Foundation for a wind turbine and method of making same

Abstract

A method for assembling a modular foundation of a wind turbine having a base and a plurality of foundation sections includes positioning the base of the foundation on a support surface, arranging a plurality of tensioning elements so as to extend from the base to a second location spaced from the base, and stacking a plurality of foundation sections on the base by guiding the foundation sections from the second location toward the base using the tensioning elements. A modular wind turbine foundation includes a base positioned on the seabed; a plurality of tensioning elements extending from the base to a location adjacent the surface of the water; and a plurality of serially stacked foundation segments on top of the base.

Claims

1. A method of assembling a foundation for an offshore wind turbine installation, the foundation having a modular design including a base and a plurality of foundation sections, the method comprising: lowering the base of the foundation through a body of water so as to position the base on a seabed; arranging a plurality of tensioning elements so as to extend from the base to a second location positioned adjacent a surface of the body of water; threading an end of each of the plurality of tensioning elements at the second location through bores formed in one of the plurality of foundation sections and lowering the foundation section towards the base so that movement of the foundation section toward the base is guided by the plurality of tensioning elements; and repeating the threading and lowering steps to stack each of the plurality of foundation sections on the base and thereby assemble the foundation for the offshore wind turbine installation.

2. The method of claim 1, wherein the second location is above the surface of the body of water.

3. The method of claim 1, further comprising tensioning the tensioning elements after having stacked the plurality of foundation sections on the base.

4. The method of claim 3, wherein tensioning the tensioning elements is done above the surface of the water.

5. The method of claim 1, further comprising: using the tensioning elements to self-align the bores in the plurality of foundation sections; and filling the bores with a filler material after having stacked the plurality of foundation sections on the base.

6. The method of claim 1, wherein each of the foundation sections includes a central passageway inboard of the bores, the method further comprising: using the tensioning elements to self-align the central passageways in the plurality of foundation sections; and filling the central passageways with a filler material after having stacked the plurality of foundation sections on the base.

7. A method of constructing an offshore wind turbine installation, comprising: assembling the foundation for the offshore wind turbine installation according to claim 1; and coupling a wind turbine to the foundation.

8. The method of claim 1, wherein each of the plurality of tensioning elements extends continuously from the base to the second location.

9. A method of assembling a foundation for a wind turbine, the foundation having a modular design including a base and a plurality of foundation sections, the method comprising: positioning the base of the foundation on a support surface; arranging a plurality of tensioning elements so as to extend from the base to a second location spaced from the base, the second location located adjacent to a water surface; and stacking the plurality of foundation sections on the base by sequentially threading an end of each of the plurality of tensioning elements at the second location through bores formed in each of the plurality of foundation sections so that movement of each of the plurality of foundation sections from the second location toward the base is guided by the plurality of tensioning elements.

10. The method of claim 9, further comprising tensioning the tensioning elements after having stacked the plurality of foundation sections on the base.

11. The method of claim 10, wherein tensioning the tensioning elements is done from a top end of the foundation.

12. The method of claim 9, further comprising: using the tensioning elements to self-align the bores in the plurality of foundation sections; and filling the bores with a filler material after having stacked the plurality of foundation sections on the base.

13. The method of claim 9, wherein each of the foundation sections includes a central passageway inboard of the bores, the method further comprising: using the tensioning elements to self-align the central passageways in the plurality of foundation sections; and filling the central passageways with a filler material after having stacked the plurality of foundation sections on the base.

14. The method of claim 9, wherein each of the plurality of tensioning elements extends continuously from the base to the second location.

15. A foundation for an offshore wind turbine installation, comprising: a base positioned on the seabed of a body of water; a plurality of tensioning elements, each tensioning element having a first end permanently embedded within the base and a second end adjacent a surface of the body of water; and a plurality of serially stacked foundation sections on top of the base, each foundation section having a plurality of bores positioned internally within the foundation section and each of which receives a respective one of the plurality of tensioning elements therethrough, the stacked foundation sections extending to a location above the surface of the body of water, and wherein the tensioning elements are configured to guide the plurality of foundation sections from the second end toward the base.

16. The foundation of claim 15, wherein the base includes a cross dimension greater than the cross dimension of the plurality of foundation sections.

17. The foundation of claim 15, wherein the foundation sections have ends, confronting ends of adjacent foundation sections having non-planar interfaces that cooperate so as to orient one foundation section relative to its adjacent foundation section.

18. The foundation of claim 15, wherein each of the plurality of tensioning elements extends continuously between the first and second ends.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various embodiments of the invention and, together with a general description of the invention given above and the detailed description of the embodiments given below, serve to explain the embodiments of the invention.

(2) FIG. 1 is perspective view of an offshore wind turbine installation having a foundation in accordance with an embodiment of the invention;

(3) FIG. 2 is a perspective view of a base of the foundation shown in FIG. 1;

(4) FIG. 3 is a perspective view of a foundation section of the foundation shown in FIG. 1;

(5) FIG. 4 is a top plan view of the foundation section shown in FIG. 3;

(6) FIG. 5 is a partial cross-sectional view of the foundation shown in FIG. 1 adjacent a top end of the foundation;

(7) FIG. 6 is a partial cross-sectional view illustrating the initial stages of placement of the base of the foundation on the seabed during assembly;

(8) FIG. 7 is a partial cross-sectional view similar to FIG. 6, but illustrating the base resting on the seabed;

(9) FIG. 8 is a partial cross-sectional view illustrating the initial stages of placement of the foundation sections of the foundation on the base during assembly;

(10) FIG. 9 is a partial cross-sectional view similar to FIG. 8, but illustrating the foundation section on the base;

(11) FIG. 10 is a partial cross-sectional view of adjacent foundations sections having interlocking features in accordance with a first embodiment;

(12) FIG. 11 is a partial cross-sectional view similar to FIG. 10, but illustrating a second embodiment of interlocking features;

(13) FIG. 12 is a partial cross-sectional view of the assembled foundation; and

(14) FIG. 13 is an enlarged view of the circled portion shown in FIG. 12.

DETAILED DESCRIPTION

(15) With reference to FIG. 1, an offshore wind turbine installation 10 includes a foundation 12 generally disposed in a body of water 14 and supported by the seabed 16, and a wind turbine 18 fixedly secured to the foundation 12. The wind turbine 18 includes a tower 20, a nacelle 22 disposed at the apex of the tower 20, and a rotor 24 operatively coupled to a generator (not shown) housed inside the nacelle 14. The rotor 24 includes a central hub 26 and a plurality of blades 28 that project outwardly from the central hub 20 at locations circumferentially distributed thereabout. The blades 28 are configured to interact with the passing air flow to produce lift that causes the central hub 26 to spin about its central axis. In accordance with embodiments of the invention, the foundation 12 is designed so as to provide a lower cost, less complex alternative to existing methods and foundations used in medium water depth wind turbine installations. More particularly, foundation 12 has a modular design that overcomes many of the drawbacks of existing foundations and their installation.

(16) In this regard and in reference to FIGS. 1-4, foundation 12 includes a base 30 configured to be supported on the seabed 16, and a plurality of serially stacked foundation sections 32 arranged on top of the base 30 and configured to extend to adjacent the surface 34 of the water 14. In one embodiment, for example, the foundation sections 32 may extend slightly above the surface 34 of the water 14, as illustrated in FIG. 1. The foundation 12 may further include a platform 36 to which the wind turbine 18 is secured. In one embodiment, foundation 12 is configured as a gravity foundation wherein the collective weight of the foundation 12 sufficiently stabilizes the wind turbine 18 relative to the seabed 16. In this way, the costs associated with piles, ballasts, extensive seabed preparation, etc. may be avoided or at least reduced. However, unlike other gravity foundations, these cost benefits may be achieved while also minimizing transportation and assembly costs, as will now be explained.

(17) As illustrated in FIGS. 1 and 2, the base 30 is configured to rest on the seabed 16 and, in one embodiment, may be formed as a generally solid body having a generally cylindrical configuration. Although the base 30 is shown and described as being generally cylindrical, it should be recognized that the base 30 may have a wide range of shapes including rectangular, square, triangular, octagonal, etc (not shown). By way of example and not limitation, the base 30 may be formed from concrete, reinforced concrete, or other materials suitable for long term submersion in a water environment including, for example, a salt water environment. The cross dimension and the height of the base 30 may vary depending on the particular wind turbine installation (e.g., water depth, general water conditions, wind turbine size, etc.). However, as illustrated in FIG. 1, the base 30 may be generally larger and heavier than the foundation sections 32 that make up a significant portion of the foundation construction. As is recognized, configuring the base 30 larger than the foundation sections 32 provides for a more stable modular configuration.

(18) Due to the relatively large size of foundation 12 as a whole, foundation 12 includes tensioning elements that enhance the strength and structural integrity of the overall foundation 12. To this end, and in accordance with one embodiment of the invention, the foundation 12 includes a plurality of tensioning cables 38 extending along at least a portion of the length of the foundation 12. For example, in one embodiment, the tensioning cables 38 may extend from the base 30 to adjacent the surface 34 of the water 14, such as at platform 36 (FIG. 5). More particularly, and as illustrated in FIG. 2, base 30 includes a plurality of tensioning cables 38 having a first end 40 securely embedded within the base 30 and extending upwardly therefrom in a direction away from the seabed 16 and toward surface 34. By way of example, the ends 40 of the tensioning cables 38 may be positioned in a concrete pre-form prior to pouring the concrete such that the ends 40 are securely embedded therein upon curing of the concrete that forms base 30. Alternatively, the ends 40 may be inserted into pre-formed (e.g., during casting) or post-formed bores in base 30 and the bores subsequently filled with concrete or other suitable filler material that secures the ends 40 to base 30 (not shown). Still further, the base 30 may include various securing devices coupled thereto configured to capture the ends 40 of tensioning cables 38 upon their insertion therein (not shown). Other processes, devices, etc. may also be used to securely fix the ends 40 of tensioning cables 38 to base 30.

(19) As illustrated in FIGS. 1, 3 and 4, a significant portion of the foundation 12 is formed by a plurality of serially stacked foundation sections 32 located on top of base 30. Each of the foundation sections 32 may be formed as a generally tubular body having a generally cylindrical configuration and a central passageway 44 (e.g., the foundation sections may be hollow). A plurality of throughbores 46 may be disposed outboard of the central passageway 44 and be configured to receive a tensioning cable 38 therethrough. Similar to above, although the foundation sections 32 are shown and described as being generally cylindrical, it should be recognized that the sections 32 may have a wide range of shapes including rectangular, square, triangular, octagonal, etc (not shown). The central passageway 44 may also have a wide range of shapes, which may or may not correspond to the overall shape of the foundation sections 32.

(20) The foundation sections 32 may be formed from concrete, reinforced concrete, or other materials suitable for long term submersion in a water environment. The cross dimension and the height of the foundation sections 32 may vary depending on the particular wind turbine installation or other considerations. For example, the size of the foundation sections 32 may be selected in a manner that optimizes their transport to the offshore site. In any event, the size of the foundation sections 32 are such that the heavy lift crane vessels typically used in medium water wind turbine installations are not needed for assembly and/or placement of the foundation sections, as will be discussed in more detail below.

(21) As illustrated in FIGS. 1 and 5, the foundation sections 32 are stacked one on top of another until the foundation 12 extends to adjacent the surface 34 of the water 14, such as above the surface 34 of the water 14. As noted above, a platform 36 may be positioned atop the last foundation section 32. In this regard, the platform 36 may include throughbores 48 that are aligned with the throughbores 46 in the foundation sections 32 so as to receive the tensioning cables 38 therethrough. In one embodiment, the platform 36 may include a steel plate 50 that facilitates post-tensioning of the tensioning cables 38.

(22) To protect the tensioning cables 38 from the water, the cables 38 may be clad in polyurethane or other protective covering 52 (FIG. 13). Additionally, the throughbores 46 in the collection of foundations sections 32 (and possibly the throughbores 48 in the platform 36), which receive the tensioning cables 38, may be filled with suitable filler material 54 that further protects the tensioning cables 38 from the negative effects of the water environment. For example, the throughbores 46, 48 may be filled with a treated concrete suitable for sealing the cables 38 from the water. Furthermore, the central passageway 44 in the collection of foundation sections 32 may also be filled with concrete or other suitable filler material 56. Filling the central passageway 44 with a filler material 56 increases the overall weight of the foundation 12, further increasing the stability of the wind turbine 18 mounted to foundation 12.

(23) A method of forming or assembling foundation 12 will now be explained in greater detail. In accordance with one aspect of the invention, the modular nature of foundation 12 avoids the need to use a heavy lift crane vessel to erect the foundation 12. Instead, and as illustrated in FIG. 6, it is contemplated that a vessel 60 having a relatively small gantry crane 62 may be sufficient to erect the foundation 12. In this regard, the crane 62 does not have to be sized so as to lift the entire foundation 12, as in previous methodologies, but may be sized to lift the heaviest component thereof, which in the normal course is expected to be base 30. As the base 30 is much smaller in size and weight in comparison to the overall foundation 12, a much smaller crane may be utilized to assemble the foundation 12. The utilization of such a smaller crane significantly reduces the transportation and assembly costs of the offshore wind turbine installation 10. Although a gantry crane 62 is illustrated in the figures and described in an exemplary embodiment, it should be recognized that other cranes may also be used to erect the foundation 12. In any event, it is expected that the particular crane utilized will be significantly smaller than the heavy lift vessel cranes currently used such that a similar reduction in transportation and assembly costs would result.

(24) In regard to the particulars of the exemplary methodology and as illustrated in FIGS. 6 and 7, in a first step, the base 30 of foundation 12 may be lowered down to the seabed 14 using, for example, crane 62. As noted above, the tensioning cables 38 have a first end 40 embedded or otherwise coupled to base 30, which is preferably done prior to the base 30 being submersed in the water 14. However, in alternative embodiments, the first end of the tensioning cables 38 may be coupled to base 30 after submersion. Thus, in accordance with an exemplary method, the base 30 is positioned on the seabed 16 such that the tensioning cables 38 extend from the base 30 toward the surface 34. For example, a second end 64 of the tensioning cables 38 may terminate adjacent surface 34. In one embodiment, the second end 64 of cables 38 may be positioned above the surface 34 of the water 14. It should be recognized that prior to positioning the base 30 on seabed 16, and depending on the particular conditions of the seabed 16 at the wind turbine installation site, some preparation of the seabed 16 may have to be performed to ensure the base 30 is properly supported thereon. Such preparation techniques are generally known in the industry and will not be explained in further detail herein.

(25) As illustrated in FIGS. 8 and 9, after the base 30 of foundation 12 has been positioned on the seabed 16, a first foundation section 32 may be lowered through the water 14 using, for example, crane 62 and positioned on top of the base 30. In this regard, the foundation sections 32 may include a connecting element, such as cross bar 65 extending across central passageway 44 adjacent at least one of the ends of foundation section 32. The connecting element is configured to cooperate with a corresponding connecting element on gantry crane 60 to allow crane 60 to move the foundation sections 32. For example, the gantry crane 62 may include a hook 66 configured to engage cross bar 65 for lifting, moving or otherwise manipulating foundation sections 32. Those of ordinary skill in the art may recognize a wide variety of other connecting elements that allow crane 62 to move foundation sections 32. Such connecting elements may also be used to manipulate base 30.

(26) In a particularly advantageous aspect of the invention, the tensioning cables 38 are used as a guide for guiding the foundation section 32 from a location adjacent surface 34 of the water 14 to its proper position in foundation 12 (e.g., such as beneath the surface 34 of the water 14). In this regard, the second ends 64 of the tensioning cables 38 may be inserted through bores 46 (i.e., threaded through bores 46) of the foundation section 32 topside (e.g., above the surface 34), such as on vessel 60 (FIG. 8). After threading the cables 38 through bores 46, the foundation section 32 may be lowered by crane 62 into position on top of the base 30. As noted above, as the foundation section 32 is being lowered beneath the surface 34 of the water 14, the tensioning cables 38 essentially limit its movement and guide the section 32 into place. Such a bead on a string approach exemplified by the present method tremendously simplifies and increases the speed of the assembly process of foundation 12. Of course after the placement of the first foundation section 32, another foundation section 32 may be threaded onto the tensioning cables 38 and lowered into place on top of base 30 (and on top of the prior foundation section). This process may continue until the foundation 12 is at its desired height, such as extending above the surface 34 of the water 14.

(27) Using the tensioning cables 38 as a guide for placing the foundation sections 32 provides additional benefits. For example, for purposes mentioned above and discussed further below, it is considered important that after the foundations sections 32 are stacked, the throughbores 46 of the sections 32 be substantially aligned so as to form one generally continuous conduit (FIG. 12). Using the tensioning cables 38 as a guide essentially provides a self-alignment feature such that the throughbores 46 are aligned upon placement of the foundation sections 32, i.e., the sections 32 are in essence automatically aligned as a result of the particular methodology described above. Accordingly, small, frustrating, and time-consuming adjustments to the placement of the foundation sections 32 during assembly so as to align the bores 46 of adjacent sections 32 may be avoided.

(28) In addition to the above, and to further facilitate proper alignment of adjacent foundation sections 32, the ends 68 of the foundation sections 32 may be shaped to facilitate seating of adjacent sections and alignment of throughbores 46. By way of example, and as illustrated in FIGS. 10 and 11, in various embodiments the ends 68 of the sections 32 may not be generally planar, but instead may be distorted or convoluted in some manner to provide an interlocking feature to the sections 32. FIG. 10, for example, illustrates the ends 68 having a wavy pattern 70 (e.g., sinusoidal shape) formed therein. FIG. 11 illustrates the ends 68 as having alternating projections 72 and recesses 74. In this way, when two sections 32 are put end-to-end, such a during assembly of foundation 12, the positioning of one section relative to the other section must take on a certain orientation or configuration before the sections 32 may be successfully mated together. This orienting required for seating adjacent sections 32 allows the positioning of features (such as bores 46) to become predictable by virtue of the seating. In addition or alternatively, the ends 68 may include other interlocking features, such as tongue and groove features (not shown), that prevent or minimize relative movement between two adjacent foundation sections 32.

(29) Due to one or more of these above-described features, the foundation 12 may be assembled such that the throughbores 46 and/or the central passageways 44 of the foundation sections 32 are aligned so as to form essentially one continuous conduit along the length of the foundation 12, as illustrated in FIG. 12. Additionally, the features described above may result in the outer surface 76 of the foundation 12 being relatively smooth.

(30) In a further aspect, once the foundation sections 32 are stacked to a desired height, the platform 36 may be positioned atop the last foundation section 32. In this regard, the tensioning cables 38 may similarly be threaded through the throughbores 48 formed therein and the platform 36 guided into place thereby. This may be done, for example, by the gantry crane 62 or by another relatively small-sized crane. In any event, the tensioning cables 38 again provide a self-alignment feature that, in essence, aligns the throughbores 48 in the platform 36 with the throughbores 46 in the foundation sections 32.

(31) With the platform 36 in place, the tensioning cables 38 may be tensioned. Thus, in the exemplary embodiment the tensioning cables 38 operate as post-tensioning elements which are tensioned after assembly of the foundation 12. In this regard, once the platform 36 is in place, the cables 38 may be tensioned, such as by pulling on the second ends 64 or by other known methodologies, so as compress the foundation 12 together. As is understood in the art, tensioning cables 38 significantly improve the strength and structural integrity of the foundation 12. Unlike many conventional post tensioning techniques, however, which impose tension at the bottom or lower end of the structure, in the present embodiment, the tension is applied at the top or upper end of the structure. Of course in the instant implementation, tensioning from the upper end may be advantageous in that it may be done adjacent surface 34, such as from a surface of a vessel, instead of having to be done adjacent the seabed 16. In any event, the tensioning cables 38 may be tensioned and appropriately terminated so as to maintain the tension formed therein.

(32) After the cables 38 are tensioned, or alternatively prior to tensioning the cables 38, the througbores 46 may be filled with treated concrete or other filler materials 54 to further protect the cables 38 from the water environment. In this regard, a fill pipe (not shown) may be inserted into the throughbores 46 so as to dispense the fill material 54 into the throughbores 46. The fill material 54 is configured to have a higher density than the water such that the fill process forces the water out of the bores 46 as the bores 46 are being filled. Once the fill material 54 cures, the tensioning cables 38 are further protected from the corrosive or other undesirable effects of the water. A similar process may also be used to fill the elongate conduit formed by the plurality of aligned central passageways 44 of the foundation sections 32 with fill material 56. As noted above, this process may be utilized to increase the overall weight of the foundation 12 and thus enhance its stability.

(33) With the foundation 12 fully assembled as described above, the wind turbine 18 may be assembled and coupled to foundation 12 in accordance with methodologies known in the art. Through these known methodologies, and in one embodiment, the wind turbine tower 20 may be positioned on the platform 36 and securely fastened thereto by, for example, a plurality of nuts threadably coupled to corresponding throughbolts projecting from the platform 36 and extending through holes in a flange at the lower end of the tower 20.

(34) While the invention has been illustrated by a description of various embodiments and while these embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. For example, while the methods described above were directed to offshore foundation construction, similar methodologies may be employed for onshore construction. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus, representative methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general inventive concept.