TECHNOLOGY AND INNOVATION Substructure design, manufacturing and new concepts

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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 15th
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TECHNOLOGY AND INNOVATION Substructure design,
manufacturing and new concepts
INNOVATIONS IN DESIGN AND INSTALLATION OF
OFFSHORE WIND TURBINE FOUNDATIONS THE DRILLED
CONCRETE MONOPILE Presented by Maarten van
der Veen Engineering Manager Ballast Nedam
Offshore
Stockholm, 2009 September 15th
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Saudi Bahrein Causeway
Basis Offshore Wind Design Construct Offshore
Wind Innovation
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Basis Offshore Wind Design Construct Offshore
Wind Innovation
Storebaelt Bridge
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Confederation Bridge
Basis Offshore Wind Design Construct Offshore
Wind Innovation
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Offshore Windpark Egmond aan Zee
Basis Offshore Wind Design Construct Offshore
Wind Innovation
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Rhyl Flats Offshore Windfarm
Basis Offshore Wind Design Construct Offshore
Wind Innovation
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Gunfleet Sands Offshore Windfarm
Basis Offshore Wind Design Construct Offshore
Wind Innovation
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Basis Offshore Wind Design Construct Offshore
Wind Innovation
Belwind Offshore Windfarm
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Basis Offshore Wind Design Construct Offshore
Wind Innovation
Experience steel monopiles

• 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 Monopile
• Concrete
• 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

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Basis Offshore Wind Design Construct Offshore
Wind Innovation
RD Drilled Concrete Monopile

• 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)

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FOUNDATION DESIGN
Basis Offshore Wind Design Construct Offshore
Wind Innovation

• 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

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FOUNDATION DESIGN
Basis Offshore Wind Design Construct Offshore
Wind Innovation

• Kriegers Flak (Baltic Sea)

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FOUNDATION DESIGN
Basis Offshore Wind Design Construct Offshore
Wind Innovation
North Sea (Moderate Hmax 11m)
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FOUNDATION DESIGN
Basis Offshore Wind Design Construct Offshore
Wind Innovation

• North Sea (Extreme Hmax 18m)

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MT Piling
Basis Offshore Wind Design Construct Offshore
Wind Innovation

• 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

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Basis Offshore Wind Design Construct Offshore
Wind Innovation
drilling equipment

• Drilling inside and under monopile

• Inside monopile
• Start drilling process
• Soft upper layers
• Diameter 5300 mm

• Under monopile
• Deeper soil layers
• Extended cutter head (6700/7100 mm)

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FABRICATION
Basis Offshore Wind Design Construct Offshore
Wind Innovation

• 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

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cost
Basis Offshore Wind Design Construct Offshore
Wind Innovation

• 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

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cost
Basis Offshore Wind Design Construct Offshore
Wind Innovation

• Total cost per MW as function of amount and
  turbine type

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CONCLUSIONs
Basis Offshore Wind Design Construct Offshore
Wind Innovation

• 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

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Thank you for your interest
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