting system are depicted.

(37) An advantage of the crane 10 according to the invention is that the three main hoisting systems can be used in various ways depending on the hoisting demand. A first example is depicted in FIGS. 6A and 6B, in which FIG. 6A is a side view of FIG. 6B. In this example, only the outer hoisting blocks 32.1, 32.3 are used. The outer hoisting blocks are pivoted sideways about respective axes 33.1, 33.3 allowing to be connected to a longitudinal structure with a relatively large distance between the hoisting block. This hoisting configuration is especially suitable in case the hoisting blocks are lifted and lowered simultaneously and thus carry a load in the same order of magnitude. The two outer hoisting systems allow to control movement of the hoisted objects in two degrees of freedom.

(38) A second example is depicted in FIGS. 7A and 7B, in which FIG. 7A is a side view of FIG. 7B. In this example, all hoisting blocks are used. The outer hoisting blocks 32.1, 32.3 are spread similar to the example of FIGS. 6A and 6B, but the hoisting blocks are also pivoted about respective second pivot axes 34.1 and 34.2. The middle hoisting block 32.3 is kept straight seen in the view of FIG. 7B, but is also pivoted about second pivot axis 34.2, albeit in an opposite direction as the outer hoisting blocks 32.1 and 32.3. As a result thereof, the three main hoisting systems can be connected to three distinct locations of an object, which three locations form a triangle seen in plan view. This hoisting configuration is especially suitable in case the hoisting blocks are lifted and lowered simultaneously and thus carry a load in the same order of magnitude. The configuration further allows to control movement of the hoisted object in three degrees of freedom.

(39) A third example is depicted in FIGS. 8A and 8B, in which FIG. 8A is a side view of FIG. 8B. In this example, all hoisting blocks are used, but one of the outer hoisting blocks, in this case outer hoisting block 32.1 is combined with the middle hoisting block 32.2 to hoist one end of an object and the other outer hoisting block, in this case outer hoisting block 32.3, is used to hoist another end of an object. This configuration is especially suitable for situations in which during hoisting the load is or becomes asymmetrical, e.g. during up-ending of longitudinal structures.

(40) It is noted with respect to the example of FIGS. 8A and 8B that the sheave block 31.2 associated with the middle hoisting block 32.2 is arranged somewhat lower than the other sheave blocks 31.1 and 31.3. In other words, a centre plane 15F of the A-frame can be defined as the plane spanned by the first pivot axis 16 and the longitudinal axis 15G of the A-frame, wherein the middle sheave block 31.2 is mounted at a larger distance from the centre plane 15F than the other two outer sheave blocks 31.1 and 31.3. The advantage of this arrangement is that for large angles , in this embodiment an angle of 40 degrees, the hoisting cables 30.1 and 30.2 are not too close to each other (do not touch or interfere with each other) and in this case are parallel to each other.

(41) With reference to FIGS. 9-13, a method according to the invention will be described in which a monopile is up-ended by the crane 10 on the vessel 1 of FIG. 1. FIGS. 9 and 10 depict the rear side of the vessel 1 with the hull 2 and legs 3A and 3D and crane 10 arranged around leg 3D.

(42) On a deck 2E of the hull 2 of the vessel, a stack of monopiles 50 are provided in a substantially horizontal orientation. As shown in FIG. 9, the monopiles 50 may even extend beyond the rear side of the hull 2. Alternatively, the monopiles may be provided using a separate vessel, e.g. a barge.

(43) In FIG. 9, the boom 15 of the crane 10 is positioned for hoisting the nearest monopile 50, i.e. the monopile 50 nearest to leg 3D, and in FIG. 10, the boom 15 of the crane 10 is positioned for hoisting the monopile 50 nearest to leg 3A. Both monopiles 50 have been positioned relative to the crane 10, such that in plan view (see FIG. 9) a straight line between a centre of gravity 50C of the longitudinal structure and the slewing axis 14 of the crane 10 is perpendicular to a longitudinal axis 50D of the longitudinal structure 50.

(44) FIG. 11 depicts a monopile 50 that is suspended by the three main hoisting systems of the crane 10 (which is further omitted for clarity reasons) using the configuration of FIGS. 8A and 8B. Hence, the middle hoisting block 32.2 of the three main hoisting systems and one of the outer hoisting blocks 32.1 are connected to an upper end 50A of the monopile 50 via connection element 51.

(45) The other outer hoisting block 32.3 is connected to a lower end 50B of the monopile 50 using a gripping element 52 that is provided around the lower end 50B of the monopile 50.

(46) By synchronized hauling in of the hoisting cables 30.1, 30.2, possibly in combination with the paying out of hoisting cable 30.3, the monopile 50 is up-ended. FIG. 12 depicts the monopile 50 in an oblique orientation halfway the up-ending process, and FIG. 13 depicts the monopile 50 after up-ending. In FIG. 13 it can be clearly seen that when the hoisting blocks 32.1, 32.2 are connected to a centre of the monopile and the hoisting block 32.3 is connected to the gripping element on the side of the monopile, the hoisting cables 30.1, 30.2, 30.3 are nearly parallel to each other.

(47) After up-ending, the gripping element 52 and thereby the outer hoisting block 32.3 are disengaged for driving the monopile into a sea bottom 55. While lowering the monopile 50 towards the sea bottom 55, the monopile 50 may be guided by a guide 60 extending from the hull 2 as shown in FIG. 14. The weight of the monopile itself will cause the monopile to be partially driven into the sea bottom. The monopile can then be disconnected from the hoisting systems and a separate device for driving the monopile further into the sea bottom may be provided.

(48) FIG. 15 depicts the use of the crane 10 to install a tower 70 on top of the previously installed monopile 50. The tower may have a lower weight than the monopile, so that in case of up-ending the tower, if applicable, the crane may use the hoist configuration of FIGS. 6A and 6B. In case the tower is too heavy, the hoist configuration of FIGS. 8A and 8B can be used.

(49) FIG. 16 depicts the use of the crane 10 to install a nacelle 80 on top of the previously installed tower 70. In this embodiment, the nacelle is such a light weight component that the nacelle can be hoisted by the first auxiliary hoisting system.

(50) FIG. 17A depicts the use of the crane 10 to install a platform 100 on top of a previously installed other foundation 90 in the form of a truss construction. In this embodiment, platform 100 has a weight requiring all three hoisting systems to use the combined hoisting capacity.

(51) However, when connecting all three hoisting blocks 32.1, 32.2, 32.3 directly to the platform or indirectly via single connection element whereto the three hoisting blocks are directly connected to, it is not possible to use the full potentially available hoisting capacity.

(52) Hence, for these cases, two of the hoisting blocks, in this embodiment hoisting blocks 32.1 and 32.3 are connected to a first intermediate member 110, see FIG. 17B. The first intermediate member 110 and the other remaining hoisting block 32.3 are connected to a second intermediate member 120. Connected to the second intermediate member 120 is a load connector 130 to be connected to the platform 100. The connections between the hoisting blocks and intermediate members and the connection between the first and second intermediate members are such that the load of the platform 100 is substantially evenly distributed over the three hoisting systems, e.g. by providing sheave and cable connections between the various components.

(53) It is noted here that although the examples and embodiments described disclose the use of a specific number of winches, cables and sheaves, it is apparent to the skilled person that additional components may be provided. Hence, it is very common to use two winches for one hoisting or luffing cable or to provide additional combinations of winch and cable. In other words, any specific number provided in the description should be construed as meaning at least that specific number. The same holds for the number of main hoisting systems. Although three main hoisting systems have been described, a fourth and even a fifth main hoisting system may be provided and falls within the scope of the invention.