Case: Aalborg University - Universal Foundation

Transcription

1 Vindmølleindustrien - dansk konkurrenceevne i en global industri Case: Aalborg University - Universal Foundation Søren A. Nielsen, Director Technology 2. juni 2014

2 Universal Foundation - HQ: Aalborg Universal Foundation is the recognized design office of product brand of THE BUCKET FOUNDATION. In 2011, Fred Olsen acquired 60% of the Danish company Universal Foundation A/S from DONG. The stake is further increased to 82% in Along with a board of directors from Fred. Olsen, Novasion and Aalborg University, the company is experiencing even further growth and promising prospects positioning The Bucket Foundation in the offshore market. Universal Foundation NO 82% Minority investors 18%

3 THE BUCKET FOUNDATION by Universal Foundation The Bucket Foundation A hybrid design The design combines the benefits and main proven aspects of a gravity base foundation, a monopile and a suction ackert. Range coverage: meters A hybrid solution linking the gap between the Industry Darling Monopile and the Inherently expensive transitional waters Jacket

4 THE BUCKET FOUNDATION by Universal Foundation The Competitive Advantage The Carbon Trust / Offshore Wind Accelerator (OWA) Perspective Fabrication Fabrication Simple welds Reduced weight Installation Installation Reduced vessel requirements, fewer offshore operations No piling noise eco-friendly O&M O&M No grout failures Easy decommissioning Commercial Commercial Fred Olsen end-to-end One Stop Shop model

5 THE BUCKET FOUNDATION by Universal Foundation The Design The Shaft Integrated transition piece, TP. i.e. no grout, no additional marine ops. Similar to tower production based on coned upper section Variation in depth in cylindrical lower part The Lid 8.0MW CT Project Bucket Foundation Comparable Monopile Transfer of loads Welded of cut plates mm Suitable for mass production of elements 25m 670 t +25% 840 t 35m 820 t n/a The Skirt Pre-fabrication of shell plates Cell-assembly Flushing system on the rim 45m t n/a 55m t n/a Estimates only accounts for primary steel Excludes secondary steel

6 Aalborg University Universal Foundation A long lasting relation Joint projects since 2001: Geotechnical Professor (MSO) for 8 years Test Field in Frederikshavn with bucket prototype (Elsam) 2 Ph.D.s with relation to the Test Field in Frederikshavn Havn 2 Ph.D.s joint with DONG, Buckets in Clay, High Tension Concert 2 EFP project regarding soil/structure interaction Bucket prototype in Wilhelmshaven (Enercon/Bladt) Mobile met mast on Horns Rev 2 (DONG) Carbon Trust Offshore Wind Accelerator (CT OWA), Foundation Competition PSO Wavestar foundation study CT OWA, Dogger Bank Met Mast project (Forewind) CT OWA, Large Rotor Study (8 MW / m water depth) Højteknologifonden, Cost-Effective mass production of Universal Foundations for large offshore wind parks (DtU, Force, LIC Engineering) 1 Ph.D. Hydrodynamic / Scour Development (on going) CT OWA, Trail Installation (Statoil, E.on, DONG) CT OWA, Full Scale Demonstrator (xxx)

7 Test site for offshore wind turbine in Frederikshavn

8 8 Frederikshavn in operation for 11 years The Ø12x6 m prototype bucket foundation was designed for a Vestas V90 3MW turbine placed on 4 m of water. The design is certified by DNV. The bucket was installed in late 2002 and is in normal operation. The structure/soil interaction has been investigated with sophisticated modal analyse equipment.

9 Installation of prototype Nov. 2002

10 Penetration Control AaU active participation

11 Installation of Bucket Foundation in Frederikshavn

12 Physical Modelling Sand - Transient Loading

13 Physical Modelling Sand - Transient Loading Bucket for Model Testing 13 Pore Pressure Transducers 2 Buckets H/D = 0,5 H/D = 1,0

14 Physical Modelling Sand - Transient Loading

15 Physical Modelling Sand - Transient Loading Foglia, Aligi; Ibsen, Lars Bo; Nielsen, Søren Kjær; Mikalauskas, Linas (2013): A Preliminary Study on Bucket Foundations under Transient Lateral Loading. The Proceedings of the 23 rd (2013) International Offshore and Polar Engineering Conference. Vol. 2 International Society of Offshore & Polar Engineers, 2013, pp (International Offshore and Polar Engineering Conference. Proceedings). The Boot Effect

16 Wilhelmshaven Bucket ENERCON E MW 16 m diameter / 15 m skirt / 450 tons

17 Soil Profile Wilhelmshaven

18 Debunking Myths about the installation failure in Wilhelmshaven The bucket foundation is a thin shell structure At deeper waters, the diameter of the bucket increases Large aspect ratio between caisson diameter and wall thickness Instability (buckling) critical issue during installation Crucial case of buckling in Wilhelmshaven, Germany in 2005 Bucket diameter 16 m, height 15 m, and skirt thickness 25 mm 6 MW offshore wind turbine The Giant 4 barge came in drift and hit the skirt at a penetration depth at 3m resulting in a mm bump. (back calculated) Buckling at a penetration of 6.8 m

19 Mobile Met Mast Horns Rev 2. Objectives "The Mobile Met Mast" is a prototype of a monopod bucket foundation designed as support structure for a met-mast. Objective: To gain confidence that a monopod bucket foundation can be successfully installed offshore. To obtain a movable met-mast, which can be used in several offshore wind farms. Specification Total height: 38 m Weight: 165 tones Skirt length: 6 m Skirt diameter: 12 m Fabricated in Aalborg in August Installed at Horns Rev 2 Offshore wind farm in March Decommission 2014

20 Fabrication The geometric skirt imperfections was measured by a 3D point cloud laser scanner The maximum out-of-roundness was 50mm The largest imperfections were along the vertical weldings.

21 Up-ending and adding connections

22 Installation A penetration velocity of 2 m/hour was obtained. After 2.5 m penetration, the foundation started tilting. At 4 m penetration, the process was reversed until 3 m penetration. Then the penetration process was repeated without tilting problems. We believe the tilt problem was caused by a stone along the skirt circumference. The flow induced in the soil was blocked, indicating that a clay layer was present. Installation continued. The foundation was successfully installed with a 0.1 degree inclination out of vertical. 0,6 m stick-up due to sand wave.

23 Horns Rev 2, Scour protection Present Ph. D. Study Bucket lid, +0,7 m Seabed level Scour depth, -0,6 m Image: DONG Energy

24 Universal Foundation Suction Bucket Qualification Process Market Penetration Strategy Dogger Bank Met. Masts Trial Installations several sites on east coast England Demonstrator project Large scale commercial project Test of new technology Technology qualified for use Proof of concept Building experience & track record Industrialization

25 THE BUCKET FOUNDATION by Universal Foundation Present Innovation Projects in cooperation with AaU Carbon Trust Trial Installation Højteknologifonden Scope: To install THE BUCKET FOUNDATION in varying soil layers at up to 12 positions at the Dogger Bank/Dudgeon/Hornsea sites. The project is initiated through the Carbon Trust Offshore Wind Accelerator (OWA) where this THE BUCKET FOUNDATION is one of the final 2 chosen concepts. Timing: Two year period with start 1 st January 2013 Partners: Universal Foundation and Aalborg University External funding: the project is partly funded by Statoil / E.on / DONG / OWA and EUDP Cost-Effective mass production of Universal Foundations for large offshore wind parks Scope: Focus on design for mass production including introduction of a new laser welding process and a design configurator Timing: Three year period starting 1 st August 2013 Partners: Universal Foundation, FORCE Technology, LICengineering, Aalborg University and DTU Wind External funding: the project is partly funded by Højteknologifonden

26 THE BUCKET FOUNDATION by Universal Foundation Current Innovation Projects Carbon Trust Large Rotor Sensitivity Study Scope: Study of foundation sensitivity to large turbine rotor (5.0MW + 8.0MW) at increasing water depth The project is initiated through the Carbon Trust Offshore Wind Accelerator (OWA) where this THE BUCKET FOUNDATION is one of the final 2 chosen concepts. Timing: Completed mid-july 2013 Partners: Universal Foundation External funding: the project is fully funded by CT

27 Case: Forewind Dogger Bank East - Carbon Trust Offshore Wind Accelerator De-risk Project

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29 Case: Forewind Dogger Bank East - Carbon Trust Offshore Wind Accelerator De-risk Project

30 Case: Forewind Dogger Bank East - Carbon Trust Offshore Wind Accelerator De-risk Project

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