Challenges in the Construction of Offshore Wind Structures. Dr Ned Minns IT Power UK

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1 Challenges in the Construction of Offshore Wind Structures Dr Ned Minns IT Power UK

2 Foundations - Options Floating >60m <40m <40m <60m <60m Gravity Monopile Jacket Tripod Shallow Intermediate Deep

3 Floating Wind Foundations Tested Prototypes WindFloat 2MW HyWind 2.3MW 100m BlueH 80 kw

4 Challenges Not just installing onshore WT at sea. Specialist skills required. Marinisation. Maintenance. Supply chain. Cables

5 Installation Typical offshore works process for monopile foundation Finish Start Approximately 4 10 days

6 Vessels Small survey boats required for initial work

7 Vessels Aura and Toisa Sonata - Transport of monopiles from the Netherlands Carry two monopiles per voyage ~100m long vessels

8 Vessels Oleg Strashnov Installation of 1,000 tonne substations and 88 monopiles Four piles per voyage cycle 5,000 tonne crane, 183 m long vessel

9 Vessels Three Jack Up Barges to install turbines and towers two turbines at a time GMS Endeavour SEA JACK Leviathan All +90m long vessels, with ~90m long legs

10 Vessels Team Oman Cable laying vessel transport of cable from Norway and installation of infield and export cable

11 Vessels Toisa Warrior infield and export cable burying using an ROV trencher

12 Vessels Rock dumping for scour protection of turbines and cable Larger rocks to protect underlying layers Jan Steen Four foundations per day HAM 602 Two foundations per day

13 Vessels Regina Baltica - Personnel accommodation Floatel Temporary living for 100 workers Former cruise ferry

14 Vessels Windcat Operations and maintenance vessels for transportation of personnel

15 Vessels Helicopter expensive but quick

16 Transition Piece Transition piece between tower and monopile Grouted to compensate imperfection in pile verticality to ensure turbine tower will be vertical Transition Piece Grout Export Cable Supports for installation J Tube Monopile Scour Protection

17 Transition Piece - Solutions Conical Joint Allows and expects failure in the grout Shape of tapered interface causes recompression to a stable condition Quality is key as any ovality of either component will affect the locking together of the two Used on the recently completed London Array

18 Transition Piece - Solutions Shear Keys Circumferential rings on the outside of the monopile and inside of the transition piece Increase the sliding resistance between the grout and steel Requires more fabrication and cost but benefits outweigh cost of offshore repair Transition Piece Grout Pile

19 Transition Piece - Solutions Elastomeric Bearings If slippage occurs, bearings gradually take load to assist grout Transition piece wall Compression jack Elastomer bearing Grout Top of pile wall Used on: Sheringham Shoal, Belwind (BE), Greater Gabbard, Gwynt y Môr & Rhyl Flats Bearing units

20 Challenges Not just installing onshore WT at sea. Specialist skills required. Marinisation. Maintenance. Supply chain. Cables. Learn from worldwide experience and mistakes.

21 Offshore Wind in the UK Offshore Wind Resource UK wind farms Practical OSW Resource of ~ 400 TWh/yr

22 IT Power Marine Energy Group Supporting the emergent marine energy industry Covering the following technologies Tidal stream Tidal barrages Wave power Hydropower Offshore wind

23 Marine - Long Track Record Courtesy Severn Tidal Fence Group

24 Support Services to: Investors Project developers Venture capital companies Public Sector National & regional government Resource owners Research organisations Developers & Utilities Site developers Resource owners Grid operators Power purchasers Industry Device developers Component or system suppliers Integrators

25 Thank you Dr Ned Minns

26 Supporting Information

27 OSW Vessel Costs Jack-up k/day Floating crane ships k/day Trenching vessel k/day Export cable laying vessel k/day Array cable laying vessel k/day Ornithological survey vessel k/day Coastal survey vessel - 4-6k/day Geophysical survey vessel k/day Geotechnical survey vessel k/day Windcat workboat - 1,500/day

28 Monopiles

29 Jackets

30 Tripods Narec, UK Alpha Ventus, Germany

31 Gravity Foundations

32 Suction Caisson

33 Floating Wind Foundations Semi-Submersible (Buoyancy Stabilised) Tension Leg Platform (Mooring Stabilised) Spar Buoy (Ballast Stabilised)

34 Conclusions Many challenges and important lessons are still being learned A variety of expensive, specialist vessels are required for installation

35 Offshore Wind Turbines Growing! 5000 kw Ø 125 m 2000 kw Ø 80 m 50 kw Ø 15 m 100 kw Ø 20 m 500 kw Ø 40 m 600 kw Ø 50 m

36 Name Operation date Size, MW Turbine Distance to Shore km Water Depth, m Foundation Type Cost, million Barrow 03/ Vestas V90 3MW Steel Monopile Beatrice 07/ REpower 5MW Steel Quadropod 35 Blyth 11/ Vestas V66 2MW Steel Monopile 4 Burbo Bank 07/ Siemens SWT MW Steel Monopile 181 Gunfleet Sands I + II 01/ Siemens SWT 3.6MW Steel Monopile 420 Inner Dowsing 10/ Siemens SWT MW Steel Monopile 300 Kentish Flats 08/ Vestas V90 3MW Steel Monopile 105 Lynn 10/ Siemens SWT MW Steel Monopile 300 North Hoyle 03/ Vestas V80 2MW Steel Monopile 80 Ormonde 03/ Repower 5MW Jacket 500 Ryhl Flats 12/ Siemens 3.6MW Steel Monopile 198 Robin Rigg 04/ Vestas V90 3MW Steel Monopile 396 Scroby Sands 12/ Vestas V80 2MW Steel Monopile 75.5 Thanet 09/ Vestas V90 3MW Steel Monopile 900 Walney Phase 1 04/ Siemens SWT MW Steel Monopile Walney Phase 2 04/ Siemens SWT MW Steel Monopile Greater Gabbard 09/ Siemens SWT MW Steel Monopile 1,300 Sheringham Shoal 12/ Siemens SWT MW Steel Monopile 1,100 Gwynt y Mor Under construction 576 Siemens SWT MW Steel Monopile 1,600 Lincs Under construction 270 Siemens SWT MW Steel Monopile 725 London Array Ph 1 Under construction 630 Siemens SWT MW Steel Monopile 2,200 Teeside Under construction 62.1 Siemens SWT MW Steel Monopile

37 Turbine Failures Electrical control, gearbox, yaw system, generator, hydraulic, grid and blades are rated (60% of the total failures)

38 Turbine Failures Yaw Control - cracking of yaw drive shafts, fracture of gear teeth, pitting of the yaw bearing race and failure of the bearing mounting bolts Gearbox wear and tooth breakage due to particle contaminations, frequent stoppage and starting and high loaded operation conditions

39 Turbine Failures Hydraulics leakages in the pitch, yaw, braking system and gearbox lubrication system. Failure due to high/low temperature, corrosion, vibration and improper installation Blades - turbulent wind, out-of-control rotation, lightning and production defects.

40 Turbine Failures Lightning Damage to Transformer

41 Vessel Failures Failure of jacking mechanisms on installation vessels

42 Vessel Failures Foundation failure below legs feet pierce the sea bed causing the platform to list

43 Met Mast Failures Failure of met mast structures due to fatigue

44 O&M Access Windcat cheaper but can be slow travel and limited by sea conditions

45 UK Offshore Wind - Rounds Robin Rigg Ormonde Sheringham Shoal Greater Gabbard

46 Sheringham Shoal - Information

47 Sheringham Shoal - Information

48 OSW Vessel Costs Jack-up k/day Floating crane ships k/day Trenching vessel k/day Export cable laying vessel k/day Array cable laying vessel k/day Ornithological survey vessel k/day Coastal survey vessel - 4-6k/day Geophysical survey vessel k/day Geotechnical survey vessel k/day Windcat workboat - 1,500/day

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