WO2025008032A1

WO2025008032A1 - Improvements relating to service galleries in wind turbine towers

Info

Publication number: WO2025008032A1
Application number: PCT/DK2024/050146
Authority: WO
Inventors: Nilaventhan Irulappan; Shoban P K; Mohan Ramasamy; Zuvera NASREEN
Original assignee: Vestas Wind Systems AS
Current assignee: Vestas Wind Systems AS
Priority date: 2023-07-04
Filing date: 2024-06-18
Publication date: 2025-01-09
Anticipated expiration: 2026-01-04

Abstract

According to one aspect there is provided a wind turbine tower platform assembly comprising a platform floor adapted to be connected to a wind turbine tower section. The platform floor defines a hatchway, and the wind turbine tower platform assembly further comprises a fall protection barrier surrounding at least a portion of the hatchway in the platform floor. The fall protection barrier comprises a first barrier module connected to the platform floor and configured to extend away from the platform floor for a first distance. The fall protection barrier further comprises a second barrier module connected to the first barrier module and configured to extend away from the first barrier module for a second distance.

Description

IMPROVEMENTS RELATING TO SERVICE GALLERIES IN WIND TURBINE TOWERS

Technical Field

The present disclosure relates to a wind turbine tower, and more particularly to a wind turbine tower platform assembly.

Background

Wind turbine towers are typically tall, tubular structures that support the rotor and nacelle of a wind turbine and are designed to elevate the turbine components to a height where the wind is stronger and more consistent, thereby maximizing the efficiency of energy generation. The construction and maintenance of wind turbine towers require specialized equipment and techniques, as well as skilled personnel who can safely and effectively perform the necessary tasks.

A wind turbine tower may be constructed according to several different principles, for example, as tubular steel towers, lattice towers, or even concrete towers. Most large wind turbines comprise tubular steel towers manufactured in sections (referred to herein as ‘tower sections’) of 20-40 meters in length with flanges at either end. The tower sections are bolted together at their flanges on the site of the wind turbine installation. Wind turbine towers are typically conical in order to increase strength and save materials.

Tower sections typically are manufactured complete with internal components to make on-site installation less complex and time consuming. Therefore, each tower section is usually equipped with auxiliary items such as ladders, lights, and power cables installed on the inner surface of the tower by suitable techniques such as welded or bolted connections. Typically, a tower section will include a platform located close to its upper flange. The platform provides a safe working space for installation personnel to perform various tasks, and particularly during installation to install the bolted connection at the tower flange. Such work platforms typically include at least one hatchway which provide an access route for personnel and/or equipment to be lifted through the tower section. To improve safety, such hatchways are required to be provided with a safety cage, barrier or gallery which guards against personnel or objects falling through the hatchway. However, the proximity of the platform assembly to the upper flange of the tower section compromises the design of such safety barriers. It is against this background that the invention has been devised.

Summary of the Invention

Such an arrangement increases safety for personnel supported by the platform floor when working in the wind turbine tower. The fall protection barrier reduces the risk of accidents such as fall or trips related to the hatchway defined in the platform floor. In particular the second barrier module increases safety by increasing the height of the fall protection barrier.

Optional features of the aspects of the invention are set out in the dependent claims. Note that these optional features are combinable with each other without limitation, save for the case that a specific limitation is discussed explicitly in the discussion that follows.

Brief Description of the Drawings

So that it may be more fully understood, the invention will now be described, by way of example only, with reference to the following drawings, in which like features are assigned like reference numerals, and in which:

Figure 1 is a front view of a wind turbine comprising a nacelle supported on a tower;

Figure 2 is a perspective view of a tower section of the wind turbine in Figure 1 ;

Figure 3 is a perspective view of a tower platform assembly in the tower section;

Figure 4 is a perspective view of a fall protection barrier of the tower platform assembly; Figure 5 is another perspective view of the fall protection barrier;

Figure 6 is a perspective view of a fall protection barrier including substantially planar panels;

Figure 7 is a perspective view of a tower platform assembly including a fall protection barrier for arrangement at an upper level of the tower;

Figure 8 is a partial cross-sectional view showing an attachment arrangement for connecting first and second barrier modules of the fall protection barrier; and

Figure 9 is a perspective view of a coupling for connecting the fall protection barrier to an interior surface of the tower section.

Detailed Description

The following detailed description refers to the accompanying drawings that show, by way of illustration, specific details and examples in which the invention may be practiced. These examples are described in sufficient detail to enable those of ordinary skill in the art to practice the invention. Other examples may be utilised, and structural changes may be made without departing from the scope of the invention as defined in the appended claims.

Figure 1 shows a wind turbine 10. The wind turbine 10 includes a nacelle 12 that is supported on a generally vertical tower 14. The nacelle 12 houses a number of functional components, including a gearbox and a generator (not shown), and supports a main rotor arrangement 16. The main rotor arrangement 16 comprises a hub 18 and a plurality of wind turbine blades 20 connected to the hub 18.

The tower comprises a plurality of tower sections 22 which are substantially conical and which may be made from steel. With reference also to Figure 2, the tower sections 22 each have a tower section wall 24, and each tower section wall 24 has an upper flange 26 at an upper end of the tower section 22 and a lower flange 28 at a lower end of the tower section 22. The flanges 26, 28 of neighbouring, i.e. adjacent, tower sections 22 are bolted together to form the complete wind turbine tower 14. To facilitate access to the flanges 26, 28 during assembly of the tower 14, the wind turbine 10 further comprises a tower platform assembly 30 which will now be described in more detail with reference to Figure 2 to 7. Reference is made initially to Figure 2, which shows a schematic perspective view of a tower section 22 of the wind turbine 10. It will be appreciated that in Figure 2, and in Figures 3 to 7, the tower section wall 24 is shown as partially transparent for the purpose of illustration to enable a clearer understanding of components inside the tower section 22.

The tower platform assembly 30 includes a platform floor 32 adapted to be connected to a tower section 22 of the wind turbine 10. The platform floor 32 is connected to the tower section 22 near the upper flange 26 to facilitate access to the upper flange 26. Assembly personnel may therefore be supported by the platform floor 32 when bolting the upper flange 26 to a lower flange 28 of a different tower section 22 stacked on top of the respective tower section 22 during assembly of the tower 14. For ease of access to the flanges 26, 28 during assembly, the platform floor 32 may be connected to the tower section 22 such that the floor 32 is suspended below the upper flange 26 of the respective tower section 22, for example between 1.0 m and 1 .35 m below the upper flange 26. To expedite on-site assembly of the tower 14, the platform floor 32 and tower section 22 may be pre-assembled, for example the platform floor 32 may be connected to the tower section 22 in a manufacturing facility before the tower section 22 is transported to the installation site.

To facilitate access to the platform floor 32 during assembly of the tower 14, the platform floor 32 defines a hatchway 34. The hatchway 34 is an opening through the platform floor 32 which allows assembly personnel to pass through the platform floor 32 in each tower section 22. Whilst not shown in the accompanying figures, the wind turbine 10 may further comprise access equipment such as a ladder, stairs or a lift mechanism, extending through the hatchway 34 to help assembly personnel travel through the tower 14 to the various platform floors 32. The access equipment may remain after assembly of the tower 14 to help service personnel travel through the tower 14 when the turbine 10 is fully assembled. Accordingly, the hatchway 34 in each platform floor 32 also remains after assembly of the tower 14 to facilitate access.

Whilst the hatchway 34 in each platform floor 32 allows access equipment to extend through the tower 14 and also facilitates access for personnel, a hatchway 34 in a platform floor 32 can also present a risk of accidents such as trips or falls in the tower 14. Accordingly, the tower platform assembly 30 includes a fall protection barrier 35 surrounding at least a portion of the hatchway 34 in the platform floor 32, shown more clearly in Figure 3. The fall protection barrier 35 provides an obstruction to stop personnel from accidentally stepping or tripping into the hatchway 34 or to guard against dropped tools or equipment falling down the hatchway 34. The fall protection barrier 35 comprises a first barrier module 36 connected to the platform floor 32. The first barrier module 36 may have an open-frame structure, as shown in the example of Figure 3, although it should be appreciated that other configurations are also possible, as described later in more detail.

The first barrier module 36 is configured to extend away from the platform floor 32 for a first distance Hi. The first barrier module 36 may be configured to extend away from the platform floor 32 by a first distance Hi that is less than or equal to the distance that the platform floor 32 is located below the upper flange 26 of the respective tower section 22. Accordingly, the first distance Hi may be a height in the range of 1.0 m to 1.3 m.

A first barrier module having a height Hi that is less than or equal to the distance that the platform floor 32 is located below the upper flange 26 enables further pre-assembly of the tower section 22. For example, in addition to pre-assembling the tower section 22 and the platform floor 32, the first barrier module 36 may be pre-assembled with the platform floor 32 before the preassembled tower section 22 is transported. As well as reducing on-site assembly time, this also helps to ensure that a safety barrier is provided with the hatchway 34 even in the initial stages of assembling the tower 14. A first barrier module 36 having a height Hi as described above advantageously ensures that the first barrier module 36 does not extend above the upper flange 26 of the tower section 22. The first barrier module 36 is therefore protected by the tower section wall 24 and upper flange 26 during transport of the pre-assembled tower section 22 and assembly of the tower 14 when stacking tower sections 22 on top of one another. Such a configuration also enables a more space-efficient arrangement of pre-assembled tower sections 22 for transport and storage.

As shown in Figure 4, the fall protection barrier 35 therefore further comprises a second barrier module 38 connected to the first barrier module 36. The second barrier module 38 is stacked on top of the first barrier module 36. The second barrier module 38 is configured to extend away from the first barrier module 36 for a second distance H2. This increases the overall height of the fall protection barrier 35, thereby increasing safety for personnel working whilst being supported by the platform floor 32. In some examples, the second distance H2, i.e. the height of the second barrier module 38, may be greater than the first distance Hi , i.e. greater than the height of the first barrier module 36. Accordingly, the second barrier module 38 may extend away from the first barrier module 36 for a greater distance than the distance that the first barrier module 36 extends from the platform floor 32. Such a configuration helps to further increase safety for personnel in the tower section 22. The connection between the first and second barrier modules 36, 38 is shown most clearly in the partial cross-sectional view of Figure 8. In some preferred examples the second barrier module 38 may be removably connected to the first barrier module 36. For example, the first and second barrier modules 36, 38 may be configured with a cooperating socket and rail arrangement 40 to facilitate attachment of the second barrier module 38 to the first barrier module 36. As shown in the example of Figure 8, the first barrier module 36 may include a rail arrangement 42, and the second barrier module 38 may comprise a socket arrangement 44 which engages with the rail arrangement 42. Providing a rail arrangement 42 on the first barrier module 36 may improve ergonomic use of the first barrier module 36 in the tower section 22 before the second barrier module 38 is stacked on top of, and connected to, the first barrier module 36. After engaging the rail arrangement 42 in the socket 44, a plurality of fixings 46, such as bolts, may be inserted through both the socket 44 and the rail 42 to releasably fix these together.

Referring again to Figures 4 and 5, to assemble the fall protection barrier 35, the second barrier module 38 may be transported through the hatchway 34 to a position above the platform floor 32. For example, the second barrier module 38 may be carried on the access equipment extending through the hatchway 34, such as on a ladder or a lift mechanism (not shown), to deliver the second barrier module 38 to the installation location.

As another example, the second barrier modules can be latched on the platform 32 and upended along with the tower section 22 during tower installation

The second barrier module 38 is then assembled, i.e. stacked, on top of the first barrier module 36. In some preferred examples the second barrier module 38 may therefore extend away from the first barrier module 36 and above the upper flange 26 of the tower section 22, when the fall protection barrier 35 is assembled.

To transport the second barrier module 38 through the tower 14 it may be advantageous to minimise the weight of the second barrier module 38. This may improve handling during transport and assembly of the second barrier module 38. As shown in Figures 4 and 5, the second barrier module 38 may therefore have an open-frame structure. To further improve handling during assembly and transport, the open-frame structure of the second barrier module 38 may comprise a plurality of interconnected frame members 48.

For ease of transport, the interconnected frame members 48 may be attachable independently to the first barrier module 36. Accordingly, assembling the second barrier module 38 on top of the first barrier module 36 may comprise connecting a plurality of second barrier module frame members 48 to the first barrier module 36. By independently assembling each second barrier module frame member 48 with the first barrier module 36, the assembly process may be simplified for the assembly personnel, and the strain and load for personnel handing the frame members 48 during assembly may also be reduced. Additionally, the frame members 48 may be configured to be compact and therefore portable enough to be carried up through the hatchway 34 by a conventional lift mechanism, which makes them particularly suitable for easy assembly by an installation crew.

Referring now to Figure 6, the wind turbine tower platform assembly 30 may include a plurality of substantially planar panels 50 attached to the open-frame structure of the first barrier module 36 in some examples. The planar panels 50 may help to reduce the risk of dropping or kicking items, such as tools or fixings, down into the hatchway 34. A plurality of substantially planar panels 50 may also be attached to the second barrier module 38. This further improves safety within the tower section 22 and again reduces the risk of dropping items into the hatchway 34 even further. It follows that assembling the second barrier module 38 on top of the first barrier module 36 may therefore involve attaching substantially planar panels 50 to the second barrier module 38.

The fall protection barrier 35 may include a viewing window 52 defined by one or more of the planar panels 50 attached to the first and/or second barrier module 36, 38. The viewing window 52 allows assembly or service personnel to see into the hatchway 34. This may be useful for observing the delivery of tools and/or materials by a lifting mechanism extending through the hatchway 34.

With reference now to Figure 7, in some examples the hatchway 34 in a platform floor 32 may be substantially enclosed, i.e. surrounded, by a combination of the fall protection barrier 35 and the tower section wall 24. This helps to ensure that the hatchway 34 is safely protected on all sides to ensure the hatchway 34 is not entered accidentally from any direction.

To simplify the configuration of access equipment (not shown) extending through the hatchways 34, it may be advantageous for the hatchway 34 in each respective platform floor 32 to be aligned with one another. This may allow the access equipment to extend substantially vertically throughout the tower 14, i.e. between upper and lower levels of the tower 14. The platform assembly 30 shown by way of example in Figure 7 may be located at an upper level of the tower 14. Whilst the hatchway 34 at an upper level of the tower 14 may be enclosed at least partially by the tower section wall 24, hatchways on lower levels which are aligned with a hatchway 34 on an upper level may be spaced apart from the respective tower section wall 24, due to the conical form of the tower 14.

Accordingly, as shown in the examples of Figures 2 to 6, in some examples the first barrier module 36 may substantially enclose the hatchway 34, i.e. may extend entirely around a perimeter of the hatchway 34. This configuration may be particularly relevant for tower sections 22 in a lower half of the tower 14. It follows that in some examples, the second barrier module 38 attached to the first barrier module 36 may also substantially enclose the hatchway 34.

Referring now more particularly to Figure 9 in combination with the preceding figures, in some examples at least one of the first or second barrier modules 36, 38 may include a coupling 54 adapted to be connectable to a surface of the respective tower section 22 (not shown in Figure 9), such as an interior surface of the tower section wall 24. In use, wind may cause the tower 14 to sway, and upper levels of the tower 14 in particular may experience significant movement. The coupling 54 connecting the fall protection barrier 35 to the respective tower section 22 helps to stabilise the fall protection barrier 35 in use.

Preferably, the coupling 54 is releasable to facilitate assembly and disassembly of the fall protection barrier 35. It follows that assembling the second barrier module 38 on top of the first barrier module 36 may therefore involve connecting the second barrier module 38 to the tower section wall 24 using a releasable coupling arrangement 54. In some examples, such a releasable coupling arrangement 54 may include one or more magnetic modules 56, and the coupling 54 may therefore be magnetically affixed to the tower section 22. This facilitates particularly simple and effective assembly of the fall protection barrier 35, and, whilst providing a connection to the tower section 22, does not cause any damage to the tower section 22 which could otherwise result in stress concentrations in use.

Finally, with reference still to Figure 9, the coupling may be adapted to provide at least one degree of freedom for the respective barrier module 36, 38 that it is connected to. In particular, as indicated by arrow A in Figure 9, the at least one degree of freedom may be perpendicular to the surface of the associated tower section 22 to which the coupling 54 is connected. Providing at least one degree of freedom allows the fall barrier 35 to move and compensate in response to the movement of the tower 14 in use, thereby reducing the risk of tower movement damaging the fall protection barrier 35 in use.

It will be appreciated that features described in relation to any of the examples above may be readily combined with any other features described with reference to different examples without departing from the scope of the invention as defined in the appended claims.

Claims

1. A wind turbine tower platform assembly (30) comprising: a platform floor (32) adapted to be connected to a wind turbine tower section (22), the platform floor defining a hatchway (34); a fall protection barrier (35) surrounding at least a portion of the hatchway in the platform floor; wherein the fall protection barrier comprises: a first barrier module (36) connected to the platform floor and configured to extend away from the platform floor for a first distance Hi; a second barrier module (38) connected to the first barrier module and configured to extend away from the first barrier module for a second distance H2.

2. The wind turbine tower platform assembly (30) of Claim 1, wherein the second barrier module (38) is removably connected to the first barrier module (36).

3. The wind turbine tower platform assembly (30) of Claim 1 or Claim 2, wherein one of the first barrier module (36) and the second barrier module (38) comprises a socket arrangement (44) which engages with a rail arrangement (42) of the other one of the first barrier module and the second barrier module.

4. The wind turbine tower platform assembly (30) of any one of the preceding claims, wherein the first barrier module (36) has an open-frame structure.

5. The wind turbine tower platform assembly (30) of Claim 4, further comprising a plurality of substantially planar panels (50) attached to the open-frame structure of the first barrier module (36).

6. The wind turbine tower platform assembly (30) of any one of the preceding claims, wherein the second barrier module (38) has an open-frame structure.

7. The wind turbine tower platform assembly (30) of Claim 6, wherein the open-frame structure of the second barrier module (38) comprises a plurality of interconnected frame members (48).

8. The wind turbine tower platform assembly (30) of Claim 7, wherein the interconnected frame members (48) are attachable independently to the first barrier module (36).

9. The wind turbine tower platform assembly (30) of any one of the preceding claims, further comprising a plurality of substantially planar panels (50) attached to the second barrier module (38).

10. The wind turbine tower platform assembly (30) of Claim 5 or Claim 9, wherein at least one of the plurality of substantially planar panels (50) defines a viewing window (52).

11. The wind turbine tower platform assembly (30) of any one of the preceding claims, wherein the first barrier module (36) and/or the second barrier module (38) includes a coupling (54) adapted to be connectable to a surface of an associated tower section (22).

12. The wind turbine tower platform assembly (30) of Claim 11 , wherein the coupling (54) is adapted to provide at least one degree of freedom for the respective first and/or second barrier module (36, 38).

13. The wind turbine tower platform assembly (30) of Claim 12, wherein the at least one degree of freedom is perpendicular to the surface of the associated tower section (22).

14. The wind turbine tower platform assembly (30) of any one of Claims 11 to 13, wherein the coupling (54) is adapted to releasably affix to the associated tower section (22) and, optionally, to releasably affix magnetically.

15. The wind turbine tower platform assembly (30) of any one of the preceding claims, wherein the second distance H2 that the second barrier module (38) extends away from the first barrier module (36) is greater than the first distance Hi that the first barrier module extends away from the platform floor (32).

16. A method of enhancing safety in a wind turbine tower section (22), wherein the wind turbine tower section comprises a tower section wall (24) having a tower section upper flange (26), a wind turbine tower platform assembly (30) attached to the tower section wall below the tower section upper flange, wherein the wind turbine tower platform assembly comprises a platform floor (32) defining a hatchway (34), wherein a fall protection barrier (35) surrounds at least a portion of the hatchway, the fall protection barrier comprising a first barrier module (36) connected to the platform floor, the method comprising: transporting a second barrier module (38) through the hatchway to a position above the platform floor; assembling the second barrier module on top of the first barrier module so as to extend away from the first barrier module so that the second barrier module extends above the tower section upper flange.

17. The method of Claim 16, wherein the first barrier module (36) is configured to extend away from the platform floor (32) for a first distance Hi that is less than or equal to the distance from the platform floor to the tower section upper flange (26) that is less than or equal to the distance from the platform floor to the tower section upper flange.

18. The method of Claim 16 or Claim 17, wherein the step of assembling the second barrier module (38) on top of the first barrier module (36) comprises connecting a plurality of second barrier module frame members (48) to the first barrier module.

19. The method of any one of Claims 16 to 18, wherein the step of assembling the second barrier module (38) on top of the first barrier module (36) comprises attaching substantially planar panels (50) to the second barrier module (38).

20. The method of any one of Claims 16 to 19, wherein the step of assembling the second barrier module (38) on top of the first barrier module (36) comprises connecting the second barrier module to the tower section wall (24) using a releasable coupling arrangement (54).

21. The method of Claim 20, wherein the releasable coupling arrangement (54) includes one or more magnetic modules (56).