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TECHNOLOGY AND INNOVATION Substructure design, manufacturing and new concepts. INNOVATIONS IN DESIGN AND INSTALLATION OF OFFSHORE WIND TURBINE FOUNDATIONS. Stockholm, 2009 September 15 th. TECHNOLOGY AND INNOVATION Substructure design, manufacturing and new concepts. - PowerPoint PPT Presentation
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15-09-2009
TECHNOLOGY AND INNOVATION Substructure design, manufacturing and new concepts
Stockholm, 2009 September 15th
INNOVATIONS IN DESIGN AND INSTALLATION OF OFFSHORE WIND TURBINE FOUNDATIONS
15-09-2009
TECHNOLOGY AND INNOVATION Substructure design, manufacturing and new concepts
Stockholm, 2009 September 15th
INNOVATIONS IN DESIGN AND INSTALLATION OF OFFSHORE WIND TURBINE FOUNDATIONS
THE DRILLED CONCRETE MONOPILE
Presented by:
Maarten van der VeenEngineering Manager Ballast Nedam Offshore
15-09-2009
Offshore Windpark Egmond aan ZeeBasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
Rhyl Flats Offshore WindfarmBasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
Gunfleet Sands Offshore WindfarmBasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
BasisOffshore Wind – Design & ConstructOffshore Wind – InnovationBelwind Offshore Windfarm
15-09-2009
Driven Steel monopiles• Expensive solution due to high and fluctuating steel price• Limited amount of suppliers• Limited production capacity• Drive and drill installation method• High noise impact
Drilled Concrete MonopileConcrete• Moderate and stable material price• Almost unlimited production capacity• Production can be done locally
Drilled working method• One method suitable for different soil conditions• No or limited noise impact
Monopile weight• Lifting capacity HLV Svanen (8.700 tons) more than sufficient
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
Experience steel monopiles
15-09-2009
Client: Vattenfall Vindkraft AB; Sweden
Location: Kriegers Flak
Power: 640 MW
Turbine type: 3.6 MW / 5.0 MW
Research executed in cooperation with MT Piling (50% Ballast Nedam Company)
Rostock
Kriegers Flak
Sassnitz
Świnoujście
R&D: Drilled Concrete MonopileBasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
FOUNDATION DESIGN
Performed design activities:
• Monopile for 3.6 MW windturbine at water depth of 30 m
• Monopile for 5.0 MW windturbine at water depth of 30 m
Representative soil profiles:
• Profile 1: Sand
• Profile 2: Clay
Stability
ULS: section forces, post tensioning and reinforcement
FLS: section forces, concrete
Strength Drillmix
Clamping force drilling machine
Storage concrete ring elements, lifting complete monopile
Concept design concrete ice cone
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
FOUNDATION DESIGN
Kriegers Flak (Baltic Sea):
5 MW3.6 MW
I II
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
FOUNDATION DESIGN
North Sea (Moderate; Hmax = 11m):
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
IVIII
15-09-2009
FOUNDATION DESIGN
North Sea (Extreme; Hmax = 18m):
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
V VI VII
15-09-2009
MT PILING
MT Piling modified the horizontal drilling technique to make it drill vertically. Experience gained in vertical drilling on the following projects which were completed successfully:
•Steel pile walls Amsterdam Central Station: - 90 piles Ø 1920 mm, max. length 70 m - no settlements occurred
•Ibis hotel Amsterdam:- 10 piles Ø 1220 mm; length 24 m
•Combi pile wall Den Haag:- 13 piles Ø 1420 mm; length 20 m
•City Inn hotel Amsterdam:- 2 piles Ø 1920 mm; length 20 m
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
Drilling inside and under monopile:
Inside monopile • Start drilling process• Soft upper layers• Diameter 5300 mm
DRILLING EQUIPMENT
Under monopile• Deeper soil layers• Extended cutter head (6700/7100 mm)
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
FABRICATION
Fabrication method conform
Saudi Arabia Bahrain Causeway (1984):
• Prefab reinforcement cages
• Casting ring elements
• Storage and curing ring elements
• Monopile assembly
• Aligning elements
• Grouting element joints
• Installation post tensioning
• Grouting post tensioning ducts
• Finishing works:
• Installation cutting toe
• Installation injection lines for drillmix
• Installation pile plugs
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
COST
Assumptions for cost indication:
• Production yard in port of Sassnitz
• Investment in 2 drilling machines for complete project
• Water depth 30 m
• Production and installation of complete project (128 foundations) in continuous process
• Prefab yard equipped for production of 1 monopile each 2 days; (365 days incl. start-up)
• Installation with HLV Svanen (net cycle 48 hr; 256 days)
• Excavated soil may be discharged into the sea
• Excluding weather downtime
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
COST
Total cost per MW as function of amount and turbine type:
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation
15-09-2009
CONCLUSIONS
Design:
• The concrete monopile is a technical sound foundation concept
Installation:
• The installation of the concrete monopile by vertical tunnelling from HLV Svanen is a technical feasible concept
• Foundation weights stay well within limits of HLV Svanen
Cost:
• The drilled concrete monopile is economically very competitive, especially for projects consisting of 40 or more foundations
Way forward:
• Further study and detailing of concept
• Conceptual design certificate – Det Norske Veritas
• Scale test
• Project realisation
BasisOffshore Wind – Design & ConstructOffshore Wind – Innovation