Industrializing Offshore Wind Power with Serial Assembly and Lower-cost Deployment - Final Report
A team of engineers and contractors has developed a method to move offshore wind installation toward lower cost, faster deployment, and lower environmental impact. A combination of methods, some incremental and some breaks from past practice, interact to yield multiple improvements. Three designs were evaluated based on detailed engineering: 1) a 5 MW turbine on a jacket with pin piles (base case), 2) a 10 MW turbine on a conventional jacket with pin piles, assembled at sea, and 3) a 10 MW turbine on tripod jacket with suction buckets (caissons) and with complete turbine assembly on-shore. The larger turbine, assembly ashore, and the use of suction buckets together substantially reduce capital cost of offshore wind projects. Notable capital cost reductions are: changing from 5 MW to 10 MW turbine, a 31% capital cost reduction, and assembly on land then single-piece install at sea an additional 9% capital cost reduction. An estimated Design 4) estimates further cost reduction when equipment and processes of Design 3) are optimized, rather than adapted to existing equipment and process. Cost of energy for each of the four Designs are also calculated, yielding approximately the same percentage reductions. The methods of Design 3) analyzed here include accepted structures such as suction buckets used in new ways, innovations conceived but previously without engineering and economic validation, combined with new methods not previously proposed. Analysis of Designs 2) and 3) are based on extensive engineering calculations and detailed cost estimates. All design methods can be done with existing equipment, including lift equipment, ports and ships (except that design 4 assumes a more optimized ship). The design team consists of experienced offshore structure designers, heavy lift engineers, wind turbine designers, vessel operators, and marine construction contractors. Comparing the methods based on criteria of cost and deployment speed, the study selected the third design. That design is, in brief: a conventional turbine and tubular tower is mounted on a tripod jacket, in turn atop three suction buckets. Blades are mounted on the tower, not on the hub. The entire structure is built in port, from the bottom up, then assembled structures are queued in the port for deployment. During weather windows, the fully-assembled structures are lifted off the quay, lashed to the vessel, and transported to the deployment site. The vessel analyzed is a shear leg crane vessel with dynamic positioning like the existing Gulliver, or it could be a US-built crane barge. On site, the entire structure is lowered to the bottom by the crane vessel, then pumping of the suction buckets is managed by smaller service vessels. Blades are lifted into place by small winches operated by workers in the nacelle without lift vessel support. Advantages of the selected design include: cost and time at sea of the expensive lift vessel are significantly reduced; no jack up vessel is required; the weather window required for each installation is shorter; turbine structure construction is continuous with a queue feeding the weather-dependent installation process; pre-installation geotechnical work is faster and less expensive; there are no sound impacts on marine mammals, thus minimal spotting and no work stoppage Industrializing Offshore Wind Power 6 of 96 9 for mammal passage; the entire structure can be removed for decommissioning or major repairs; the method has been validated for current turbines up to 10 MW, and a calculation using simple scaling shows it usable up to 20 MW turbines.