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Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Summary - Offshore Wind Turbine Foundations
LCOE Ranges and Averages [IRENA, 2013]
Differences; Oil & Gas Platforms – Wind Turbines
Types of Foundation for Offshore Wind Turbines [OWT]
Codes and Standards; DNV, GL; IEC, US
Foundation Concepts 2012 – 2020 [Roland Berger Study 2013]
Maps UK Round 3, French & German North Sea/Baltic Sites
Environmental, Geophysical & Geotechnical Site Investigations
Monopiles – Design & Installation
4 Leg Piled Jackets – OWEC, BIFAB, Truss Towers, Twisted Jacket
Tripods – Weserwind Alpha Ventus & OGN-Aquind
Gravity Base Structures [GBS] – Arup/Hochtief, Vici Ventus, Vinci, Seatower, Etc.
Suction Caisson UF Monopod, Tripods, Quadrapods
Guyed Tower, “Twisted” Jacket, Suction Tripod, A-Framed Monopile
TITAN 200 Jack-up Foundation
Foundation Issues & Problems:
1. Early Refusals & Piling Noise
2. Vibro Installation & Scour
3. Grouted Connections
4. Monopile Resonance, Cyclic Friction Degradation & Long Term Tilt in Sands
5. Steel Corrosion
Foundation Costs – Comparisons
Offshore Wind Cost Trends – Need for Reduction
Fabrication Costs (Early 2010)
Offshore Wind; Measurement, Monitoring, Mitigation 1: BELWIND; 2: Bucket Jacket Foundation
Offshore Floating Solutions – Huge Potential Offshore Wind Resource
Conclusions, References, Contact Details
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
LCOE Ranges and Averages [IRENA, 2013]
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Differences; Oil & Gas Platforms – Wind Turbines
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Types of Foundation for Offshore Wind Turbines [OWT]
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Codes and Standards; DNV, GL IEC, US
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Foundation Concepts 2012 – 2020 [Roland Berger Study 2013]
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Maps: UK Round 3, French & German North Sea/Baltic Sites
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Environmental, Geophysical & Geotechnical Site Investigations
Environmental Surveys
Biogenic reefs & Benthic communities
Marine archaeology, wrecks and seabed obstructions
Grab and gravity core sampling of seabed surface sediments, for scour, plumes and cable burial
Seabed mobility, sand waves and shoals
Guidance Notes
Society for Underwater Technology (SUT)/ Offshore Site Investigation and Geotechnics (OSIG) Committee
(2005). Guidance Notes on Site Investigation for Offshore Renewable Projects, Rev. 02, March 2005.
Bundesamt fur Seeschifffahrt und Hydrographie [BSH], (2008). Ground Investigations for Offshore
Windfarms. BSH Standard No. 7004, p. 40.
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Monopiles – Design &
Installation
• Not a “Pile” but Driven Tubular Steel
Thin Walled Caisson Shell.
• Typically 4.5 - 9 m diameter,
sometimes tapered
• Wall thicknesses 30 - 80 mm. D/t ratio
very high ~ 80 – 120.
• WD cut-off 20 to 35 m > pile lateral &
seabed soil stiffnesses & layering.
• Weights up to 900 tonnes, limited by
float out & crane capacities
• Driven or drive-drill-drive (UK) or even
drilled and grouted (France)
• Transition piece “glued” onto monopile
with brittle high strength cement ~
very strong granite > problems
• Simple, quick, suited to shallow water:
problems - driving refusals & weight.
• Structure frequency limits, fabrication,
handling and installation constraints.
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
4 Leg Piled Jackets – OWEC, BIFAB, Truss Towers, Twisted Jacket
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Tripods – Alpha Ventus, OGN-Aquind, BARD Tripile
Weserwind - ALPHA VENTUS
• German federal funding 2001 – 2007
• 6 OWEC jackets/6 OWT tripods
• EPCI Contract value EUR 32m
• Vattenfall, EoN & Federal EWE (DOTI)
• 1st seabed template pre-piling (IHC)
• Adopted by Borkum West 2, Globaltech
1
OGN-Aquind
• Newcastle UK based Oil & Gas fabricator
• TRITON 3 leg truss jacket for use in
WDs of 30 to 80 m
• Major UK Govt. funding in 2012 for
development/design of prototype jacket
• Steel savings allow fabrication of 150
jackets/year at Hadrian’s Yard Wallsend
BARD Tripile
• “One-off German project (so far)
• 400 Te+ 3.35 m Dia. Steel piles &
transition triangle. WD 25 to 40 m
• Clever but costly – 100 units/year.
• Installed WINDLIFT1 – 2600 te lift.
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Gravity Base Structures [GBS] – Arup/Hochtief, Vici Ventus, Vinci, Seatower, Etc.
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Suction Caisson UF Monopod, Tripods, Quadrapods
• Suitable for all sand densities and
intermediate strength clay
• Installation relatively simple &
extensive oil & gas experience
from GoM, North Sea, W.Africa
• Installation/capacity prediction
analyses well developed. Scour
protection design essential
• Highest quality geotechnical data Source: DONG
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Guyed Tower, “Twisted” Jacket, Suction Tripod, A-Framed Monopile
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
TITAN 200 Based on
O&G Technology
Jack-up Sub-Structure
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Pile Foundation Issues & Problems (1); Early Refusals & Piling Noise
Piling Refusals
Heavy long large diameter monopiles
and jacket piles increasingly being over-
driven and drilled out in glacial deposits
and bedrocks: Expensive and risky.
Pile Tip Buckling
(cf. Valhall Norwegian Aker/BP problems
in 2004, Oil & Gas platform – expensive
repair and claim). Over driving in very
dense and /or cemented glacial
materials in S. North Sea may lead to
buckling failures if the industry continues
to adopt conservatively long piles
Piling Noise
2011 rules in Germany – 160 Dba @ 750
m. restricted working periods &
expensive mitigation measures. In UK
“soft start up” piling and observations
required. Helical piles considered in
Scotland. Germany – “Air Bubble
Curtains [ABC] & Hydro Sound Dampers
[HSD] – London Array, Baltic Sea tests.
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Pile Foundation Issues & Problems (2/1); Vibro Installation & Scour
Vibro-Installation
Tripods levelled using seabed vibro-
installation to ~8 – 15 m using vibro
hammers to reduce conventional hammer
noise, allowing sequential levelling. Newish
technique used on several large projects.
Accepted commercially viable offshore
Germany for partial pile installations –
through pile sleeves or pre-installed groups
or monopiles. Source: SLP Engineering Source: Thyssen-Krupp.
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Pile Foundation Issues & Problems (2/2); Vibro Installation & Scour
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Pile Foundation Issues & Problems (3/1); Grouted Connections
www.academia.edu/6616972/Offshore Wind Monopile
Grouted Connections December 2011
Monopile [MP] - Transition piece [TP] joint transmits high
bending moments. Brittle rock-like grout [cement]
connections mistakenly used on European projects - speed &
cost savings.
All but 2 excluded reinforcing shear keys due to DNV design
code omission. Settlement, cracking, failure on 70% UK Source: Lotsberg 2012
monopiles. Systemic design fault. Extensive/costly repairs.
Heavy oil & gas platforms - API leg-pile connections used for
decades, always in compression. OWTs are light, with cyclic,
complex vertical + bending force coupling & tensile stresses.
Ability to transfer large moments still not fully understood &
design theories have limitations & shortfalls. Use of conical TP
sections [“controlled failure”] uncertain in the long term.
Industry best practice and code guidelines under review &
DNV guidelines revised 2011 (new Code 2014). Still anomalies
in behaviour. Research ongoing on size & fatigue effects.
Many developers reverting to bolted flanges (Scroby Sands,
Source: Billington 2014
North Hoyle and Blyth 12 years ago), with some considering
pile swaging or even slip joints as reliable long term solution.
Requires verticality, very careful driving.
Many projects have adopted/are adopting Trelleborg spring
bearings (BELWIND, Robin Rigg, Sheringham Shoal). Long
term uncertainties for non shear keyed connections?
Source: Harding et al 2012
LONG TERM MEASUREMENT & MONITORING ESSENTIAL
Source: Billington 2014
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Pile Foundation Issues & Problems (4); Monopile Resonance, Cyclic
Friction Degradation & Long Term Tilt in Sands
Monopile Resonance
Selection of dynamic properties essential for cost
effective/reliable design. Affects rotor and support
structure interaction & soil-foundation dynamic response.
Design solutions depend upon ratio between fundamental
structure eigenfrequency fo, rotor frequency fR and blade
passing frequency fb = Nb* fR choice between “soft-soft” [fo
< fR], “soft-stiff” [fR < fo < fb] and “stiff-stiff” [fB < fo].
Cyclic Friction Degradation
Substantial reductions in axial pile friction and lateral P-Y
response may occur due to the cyclic long term loading
experienced by monopiles supporting large heavy 3-bladed
5 MW + HAWT turbines Cyclic Displacement
Accumulation in
Long Term OWT Tower Tilt in Sands Sands. Source:
Settling of towers/monopiles embedded in sands but not Achmus, Abdel-
Rahman & Kuo (2007)
keyed into bedrock may be large, leading to excessive tilt
and shutdown & resetting for gearbox turbines.
Tilt of 0.5 deg is usual for OWT. Permanent tilt due to
Construction tolerance permanent tilt is subtracted, with
typical values 0.20 to 0.25 deg. Allowable operational
rotational stiffness is typically 25 to 30 GNm/radians.
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Pile Foundation Issues & Problems (5/1); Steel Corrosion
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Pile Foundation Issues & Problems (5/2); Steel Corrosion
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Foundation Costs Comparisons
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Offshore Wind Cost Trends –
Need for Reductions
designed monopiles
- more extensive and expensive
equipment and vessel spreads
- higher downtime and weather
standby costs
• Insistence on “known technology”
leading to lack of innovation,
conservatism, risk aversion on the
part of developers and lenders.
• Lack of experience in developer
organisations; general skills
shortage.
Source: van der Zwaan et al, 2011
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Fabrication Costs (early 2010) – Why Not Concrete GBS?
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Offshore Wind; Measurement, Monitoring, Mitigation (1: BELWIND)
Poster Paper EWEA 2014 Barcelona – Vrij Universiteit Brussel – De Sitter et al
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Offshore Wind; Measurement, Monitoring, Mitigation (2: Bucket Jacket Foundation)
Presentation Oceanology International 2014 – Norwegian Geotechnical Institute – Per Sparrevik
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Main Conclusions (1)
1. Initially this new offshore industry has understandably used conservative
monopile and piled tripod (Germany) & 4-leg jacket (UK) solutions. CAPEX
and investment still limited compared to other energy industries.
2. European Offshore Wind Industry has developed several foundation
solutions, steel /concrete, monopiles, AV piled tripods, BARD tripiles, triple &
4-leg jackets, truss towers, twisted jacket, guyed & A-frame monopiles,
monopod suction caisson, triple/quad suction caissons.
3. Main Foundation Risks: Grouted connections, piling noise mitigation, over-
conservative long, stiff, heavy pile design, pile tip buckling, unplanned
drilling/re-driving, tilt and settlement.
4. As more difficult rocky, irregular sites are encountered in deeper water,
innovative and creative thinking necessary at an earlier stage (c.f. UK Atlantic
and Argyll Array cancellations due to “challenging seabed conditions”)
5. Grouted connections fiasco -70% UK MPs failed. To be avoided if possible.
Use bolted flanges or other direct connections. If unavoidable use shear keys
& robust grout seals. Are non shear keyed conical [1o-3o] sections and/or
elastomeric spring bearings valid for fatigue design life? M-M-M
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Main Conclusions (2)
6. Industry as a whole needs more realistic offshore turbine tilt criteria, based
upon sound engineering analysis. Big impact on structure costs, influencing
business cases. Development of tilt-tolerant DD turbines can reduce costs.
7. New foundation solutions [e.g. Carbon Trust] slowly & patchily embraced (Met.
Masts) in UK/Germany. Concrete GBS, twisted jackets & suction caissons more
suited to some sites. Solutions extensive in offshore oil & gas.
8. For foundation costs to reduce [halved acc. US DoE], innovative solutions
needed, selected/tailored to specific site conditions. Conservative risk averse
attitudes in a relatively new industry should change as experience is gained.
9. Measurement, Monitoring and Mitigation for offshore wind structures is
essential for long term design life O & M cost minimisation.
10. The current plans to move to ~10 m dia., 1200 Tonne, 60 m + length
monopiles in ~40 m WD may be questionable & should be challenged.
11. Globally, early development of floating alternatives increasing, HYWIND
[Statoil], Principle Power [WINDFLOAT], Wave Hub [Glosten], Blue H, Offshore
Japan [Various], France [IDEOL, WINFLO, VERTIWIND].
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Major Monopile Project Conclusions – Owner/Developer
The demand for WTGs is HIGH – There are few incentives for innovation by
established Suppliers. Innovation may have to be initiated and driven by the Owners.
Present WTG and foundation designs are not entirely suited for offshore use and not
suitable for offshore installation. A dedicated offshore designed WTG incl. foundation
must be developed by this industry.
To save cost and time you have to spend money in the early project phase in order
to safeguard so as to to… do it right the first time…
At present, lump sum installation contracts are just not achievable – no incentive for
good performance and counter-productive. Availability of suitable installation vessels
must be increased.
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
The Future: Offshore Floaters – Huge Potential Offshore Wind Resource
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
The Future: Offshore Floaters – Japanese plus European HiPR Wind
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
References & Links
References
Douglas-Westwood (2013), “World Offshore Wind Market Forecast 2013 -2022”, 5th Edition.
Golightly, C.R. (2014), “Tilting of Monopiles; Long, Heavy and Stiff; Pushed Beyond Their Limits”, Ground
Engineering; 2014, Vol. 47, No. 1, pp 20-23.
van der Zwaan, R., Rivera-Tinoco, R., Lensink, S. & van den Oosterkamp, P., (2010) “Evolving Economics of Offshore
Wind Power: Cost Reductions from Scaling and Learning “, Amsterdam 2010, p. 9.
The Offshore Evaluation Group (2010), “The Offshore Valuation Report; A Valuation of the UK’s Offshore Renewable
Energy Resource”, Public Interest Research Centre, p. 108.
Maine International Consulting (2013), “Floating Offshore Wind Foundations; Industry Consortia and Projects in the
United States, Europe and Japan; An Overview, May 2013, p. 45
Roland Berger (2013), “Offshore Wind Toward 2020; On The Pathway to Cost Competitiveness”, April 2013, p. 25.
Recommended Links
EWEA Offshore Statistics 2013 ewea.org/fileadmin/files/library/publications/statistics/EWEA_OffshoreStats_July2013.pdf
EC Marine Knowledge 2020 Database ec.europa.eu/maritimeaffairs/policy/marine_knowledge_2020
Global Wind Energy Council Country & Global Reports gwec.net/publications/country-reports
IRENA Costs Database; irena.org/costs
UK Govt. Offshore Wind Industrial Strategy gov.uk/government/uploads/system/uploads
USA Offshore Wind Database: offshorewind.net
4C Offshore Wind Database: 4coffshore.com
UPWIND EWEA Project Final Report: upwind.eu
UK Floating Wind: thecrownestate.co.uk/media/428739/uk-floating-offshore-wind-power-report.pdf
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014
Contact Details
Dr. C. R. Golightly GO-ELS Ltd. - Monopile and Tripod/Jacket Foundations for Offshore Wind Foundations 10th April 2014