Installation of suction caissons for Offshore Wind Turbines
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1 Installation of suction caissons for Offshore Wind Turbines Danish Geotechnical Society Seminar 1 st April 2014 Presented by Tor Inge Tjelta Classification: Internal
2 Installation of suction caissons for OWT s
3 Installation of suction caissons for OWT s Experience in offshore wind?
4 Installation of suction caissons for OWT s Experience in offshore wind? Not much
5 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West Images from Søren A Nielsen, Universal Foundation Technical Workshop in Hamburg, Feb. 2014
6 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else?
7 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet!
8 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations?
9 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience
10 Suction caisson foundations world wide Mid Norway North Sea Gulf of Mexico NW Africa Deep Mediterranean Columbus Amazon Campos Basin West Africa East India Barong NW Shelf Tarajam New Zealand More than 30 years experience in variable soil conditions
11 Why suction techniques & foundations First time used in 1980 «Re-invented» in 1985 and early 1990 s Extensively used since WHY? Cost and reliability Precise positioning Predictable capacity Robust solution Relatively insensitive to soil conditions «Cheap driving force» with incredible capacity Gullfaks C: > tons (300 kpa x m 2 ) Aasgard B/C: suction in the order of 1500 kpa (15 bar) Little experience prior to Floating production - Subsea structures
12 GFC and Åsgard Suction Caissons tons driving force, or 1500 KPa suction: Noise free! 12 Classification: Internal
13 Permanent Suction anchors installed Suction applications since 1980? Gullfaks C Penetration test Snorre TLP Draupner jacket Troll GBS platform Year
14 Suction history Gorm 1980 Gullfaks C 1985/89 Draupner and Sleipner Jackets w/ Bucket foundations 1994 & 95
15 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience
16 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea
17 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea
18 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea Boulder clays Sands
19 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea Boulder clays Sands Many offshore wind farm sites have mixed profiles (layered soils)!
20 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea Boulder clays Sands Many offshore wind farm sites have mixed profiles (layered soils)! Avoid! Test!
21 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea Boulder clays Sands Many offshore wind farm sites have mixed profiles (layered soils)! Avoid! or Test?
22 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea Boulder clays Sands Many offshore wind farm sites have mixed profiles (layered soils)! Avoid! or Test! 1. Gullfaks C test Dudgeon CT/OWA Trial Installation Project
23 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea Boulder clays Sands Many offshore wind farm sites have mixed profiles (layered soils)! Avoid! or Test! 1. Gullfaks C test 1989
24 Gullfaks C Penetration test 1985 Instrumented concrete skirt segment Water injection
25 Penetration depth (m) Gullfaks C Penetration test 1985 Twin cylinders penetrated 22m deep Tip resistance (MPa)
26 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea Boulder clays Sands Many offshore wind farm sites have mixed profiles (layered soils)! Avoid! or Test! 2. Dudgeon 2013
27 Dudgeon field penetration tests An offshore test program at Dudgeon test locations Multiple tests at several locations; 20 tests in total Water jets at skirt tip at 12m 3 /hr supply 27 Classification: Internal
28 Dudgeon field penetration tests objectives Prove installation feasibility of bucket foundations at Dudgeon Test program included: Investigation of skirt friction in Bolders Bank clay, several locations Investigation of mitigation techniques: Cyclic penetration Water injection at skirt tip Cyclic penetration in combination with water injection Investigation of penetration resistance in layered soils with sand layers of limited thickness Investigation of penetration through dense sand layers below clay Investigation of pump performance and in particular limits with respect to cavitation in the pump. 28 Classification: Internal
29 Test program - details The following following seabed catergories were tested: 1) Channel infill (soft clay) 2) Regular Bolders Bank clay 3) Clay with «sand-spikes» 4) Clay with sand layers 5) Clay crust 6) Sand 7) «Most challenging» 29 Classification: Internal
30 Test structure Water supply 30 Classification: Internal
31 Best and high estimate tip and total resistance at some locations 31 Classification: Internal
32 Test result Location «CPT-100» Category: Clay with sandlayer Always considered a challenge Proved to be relatively easy 32 Classification: Internal
33 Conclusions Dudgeon field tests Skirt penetration achievable all over Dudgeon to significant depths The small diameter test-anchor was penetrated to more than 4m at every location For an 8m dia bucket this scales to approx. 8-10m penetration The results proves significant penetration is achievable even without water injection Valuable information on installation equipment obtained (pump, valves, cavitation limits etc.). 33 Classification: Internal
34 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea Boulder clays Sands Many offshore wind farm sites have mixed profiles (layered soils)! Avoid! or Test! 3. CT/OWA Trial Installation Project
35 OWA Trial Installation Project Business Case (Extract from presentation to OWA partners 17 th March 2014)
36 Introduction Reducing foundation CAPEX is integral to ensuring the offshore wind industrys cost reduction ambitions are achieved. Suction bucket technology is a potentially important technology in realising this. One such suction bucket concept, is the Universal Foundation, which leads the OWA foundation workstream in terms of its cost reduction potential. Suction bucket technology however has a far wider ranging potential for the industy and it is imperative that the application of the general installation principles are understood in order to enable further technological and concept development within the industry. The suction installation process for bucket foundations needs derisking before it can be considered technically and commercially viable as a foundation solution for the offshore wind market. This is the aim of the the OWA trial installation project. 36
37 The Need Case Cost comparison using OWA foundation cost benchmarking tool Based on 8MW WTG in 25 metre water depth shows 34% cost reduction potential 600k /MW: XL MP v UF 500k 400k 300k 200k 100k 0k Monopile Universal Foundation 37
38 Project History Summer 2011 project initially proposed by Carbon Trust in OWA. Summer 2012 interested partners EON, DONG, Statkraft, Statoil. Statoil as Lead Participant Scaled down 5MW design planned to be trialled 4 x test locations on Dogger Bank Cost indication: 4.0m project ( 2.0m from OWA and 2.0m from UF) Planned for execution in 2013 however delayed due to failure at Dogger Bank met mast west 38
39 Scope of Work Test Sites Planning operations at Dudgeon, Hornsea and Dogger Bank wind farm zones. Acquire as many tests as possible in a 28 day offshore period. Site selection currently ongoing aim to test performance in challenging layered soils (clay over sand) and other conditions representative for Round 3 wind farm sites (sites selected to be presented to OWA project) 39
40 Location 1074: Clay over «layered» sand 40 Classification: Internal
41 Installation of suction caissons for OWT s Experience in offshore wind? Not much Three Met Masts: Horns Rev 2 and Dogger Bank East & West What else? Nothing, yet! oil & gas foundations? Worldwide experience Soft NC Clays North Sea Boulder clays Sands Many offshore wind farm sites have mixed profiles (layered soils)! Avoid! or Test! 1. Gullfaks C test Dudgeon CT/OWA Trial Installation Project
42 Think Installation Installation Installation Installation Installation Installation Soil limitations Critical suction Plug heave Piping/rabbit holes Structural limitations Strength and buckling of top plate (lid) Buckling of shell Suction & pump Establish and maintain suction Leakage in soil Leakage in/at mechanical components Mitigations Trial Installation Project Classification: Internal
43 Installation is always important! Installation of suction caissons can be «a piece of cake», however can also go seriously wrong Structural failure or penetration refusal are two of the issues 43 Classification: Internal
44 Some DOs and DON Ts in suction caisson installation Know your site «you pay for a soil investigation whether you do one or not - and in the latter case you are likely to pay more» Design (geotechnical, structural and marine operations) Experience important no need to repeat all past mistakes Don t make too many assumptions Don t save money on pumps! (they are not expensive anyway) Before taking equipment and/or new solutions offshore; TESTING Classification: Internal
45 Conclusions Suction caissons are used world wide Technology is simple Installation equipment is simple Require soil information Challenges High aspect ratios (L/D>>1) High pullout loads (passive suction) Drained tension loads Layered soils (installation) Boulders (not really?) Gravel beds No limitation? (few if any real failures in oil & gas)
46 Installation of suction caissons for Offshore Wind Turbines Tor Inge Tjelta Specialist Geotech Tel: Thank you for your attention! 46 Classification: Internal
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