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Vindmølleindustrien - dansk konkurrenceevne i en global industri 2. juni 2014 Case: Aalborg University - Universal Foundation Søren A. Nielsen, Director Technology
Vindmølleindustrien - dansk konkurrenceevne i en global industri
2. juni 2014
Case: Aalborg University - Universal Foundation
Søren A. Nielsen, Director Technology
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 2013. 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 - HQ: Aalborg
82%
Minority
investors
18%
Universal Foundation
NO
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: 20-55 meters
A hybrid solution
linking the gap
between the
“Industry Darling”
Monopile and the
“Inherently
expensive
transitional waters”
Jacket
THE BUCKET FOUNDATION by Universal Foundation
The Competitive Advantage
The Carbon Trust / Offshore Wind
Accelerator (OWA) Perspective
Fabrication
Simple welds
Reduced weight
Installation
Reduced vessel requirements,
fewer offshore operations
No piling noise – “eco-friendly”
O&M
No grout failures
Easy decommissioning
Commercial
Fred Olsen end-to-end “One Stop Shop” model
THE BUCKET FOUNDATION by Universal Foundation
Fabrication
Installation
O&M
Commercial
8.0MW
CT Project
Bucket
Foundation
Comparable
Monopile
25m 670 t 840 t
35m 820 t n/a
45m 1.030 t n/a
55m 1.260 t n/a
The Lid
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
Transfer of loads
Welded of cut plates 20-40 mm
Suitable for mass production of elements
Pre-fabrication of shell plates
Cell-assembly
Flushing system on the rim
The Shaft
The Skirt
+25%
Estimates only accounts for primary steel
Excludes secondary steel
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 / 25 – 55 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)
Test site for offshore wind turbine in Frederikshavn
8
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.
Frederikshavn in operation for 11 years
Installation of prototype Nov. 2002
Penetration Control
AaU active participation
Installation of Bucket Foundation in Frederikshavn
Physical Modelling Sand - Transient Loading
Bucket for Model Testing
13 Pore Pressure Transducers
2 Buckets
H/D = 0,5
H/D = 1,0
Physical Modelling Sand - Transient Loading
Physical Modelling Sand - Transient Loading
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 23rd (2013) International Offshore and Polar Engineering
Conference. Vol. 2 International Society of Offshore & Polar Engineers, 2013, pp.
465-471 (International Offshore and Polar Engineering Conference. Proceedings).
The Boot Effect
Wilhelmshaven Bucket
ENERCON E-112 – 4.5 MW 16 m diameter / 15 m skirt / 450 tons
Soil Profile Wilhelmshaven
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 80-160mm bump. (back calculated)
• Buckling at a penetration of 6.8 m
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
2008.
Installed at Horns Rev 2 Offshore
wind farm in March 2009.
Decommission 2014
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.
Up-ending and adding connections
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.
Horns Rev 2, Scour protection – Present Ph. D. Study
Image: DONG Energy
Seabed level
Bucket lid, +0,7 m
Scour depth, -0,6 m
Universal Foundation Suction Bucket Qualification Process
Dogger Bank Met. Masts
Demonstrator project Large scale commercial
project
Trial Installations several sites on
east coast England
2013 2014 2015 2016 - 2017
Test of new
technology
Technology
qualified for use
Proof of concept Building
experience &
track record
Industrialization
Market
Penetration
Strategy
THE BUCKET FOUNDATION by Universal Foundation
Present Innovation Projects in cooperation with AaU
Carbon Trust Trial Installation
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 1st January 2013
Partners: Universal Foundation and Aalborg
University
External funding: the project is partly funded by
Statoil / E.on / DONG / OWA and EUDP
Højteknologifonden
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 1st August
2013
Partners: Universal Foundation, FORCE
Technology, LICengineering, Aalborg University
and DTU Wind
External funding: the project is partly funded by
Højteknologifonden
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
Case: Forewind Dogger Bank East - Carbon Trust Offshore Wind Accelerator De-risk Project
Case: Forewind Dogger Bank East - Carbon Trust Offshore Wind Accelerator De-risk Project
Case: Forewind Dogger Bank East - Carbon Trust Offshore Wind Accelerator De-risk Project
Thank you for your attantion
For more information please contact:
www.universalfoundation.dk
Questions ?
