Patent Publication Number: US-2023137682-A1

Title: Upending and lifting tool

Description:
The invention relates to an upending and lifting tool that is to be suspended from one or more hoisting cables, e.g. from a crane hook of a crane. The tool is envisaged for use in the installation of a wind turbine, in particular for upending and lifting of a monopile of an offshore wind turbine. The tool may also be applied for other purposes, e.g. upending other piles, e.g. piles used for fixing a jacket-type foundation to the seabed, for mooring, etc. The tool could also be of use for upending other wind turbine components, e.g. like the mast, or of a jacket-type foundation. 
     In the field of monopile installation, upending of a monopile from a horizontal orientation into a vertical orientation commonly entails the use of an upending and lifting tool. 
     In a known embodiment, the tool comprises a frame that is provided with a functional part that is operable for coupling to the upper end of the monopile, e.g. onto a flange at the upper end or by frictionally gripping a part of the upper end, e.g. with an annular array of operable friction grip members of the tool engaging the inside of the upper end of the monopile. 
     An example of a rather complex upending and lifting tool is disclosed in EP3574149. 
     Another example is disclosed in DE202009006507U1, FIGS. 9d and 9e thereof. 
     In the tool of EP3574149 a robust and heavy pivotal arm is pivotally mounted to an attachment member of the frame at an inner end thereof, with the lower ends of the cables being attached to the outer end or free end of the pivotal arm. A hydraulic cylinder arrangement is provided to cause a forced pivoting of the pivotal arm relative to the frame of the tool allowing for the frame to be moved between the vertical and horizontal orientations thereof. The latter orientation is of use when the tool is to be coupled to the horizontally oriented monopile prior to the upending thereof. 
     In the tool of DE202009006507U1 the above-mentioned robust and heavy pivotal arm is absent. Instead, the one or more cables are at their lower end pivotally connected to the attachment member of the frame via a shackle. This arrangement does not allow for any controlled pivoting of the frame into the horizontal orientation. Mounting the tool to a horizontally arranged monopile is done by first lifting the tool using another cable, e.g. using another crane, e.g. a smaller crane, that is connected to a stationary stabilization arm of the frame that extends in longitudinal direction. The cable is attached to this stabilization arm at a point that is vertically above the center of gravity when the frame is in the horizontal orientation. 
     The present invention aims to provide an improved or at least alternative upending and lifting tool which provides for controlled motion of the frame between the horizontal orientation and vertical orientation. 
     The present invention proposes an upending and lifting tool according to claim  1 . 
     The invention is based on the insight that by the application of a cable shifting force to the one or more hoisting cables above the pivot axis where the cable(s) connect to the frame, so somewhere along the length of the one or more cables, the pivoting movement of the frame can be obtained without the use of the robust heavy pivotal arm as in EP3574149. It is noted that in the inventive tool the weight of the tool and of the object that is upended/lifted thereby, is absorbed by the one or more cables that attach to the attachment member of the frame, and the cable shifting mechanism only applies the force that is required for the controlled pivoting of the frame of the tool. This allows for a reduction in weight and size of the tool compared to EP3574149. Compared to DE202009006507U1 the handling of the tool is simplified. 
     Preferably, the cable shifting member comprises one or more pivotal cable shifting arms. For instance, the tool comprises two laterally spaced cable shifting arms connected at their outer ends by a horizontal cable engaging member, e.g. a horizontally extending tube. 
     The one or more pivotal cable shifting arms are at the inner end thereof pivotally connected to the frame. One or more shifting actuators are operative between the frame on one hand and the cable shifting arm(s) on the other hand. These shifting actuators are provided to drive the movement of the cable shifting member which brings it into engagement with the one or more hoisting cables when the frame is still vertically, and applies the force thereon so that, in reaction, the controlled pivoting of the frame to the horizontal orientation is caused. 
     In a preferred embodiment, the cable shifting member, for example comprising one or more pivotal cable shifting arms, forms one unitary rigid part, movable, e.g. pivotal, as a whole relative to the frame. The one or more of the shifting actuators are operative between the frame and the cable shifting member. 
     In an embodiment, the one or more cable shifting arms are each embodied as articulated arms each comprising multiple pivotally interconnected arm segments. 
     In an embodiment, the one or more cable shifting arms are telescopic, comprising one or more telescoping arm segments. 
     In a preferred embodiment, the one or more cable shifting arms form part of a four-bar mechanism together with one or more driven linkage members, one or more intermediate linking members, and a section of the frame. Herein, the one or more driven linkage members are each pivotally mounted at an inner end thereof to the frame. The one or more intermediate linkage members are each pivotally connected at an inner end thereof to an outer end of a respective one of the driven linkage members, and at an outer end thereof pivotally connected to a respective one of the cable shifting arms, at a location between the pivotally connected inner end and the engagement member. For example, this location is approximately halfway in between the inner end and the engagement member. The location determines a lever action of the cable shifting arm, amplifying the movement. 
     In an embodiment, the one or more shifting actuators drive pivoting of the driven linkage members in the direction of the hoisting cables, and, via the intermediate linkage members, thereby pivoting of the one or more arms in the direction of and against the hoisting cables, and thereby the engagement of, and application of the cable shifting force to, the hoisting cables. The pivotal motion of the frame is a reaction to the application of the cable shifting force that is exerted against the one or more cables by the mechanism. 
     For example, the one or more shifting actuators are hydraulic cylinders. As preferred, the tool is provided with a hydraulic power unit connected to the one or more hydraulic cylinders, e.g. arranged on the frame of the tool. 
     For example, the one or more shifting actuators are controllable by a remote control. 
     The cable engagement surface may, for example, be formed by a circular cross-section tube, by one or more rollers, or by another, preferably low-friction, surface. 
     In an embodiment, the inner end of the cable shifting member may be mounted, for example pivotally mounted, to the frame at a location above the pivot axis of the tool when the frame is in the horizontal orientation. 
     If the tool has the four-bar linkage mechanism integrated with the cable shifting member, preferably the inner end of the driven linkage member is connected to the frame at a location which is below the pivot axis when the frame is in a horizontal orientation, and the one or more shifting actuators are connected to the frame at a location that is below the pivot axis when the frame is in a horizontal orientation. 
     In an embodiment, the one or more shifting actuators are one or more hydraulic cylinders, of which one end is connected to the frame and another end to the cable shifting member, e.g. to the arms. For example, an extension of the one or more cylinders drives the pivoting of the cable shifting member towards and against the one or more hoisting cables. 
     In an embodiment with the four-bar linkage mechanism, the other ends of the one or more cylinders may be mounted to the driven linkage member(s) and via these driven linkage member(s) and the intermediate linkage member(s) connected to the cable shifting arm(s). 
     In an embodiment, the tool further comprises a lock mechanism, which is operative between the cable shifting member on one hand and the frame on the other hand. The lock mechanism is configured to secure the position of the cable shifting member relative to the center of gravity—in the horizontal orientation of the frame—such as to retain the frame in the horizontal orientation. 
     In an embodiment, the lock mechanism comprises the one or more cable shifting actuators. For example, when the shifting actuators are embodied as hydraulic cylinders, the shifting actuators are configured to secure the position by maintaining the extension when the frame is in the horizontal orientation. 
     In an embodiment, the functional part of the tool is operable for gripping in the horizontal orientation a longitudinal end of a wind turbine component, for example of a monopile or a mast, and retaining the longitudinal end during upending of the wind turbine component from a horizontal to a vertical orientation thereof while pivoting towards the vertical orientation. Various embodiment of the functional part are, for example, described in EP3574149 and DE202009006507U1. 
     In an embodiment, the cable engagement surface extends over a horizontal distance which covers two or more adjacent hoisting cables, for instance extends over 5-10 meters horizontally. 
     In an embodiment the functional part is operable for coupling the tool to the object, and the functional part of the tool comprises one or more guiding members configured to guide the tool into engagement with the object when the frame is in the horizontal orientation. For example, the object is a wind turbine component, e.g. a monopile or a mast, in a horizontal orientation. The functional part is operable for gripping the wind turbine component in the horizontal orientation of the frame and for retaining the wind turbine component during upending of the wind turbine component from the horizontal orientation of the component to a vertical orientation thereof while the frame pivots towards the vertical orientation of the frame. For example the functional part is configured for gripping onto a flange at an upper end of the wind turbine component, e.g. the monopile or mast, or for frictionally gripping a part of the upper end, e.g. with an annular array of operable friction grip members of the tool engaging the inside of the upper end of the monopile. 
     For example each guiding member is configured to, when the tool is relatively proximate to the object, engage the object. The engagement by the guiding members is such as to restrict movement of the tool in at least radial directions relative to the object, and configured to during a movement of the tool towards a position wherein it can couple to, e.g. can grip, the object, maintaining the engagement thereof such as to guide the tool towards the coupling position. In an embodiment two guiding members are provided in the form of guiding arms of which outer ends are to engage the object. The arms are for instance pivotally mounted to the frame of the tool, e.g. such that the outer ends are movable in a radial direction, and/or operated by means of one or more guiding actuators. In either form, the guiding members are configured for restricting a movability of the frame relative to the object by contacting the object, e.g. through an impact with and/or a pushing off, e.g. an active pushing off, against the object, e.g. prior to any coupling members, e.g. gripping members, contacting the object. 
     The invention also relates to an installation vessel for a foundation member of an offshore wind turbine, e.g. a monopile, which vessel is provided with a crane and a tool as described herein. 
     The invention also relates to a method for upending and lifting an object, e.g. a foundation member of an offshore wind turbine, e.g. a monopile, wherein use is made of an upending and lifting tool as described herein. 
     With the tool suspended from one or more hoisting cables, e.g. from a crane hook of a crane, and with the frame initially in the vertical orientation, a routine is performed which comprises operating the one or more shifting actuators, thereby moving the cable shifting member and engaging the cable engagement surface with the one or more hoisting cables at a height above the pivot axis and further continuing said motion of the cable shifting member and thereby applying a cable shifting force on the one or more hoisting cables resulting, in reaction, in a pivoting of the frame into the horizontal orientation thereof. 
     The routine is, for example, to be performed after pick-up of the tool by means of a crane, e.g. from a deck of a vessel, with the frame initially in the vertical orientation so as to bring to tool with the frame thereof in horizontal orientation, followed by engaging the tool with the object in horizontal orientation, e.g. a monopile horizontally aboard of vessel. 
    
    
     
       The invention will now be described with reference to the appended drawings. In the drawings: 
         FIG.  1    shows schematically in a back-side perspective view an upending and lifting tool according to the invention, with the frame in the horizontal orientation thereof while approaching a longitudinal end of a monopile lying horizontally; 
         FIG.  2    shows in a side view schematically the same upending and lifting tool, with the frame in the vertical orientation thereof, e.g. as the tool is picked up by a crane; 
         FIGS.  3 , 4    show in the same side view schematically the upending and lifting tool while the cable shifting member engages the hoisting cables; 
         FIG.  5    shows in the same side view schematically the upending and lifting tool while the frame is in the horizontal orientation, engaging a longitudinal end of a monopile; 
         FIG.  6    shows in a front view schematically the same upending and lifting tool, with the frame in the horizontal orientation thereof; 
         FIG.  7    shows in the same side view as  FIG.  1    schematically the displacement of the frame from the vertical to the horizontal orientation illustrating the pivoting and the cable shifting action. 
     
    
    
       FIGS.  1 - 7    show an upending and lifting tool  1  according to an embodiment of the invention. The upending and lifting tool is suspended from one or more hoisting cables  101 , here a pair of cable slings suspended from a hook  102  of a crane. For example, the cable slings are steel wire slings, or, more preferably, synthetic rope slings. 
     The tool  1  comprises a frame  3  with a functional part that is operable for coupling to an object  201 . 
     In this case the object  201  is a wind turbine component, namely a monopile  201 . 
     The functional part  3  is operable for engaging a longitudinal end of the monopile  201  in both a horizontal and vertical orientation of the monopile, and for retaining this end while the monopile  201  is moved between a horizontal and a vertical orientation by hoisting the retained end by means of the hoisting cables  101 . 
     In  FIG.  1   , the monopile  201  is in a horizontal orientation and the tool  1  is shown approaching the monopile  201 , with the frame thereof having been pivoted into the horizontal orientation. 
     In  FIG.  5   , the monopile  201  is in a horizontal orientation as well, and the tool  1  is shown engaging the monopile  201 . 
     The tool  1  comprises a cable attachment member  2  by means of which the frame  3  of the tool  1  is pivotally connected to the hoisting cables  101 , e.g. the lower ends of the slings. 
     By this connection, the tool  1  is connected to the crane hook  102  or other tool suspension device. Here the hook  102  is suspended from a hoisting block with multiple cable sheaves, e.g. in view of the fact that the monopile or other object may weight several hundreds of tonnes or even several thousand tonnes. 
     The attachment member  2  connects the frame  3  to the lower ends of the one or more hoisting cables  101  such that the frame  3  is pivotable around a substantially horizontal pivot axis P relative to the connected hoisting cables  101  between a vertical orientation  3   v , shown in  FIG.  2   , and a horizontal orientation  3   h , shown in  FIGS.  1 ,  3 ,  5 , and  6   . 
       FIG.  4    shows an intermediate orientation of the frame  3 . 
     In this embodiment, the hoisting cables  101  each have an eye forming a loop around a horizontally extending axle of the attachment member, best visible in  FIGS.  1  and  6   . 
     As shown in the figures, in the vertical orientation  3   v  of the frame  3 , the horizontal orientation  3   h  thereof and the intermediate orientation thereof shown in  FIG.  4   , the center of gravity C of the frame  3  is naturally aligned with the line of action L of the resultant upwards tensioning force T on the tool by the hoisting cables  101 . 
     The action of a cable shifting mechanism including the cable shifting member  4  accomplishes, that the frame  3  can be brought in a horizontal orientation  3   h  wherein the pivot axis P is horizontally aligned with the center of gravity C while the tool  1  is suspended from the hoisting cables  101 . 
     The cable shifting member  4 , in this example, comprises a bracket with two cable shifting arms  43 , laterally spaced from each other, and a cable engagement tube  45 . The inner ends of each arm  43  is pivotally connected to the frame  3  so as to be pivotal in a vertical plane. The outer ends of the arms  43  support the horizontally extending tube  45  that forms the cable engagement surface  41 . The tube  45 , for example, may have a length between 5 and 10 meters in practical embodiments. 
     Shifting actuators  42  are provided to be operative between the frame  3  and the cable shifting member, here via linkage members  47  and  48  of the cable shifting mechanism. These cable shifting arms  43  and linkage members  47  and  48  are laterally spaced from each other as visible in  FIGS.  1  and  6   . The tool  1  has two shifting actuators  42 , one for each cable shifting arm  43 . 
     In this embodiment, the cable shifting mechanism comprises is a four-bar linkage mechanism. The two laterally spaced apart driven linkage members  47 , each pivotally mounted with an inner end thereof to the frame  3 , two laterally spaced apart intermediate linkage members  48 , an inner end of each of which is pivotally mounted to respective outer ends of the driven linkage members  47  and an outer end of each of which is pivotally mounted to respective linking points  49  of the cable shifting arms  43 , the cable shifting arms  43 , and the section of the frame  3  between the mountings of the drive linkage member and the cable shifting arm  43  to the frame  3  form the four bars of the four-bar mechanism. 
     The cable shifting member  4  is configured to—in the vertical orientation  3   h  of the frame  3 —engage the hoisting cables  101  at a height H above the pivot axis P by means of the cable engagement surface  41 , as illustrated in  FIGS.  2  and  3   . 
     In  FIG.  3   , the cable shifting arms  43  have been moved by means of the shifting actuators  42  relative to their positions in  FIG.  2    such as to bring the cable engagement surface  41  into engagement with the hoisting cables  101  at the height H relative to their lower ends that are pivotally secured to the frame  3 . 
     In  FIGS.  3  and  4   , the shifting actuators  42  and linkage members  47  and  48  have been removed for the sake of clarity in showing the positions of the cable shifting arms  43 . 
     By means of the continued operation of the shifting actuators  42 , the cable shifting member  4  is configured to consequently apply at said height H above the pivot axis P a cable shifting force Son the hoisting cables  101 , in this case a horizontal pushing force S. This pushing force S is such as to move the frame  3  relative to the part of the hoisting cables  101  that extends above the height H above the pivot axis P. Effectively the pivot axis P displaces over a horizontal distance D to a position that is backwards from the line of action L as the frame  3  pivots upwardly. 
     In  FIG.  4   , the frame  3  has been pivoted upwardly as a result of the cable shifting force S into an intermediate orientation, and in  FIGS.  5  and  6    it has reached the horizontal orientation  3   h.    
     It is also visible in  FIG.  5    that as a result of the pushing force S and a counterforce on the tool  1  exerted by the cables  101  at the pivot axis P, the hoisting cables  110  run slanted over the horizontal distance D in the horizontal orientation  3   h  of the functional part  3 . 
     In the shown embodiment of the upending and lifting tool  1 , the cable shifting mechanism is configured to, in one continuous movement, displace the member  4  by means of the actuators  42  such as to move the frame  3  from the vertical orientation  3   v  of  FIG.  1    to the horizontal orientation  3   h  of  FIG.  4    thereof. This displacement is composed of firstly a pivoting movement of the frame relative to the hoisting cables  101  from the vertical orientation  3   v  of  FIG.  2    to an upwardly pivoted orientation, and secondly a shifting movement of the center of gravity C relative to the cable engagement surface. The first and second components take place simultaneously, as the center of gravity C will naturally remain aligned with the line of action L during the entire movement. The components are however illustrated separately in  FIG.  7    merely for understanding. For the first, pivoting component, the corresponding displacement of the center of gravity C towards an imaginary location Ci is indicated by the bold arched arrow. For the second, cable shifting component, the corresponding displacement of the center of gravity is indicated by the bold backwards arrow. 
     In the shown embodiment of the tool  1 , the shifting actuators  42  driving the pivoting of the driven linkage members  47  with respect to the frame  3  are in the form of hydraulic cylinders  42 , which are at an inner end thereof mounted to the frame  3  and at an outer end thereof to the pivot joint between the driven linkage member  47  and the intermediate linkage member  48 . Obviously it could also have been mounted to the driven linkage member  47  at another location thereof, for instance between the inner and outer end thereof, preferably close to the outer end thereof. The tube  45  is located substantially beyond the linking points  49  such that the cable shifting arms  43  function as levers amplifying the driven movement. Upon extension of the cylinder  42 , the driven linkage member  47  is pivoted towards the line of action L, pivoting via the intermediate linkage member  48  and the linking points  49  the cable shifting arms  43  towards the line of action L, and therewith the cable engagement surface  41  towards engagement with the hoisting cables  101  as shown in  FIG.  3   . 
     Once engaged, the further extension of the cylinder  42 , shown in  FIG.  4   , makes the engaging surface  41  push against the cables  101  with the horizontal force S, by which the frame of the tool  1  is pushed off against the cables  101 . 
     As visible in  FIGS.  2 ,  3  and  4    but best in  FIG.  1   , the inner end  46  of the pivotal cable shifting member  4 , here with cable shifting arms  43 , is pivotally mounted to the frame  3  at a location above the pivot axis P when the frame is in the horizontal orientation  3   h.    
     The inner ends of the driven linkage members  47  are pivotally mounted to the frame  3  at a location below the pivot axis P when the frame is in the horizontal orientation  3   h , and the one end of each cylinder  42  is pivotally mounted to the frame  3  at a location below the mounting location of the inner ends of the driven linkage members  47 . 
     The upending and lifting tool  1  comprises a lock mechanism  44  which is operative between the cable shifting member  4  on one hand and the frame  3  on the other hand. The mechanism  44  is configured to in the horizontal position  3   h  of the frame  3  secure the position of the cable engagement surface  41  relative to the center of gravity C, such as to retain horizontal orientation  3   h  of the frame  3 . The lock mechanism  44  is formed by the cylinders  42 , which are configured to remain extended after reaching the horizontal orientation  3   h  of the frame  3 . 
     From  FIG.  5    it can be verified that, as the tool is approaching a horizontally arranged monopile  201 , e.g. having a diameter of between 5 and 12 meters, the cable engagement surface  41  extends over 5-10 meters horizontally. The cable shifting arms  43  extend from respective lateral ends of the cable engagement surface  41  to the inner end  46  of the cable shifting member  4 . 
     In the shown embodiment of the tool  1 , the functional part is operable for coupling the tool  1  to the monopile  201 , and the functional part of the tool  1  comprises one or more guiding members  52  configured to guide the tool  1  into engagement with the monopile  201  when the frame  3  is in the horizontal orientation  3   h.    
     The functional part of the tool  1  is configured for gripping the longitudinal end of the monopile  201 , with multiple operable friction grip members  51  of the tool  1  which are configured to engage the inside of the longitudinal end of the monopile  201 , and to maintain the engagement such as to maintain the coupling between the tool  1  and the longitudinal end during upending of the monopile  201 . 
     Each guiding member  52  is configured to, when the tool  1  is relatively proximate to the monopile, e.g. as shown in  FIG.  5   , engage the monopile  201 . The engagement by the one or more guiding members  51  is such as to restrict movement of the tool  1  in at least radial directions relative to the monopile  201 , and configured to during a movement of the tool  1  towards a position wherein it can grip the monopile by means of the gripping members  51 , maintain the engagement thereof such as to guide the tool  1  towards the gripping position. 
     In an embodiment two guiding members  52  are provided in the form of guiding arms, of which outer ends are to engage the monopile  201 . 
     In an embodiment, the guiding members, e.g. at the outer ends of guiding arms, comprise wheels, the circumferential surfaces of which engage the outer surface of the monopile  201 . In an embodiment, the one or more wheels are motorized to assist the motion of the tool to the gripping position. 
     The arms  52  are pivotally mounted to the frame  3  of the tool  1  such that the outer ends are movable in the radial direction of the monopile  201 .