EP3176329B1 - Schwerkraftbasiertes fundament für offshore-windturbinen - Google Patents

Schwerkraftbasiertes fundament für offshore-windturbinen Download PDF

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Publication number
EP3176329B1
EP3176329B1 EP14898896.7A EP14898896A EP3176329B1 EP 3176329 B1 EP3176329 B1 EP 3176329B1 EP 14898896 A EP14898896 A EP 14898896A EP 3176329 B1 EP3176329 B1 EP 3176329B1
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Prior art keywords
caisson
foundation
cells
previous
mast
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Application number
EP14898896.7A
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English (en)
French (fr)
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EP3176329A1 (de
EP3176329A4 (de
Inventor
Miguel A. VAZQUEZ ROMERO
Noelia GONZALEZ PATIÑO
Elena Martin Diaz
Enrique DE FARAGÓ BOTELLA
Juan Manuel GONZALEZ ESTEBAN
Jonay CRUZ FERNANDEZ
Carlos Jesús POLIMÓN OLABARRIETA
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Dragados SA
Proes Consultores SA
Drace Geocisa SA
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Dragados SA
Drace Infraestructuras SA
Proes Consultores SA
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Priority to PL14898896T priority Critical patent/PL3176329T3/pl
Publication of EP3176329A1 publication Critical patent/EP3176329A1/de
Publication of EP3176329A4 publication Critical patent/EP3176329A4/de
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    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/32—Foundations for special purposes
    • E02D27/52—Submerged foundations, i.e. submerged in open water
    • E02D27/525—Submerged foundations, i.e. submerged in open water using elements penetrating the underwater ground
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02B—HYDRAULIC ENGINEERING
    • E02B17/00—Artificial islands mounted on piles or like supports, e.g. platforms on raisable legs or offshore constructions; Construction methods therefor
    • E02B17/02—Artificial islands mounted on piles or like supports, e.g. platforms on raisable legs or offshore constructions; Construction methods therefor placed by lowering the supporting construction to the bottom, e.g. with subsequent fixing thereto
    • E02B17/025—Reinforced concrete structures
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D23/00—Caissons; Construction or placing of caissons
    • E02D23/02—Caissons able to be floated on water and to be lowered into water in situ
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/32—Foundations for special purposes
    • E02D27/42—Foundations for poles, masts or chimneys
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/32—Foundations for special purposes
    • E02D27/42—Foundations for poles, masts or chimneys
    • E02D27/425—Foundations for poles, masts or chimneys specially adapted for wind motors masts
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E02D27/32—Foundations for special purposes
    • E02D27/52—Submerged foundations, i.e. submerged in open water
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02B—HYDRAULIC ENGINEERING
    • E02B17/00—Artificial islands mounted on piles or like supports, e.g. platforms on raisable legs or offshore constructions; Construction methods therefor
    • E02B2017/0056—Platforms with supporting legs
    • E02B2017/0069—Gravity structures
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02B—HYDRAULIC ENGINEERING
    • E02B17/00—Artificial islands mounted on piles or like supports, e.g. platforms on raisable legs or offshore constructions; Construction methods therefor
    • E02B2017/0091—Offshore structures for wind turbines

Definitions

  • This invention as its title indicates, relates to a gravity foundation for offshore wind turbines, fabricated using floating dock technology.
  • the foundations of marine wind turbines are usually either deposited directly on the sea floor (gravity) or are driven into it (monopile, tripod, or jacket). These types, as well as the variations based on them, account for approximately 95% of the foundations installed to date, with other types of foundations (artificial islands and floating foundations) observed only very infrequently.
  • gravity solutions are proposed for shallower depths, with monopile and jacket solutions applied at depths of more than 35 m and up to 50 or 60 m. Floating solutions are applied at depths greater than 60 m.
  • port caissons that are fabricated on floating docks are very well known. These are large reinforced concrete structures are able to float after they have been completed due to their voided (multi-cell) cross-section. This makes them highly versatile in terms of construction (using the slipform technique), floating transport, and placement (sinking) at the port works site, for docks, breakwaters, and other structures. Caisson breakwaters (protective works) and docks (mooring works) are used widely in Spanish ports, and the technique of fabrication using floating docks is well known in Spain, and the applicant companies are international leaders in the technology of slipform reinforced concrete construction on floating docks, because to date they have constructed more than 3,000 units.
  • port caissons have a parallelepiped shape with a rectangular or square horizontal cross-section, although in some special cases, caissons with other shapes have been used in order to conform to the conditioning factors in each project.
  • the caisson does not fully submerge during any of the sinking phases (it maintains the same sinking procedure of conventional port caissons), which avoids critical phases, at the cost of significantly increasing wave loads during the service phase, because the waves strike directly against the caisson.
  • This increase in applied loads also generates a significant increase in materials (concrete, steel, and infill), in order to provide stability against these loads.
  • the caisson has a rectangular or square horizontal cross-section, rather than circular, increasing wave loads significantly.
  • the floating foundation described in this document has a totally different structural behavior and is not subject to any type of condition such as the drafts in the manufacturing docks and the range of drafts in which the solution can be used as gravity foundation of offshore wind turbines with greater probability of success, on the contrary, it has very large dimensions, of the order of 70m in diameter, which also implies special construction processes and installations.
  • This foundation is not manufactured on a floating dock, by the simple fact that it is a series of loose parts which do not form any closed caisson by the base to float by itself; in fact it is constituted by three pieces: a substantially flat floor plate 3, a mast 4, formed by several segments 15,and a floating body, formed by several rings 19; in this foundation the base of the mast 4, on which is supported the metal tower that supports the wind turbine, is not an extension of the central cell of the caisson, firstly because in this development there is no caisson, and secondly because it is a structure different from the plate 3 and from the rings 19 that form the enveloping body 5 the body 5 responsible for providing floatability to the foundation is formed by prefabricated concrete rings 19 that are mounted around the base 4 of the mast and on the floor plate 3,can be removed after submerged, or refilled to provide more weight to the foundation.
  • this foundation does not include a solid ballast in the lower zone in order to locate the gravity centre of the assembly low enough as to maintain the floatability conditions with a metacentric height greater than 1.00 in all its phases so that it can be towed and anchored in the open sea without the need for special vessels, or use of special of additional floating means.
  • Gravity foundations of marine wind turbines also known as GBF (Gravity-Based Foundations) or GBS (Gravity-Based Structures)
  • GBF Gravity-Based Foundations
  • GBS Gvity-Based Structures
  • the developed solution presented here for the foundation of marine wind turbines is as claimed in claim 1 and consists of a structure made up of a prefabricated reinforced concrete caisson that serves as a support and to transfer all of the load of the rest of the structure to the foundation bed, fabricated on a floating dock using the technique for the fabrication of port caissons.
  • This caisson has a circular horizontal cross-section and solid concrete ballast at the bottom of the cells, with the thickness varying based on the conditions of the site, whose purpose is to guarantee stable conditions during the towing and sinking of the structure.
  • the floor of this caisson is thicker than the side walls and intermediate walls that separate the cells into which it is divided, which are distributed around a central cell, forming at least two concentric rings of cells distributed radially, which are equipped with means of communication between one another and with the exterior, equipped with drainage and fill devices to enable the self-regulation of the ballast level with seawater for sinking at the final location.
  • the ratio between the diameter of the base and the height of the caisson is between 3:2 and 8:5, and is preferably 11:7.
  • a mast extends from the central part of the caisson, with the upper end of the mast connected to the metal tower of the wind turbine by means of a metal transition piece.
  • the geometry of this mast is almost cylindrical and slightly conical, and it is fabricated out of post-tensioned concrete, a lower portion fabricated inside the floating dock itself, and the upper area (approximately above 6 m) outside of the dock so that it can be slid outside of the caisson plant.
  • the height of the caisson is such that during the service phase, it will be completely submerged (but not the tower, which has a portion that extends above the water to facilitate connection to the remaining mast at an elevation that is high enough with respect to sea level).
  • the interior of the caisson is divided into cells that are closed at the top by a reinforced concrete slab. In general, the height of the mast above the caisson is similar to the height of the caisson in question.
  • the outer wall of the caisson is voided by voids with a circular cross-section and/or voids in the top slab.
  • the radial partitions that separate the cells are also equipped with a series of gaps (windows) beginning at a certain height, so that adjacent cells are connected above that height.
  • the caisson (1) that constitutes the base of this foundation, and ultimately the support for the offshore wind turbine structure as a whole, is a prefabricated reinforced concrete caisson with a circular horizontal cross-section, 33.00 m in diameter at the floor (14) and 32.00 m in diameter across the shaft (15).
  • the floor (14) has a thickness of 1.20 m, while the cover (16) of the cells is 0.60 m thick.
  • the total height of the shaft (15) is 19.20 m, and the height of the caisson (1) (including the floor, shaft, and the top cover slab) is 21.00 m.
  • a mast (2) extends from the central part of the caisson, with the connection with the metal tower (4) of the wind turbine (6) anchored at its upper end (24) by means of a metal transition piece (3).
  • the geometry of the mast is almost cylindrical and slightly conical (the outer diameter at its base is 8.00 m and 6.00 m at the upper end).
  • This mast is fabricated of post-tensioned concrete to withstand the stresses to which it will be subjected during the service phase.
  • the first 6 metres (21) are fabricated in the caisson plant using slipforming after the caisson-base, while the upper section (22), which is slightly conical, is constructed outside of the floating dock due to its height.
  • the post-tensioning cables are tensioned from the mast head (2) after it has been completed, with the passive anchors (25) of these cables installed in the floor of the caisson (14).
  • the height of the mast (2) depends on the depth at which the foundation will be installed, such that the metal tower (4) has an elevation of connection with the post-tensioned concrete mast higher than 15 m with respect to sea level (51). This connection is made using the metal transition piece (3).
  • the circular cross-section has been feasibly demonstrated to reduce wave loads during the operation phase, as a gravity foundation for different depths, from 35 m to 50 m (always depending on the geotechnical conditions and the ocean climate of the area), and without the need to modify any of the dimensions of the caisson (only the height of the mast (2)).
  • the design of this caisson (1) takes into account that it must be fabricated entirely on a floating dock, in order to take advantage of the benefits provided by this technique. For this reason, caisson shapes have been adopted that allow the walls to be slipformed, so that the construction process is the same as for a port caisson.
  • Another conditioning factor of the construction to be taken into account is due to the fact that the depth required in the fabrication docks in accordance with the described process must be limited, because in practice, the actual availability of large-draft docks may be very scarce, depending on the location of the offshore wind farm.
  • the proposed GBS requires a depth at the fabrication dock of approximately 16.50 m. With this depth, all of the construction phases can be executed without the need for additional actions.
  • voids have been added to the structural elements of the designed GBS. There are three basic types of these voids:
  • the length of the mast will be adjusted according to the depth at which the offshore wind tower will be located, because the top elevation must be at least at the level of + 15.00 m.
  • This generates different stability conditions during the naval phase (towing and sinking), because the distribution of weight differs depending on the length of the mast in each case.
  • This variability is resolved by applying different amounts of solid ballast (7) (plain concrete) inside the cells (11 and 12) of the caisson (1).
  • plain concrete is used as solid ballast (7), with no structural function and for the sole purpose of providing sufficient weight at a low elevation in order to lower the centre of gravity of the structure and improve its conditions of naval stability.
  • the application of this solid ballast is entirely compatible with the proposed construction process, because it is carried out by simply pouring plain concrete once the caisson has exited the floating dock.
  • Figure 8 shows how this accidental conditioning factor could be addressed, using a caisson corresponding to a foundation at a depth of 35 m as an example.
  • the caisson has 0.85 m (level 52) of solid ballast and does not have liquid ballast (water), so its draft during towing is 13.55 m, and its freeboard is therefore 7.45 m, with a GM >1.00 m.
  • the caisson would heel approximately 15°, but would remain afloat without submerging, thus allowing the towing process to be completed.
  • the liquid ballast aperture valves would be activated to allow seawater to be enter by gravity into the cells of the opposite side, so that the caisson would be sunk progressively, but with even higher GM values in all of its phases.
  • the gravity structure designed in this way can be towed, using the tugboats common found in ports, to the locations where they are to be installed, where they will then be sunk by adding ballast to the interior cells of the caisson with seawater, until the caisson is permanently supported on the rockfill foundation bed.
  • the ballasting process is done by adding seawater into the caisson by gravity, using a system of valves installed on the exterior wall of the caisson, and the corresponding system of interior communication between the cells.
  • the caisson is connected by mooring lines to conventional tugboats, which use winches to act on the lines to apply different amounts of tension, allowing the structure to be positioned on the horizontal plane at the specified location and within the permitted tolerances.
  • the sinking process avoids the use of special vessels or flotation elements not integrated into the structure itself, with the design of the GBS itself providing characteristics of stability during all of the intermediate phases.
  • the next phase consists of infilling the caisson cells with granular material, which is a relatively complex operation because they are underwater and covered by slabs. Also, since these are offshore structures, they can only be accessed using sea-based equipment.
  • One of the alternatives for the process of infilling the cells consists of using hydraulic equipment (such as suction dredges) by delivering the material from the dredge through a system of pipes that are connected to the caisson by flanged connection openings in the top cover slabs of the caisson.
  • This infilling provides the GBS with the necessary weight to guarantee the stability of the foundation for the entire life span of the structure.
  • a system of valves is installed in the walls of the caisson to allow air and water to enter and exit during the flooding and cell infill phases. Using this system, the excess pressure inside the cells due to the progressive entry of water delivered from the dredge is limited and dissipates gradually.
  • the GBS design can be adapted to allow the cover slabs to be removed after the caisson has been sunk and the flooding of all of its interior cells has been completed.
  • the covers that form the top cover of the cells can be removed using a floating crane.
  • the connection of the covers to the caisson walls is configured in such a way as to allow them to be disconnected easily, by manipulating a series of latch-type closures.
  • the infill material is protected at the top by applying two layers of rockfill that are heavy enough to withstand the action of the currents and guarantee the stability of the infill in the cells for the entire life span of the structure.
  • the foundation has a circular shape that has been feasibly demonstrated to reduce wave loads during the operation phase, as a gravity foundation for different depths, from 35 m to 50 m (always depending on the geotechnical conditions and the ocean climate of the area), and without the need to modify any of the dimensions of the caisson (only the height of the mast).
  • This caisson also allows the dismantling operation to be carried out without additional hoisting or flotation equipment, because the GBS has the necessary stability during all phases of the flotation phases.

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  • General Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
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Claims (8)

  1. Schwerkraftgründung für Offshore-Windkraftanlagen, hergestellt unter Verwendung von Schwimmdocktechnologie, umfassend ein vorgefertigtes Fundament aus Stahlbeton (1) mit kreisförmigem Querschnitt, mit hohlen Zellen (11, 12, 13) für innere Hohlräume, die an der Oberseite durch eine oder mehrere Abdeckungen (16) verschlossen und mit strukturellen Hohlräumen ausgestattet sind, die sein Gewicht reduzieren, um zu ermöglichen, dass die Struktur als Ganzes über Wasser bleibt und die Herstellung auf einem Dock mit einem Tiefgang zu ermöglichen, der geringer als die Höhe des betreffenden Fundaments ist, aus dem ein Mast (2) aus nachgespanntem Beton austritt, an dem ein Turm (4) aus Metall befestigt ist, welcher die Windkraftanlage trägt, dadurch gekennzeichnet, dass das Fundament (1) ein Senkkasten ist, der innen durch einen Boden (14) verschlossen ist, der dicker als die Seitenwände und Zwischenwände ist, welche die Zellen (11, 12, 13) trennen, in welche der Senkkasten unterteilt ist, wobei die Zellenverteilung in der horizontalen Ebene eine zentrale Zelle (13) präsentiert, aus welcher der Mast (2) mit zylindrischer Konfiguration in seinem unteren Abschnitt (21) austritt und der ebenfalls in Gleitbauweise in der Senkkasten-Anlage auf dem Schwimmdock hergestellt wird, während der obere Abschnitt (22) des Mastes, vorzugsweise mit einer leicht konischen Form, später außerhalb der Fabrik des Schwimmdocks hergestellt wird;
    wobei der untere Abschnitt der Zellen (11, 12), in welche der Senkkasten unterteilt ist (1), nachdem er gebaut wurde, mit einem festen Ballast gefüllt wird, der dazu dient, den Schwerpunkt der Baugruppe abzusenken, um durch Aufrechterhaltung ihrer Schwimmfähigkeit mit einer metazentrischen Höhe von mehr als 1,00 m in allen Phasen das Schleppen und Versenken im offenen Meer zu ermöglichen, ohne dass besondere Schiffe oder zusätzliche Mittel zum Schwimmen erforderlich sind.
  2. Gründung nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass der Boden des Senkkastens eine Verteilung in der horizontalen Ebene mit einer zentralen Zelle (13) hat, um die herum mindestens zwei konzentrische Ringe von Zellen (12) und (11) ausgebildet sind, welche die gleiche radiale Verteilung haben und welche mit Mitteln zur Kommunikation untereinander und mit dem Außenbereich und mit Entwässerungs- und Füllvorrichtungen ausgestattet sind, um die Selbstregulierung des Ballastniveaus mit Meerwasser zum Sinken an die endgültige Position zu ermöglichen.
  3. Gründung nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass das Verhältnis zwischen dem Durchmesser des Fundaments und der Höhe des Senkkastens (1) zwischen 3:2 und 8:5, und vorzugsweise 11:7 liegt.
  4. Gründung nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass die Höhe des Mastes (2) von der Tiefe abhängt, in welcher die Gründung installiert werden wird, sodass ihre Verbindung mit dem Offshore-Windkraftturm (4) mittels des entsprechenden Übergangsstücks (3) aus Metall in einer Höhe von mindestens 15 m mit Bezug auf den Meeresspiegel (51) erfolgt.
  5. Gründung nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass die Abdeckung oder Abdeckungen des vorgefertigten Senkkastens (1) mit Mitteln ausgestattet sind, um das Öffnen des Senkkastens zu erleichtern, um das Ausfüllen der inneren Zellen mit einem körnigen Material zu ermöglichen, sobald die Gründung an ihrer Installationsposition mit Ballast beschwert wurde, um ihre Standfestigkeit während der Nutzungsphase zu gewährleisten.
  6. Gründung nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass die Außenwand des Senkkastens (1) eine Reihe von Hohlräumen (17) mit kreisförmigem Querschnitt durch den gesamten Schaft umfasst.
  7. Gründung nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass die radialen Trennwände der inneren Zellen des Senkkastens (1) eine Reihe von Fenstern (18) haben, die zusätzlich zur Gewichtsreduzierung die Zellen oberhalb einer bestimmten Höhe verbinden.
  8. Gründung nach den vorhergehenden Ansprüchen, dadurch gekennzeichnet, dass die obere Platte, welche die Abdeckung (16) ausbildet, eine Reihe von vorgegossenen Platten mit strukturellen Hohlräumen (81) umfasst.
EP14898896.7A 2014-07-30 2014-07-30 Schwerkraftbasiertes fundament für offshore-windturbinen Active EP3176329B1 (de)

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PL14898896T PL3176329T3 (pl) 2014-07-30 2014-07-30 Fundament grawitacyjny dla morskich turbin wiatrowych

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PCT/ES2014/070617 WO2016016481A1 (es) 2014-07-30 2014-07-30 Cimentación de gravedad para aerogeneradores offshore

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EP3176329A1 EP3176329A1 (de) 2017-06-07
EP3176329A4 EP3176329A4 (de) 2018-04-11
EP3176329B1 true EP3176329B1 (de) 2020-09-02

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DK (1) DK3176329T3 (de)
ES (1) ES2835551T3 (de)
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WO (1) WO2016016481A1 (de)

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CN110027685B (zh) * 2019-05-21 2024-03-26 福建永福电力设计股份有限公司 一种海上风电基础
EP4060123A4 (de) * 2019-11-12 2023-10-11 Beridi Maritime S.L. Struktur zur unterstützung von schiffsanlagen und verfahren zu ihrer ausführung
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CN114809063A (zh) * 2022-02-28 2022-07-29 上海勘测设计研究院有限公司 一种多分舱复合筒型基础及其施工方法
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LT3176329T (lt) 2021-02-25
PT3176329T (pt) 2020-12-09
ES2835551T3 (es) 2021-06-22
EP3176329A1 (de) 2017-06-07
DK3176329T3 (da) 2020-12-07
PL3176329T3 (pl) 2021-05-04
EP3176329A4 (de) 2018-04-11
WO2016016481A1 (es) 2016-02-04

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