double slip joint - winddays...2018/06/13  · cranefree gravity foundation ( seatower) (undisclosed...

Westpoint Building 2 | De Brauwweg 60 | 3125 AE Schiedam | The Netherlands | www.kci.nl | info@kci.nl

Schiedam, 2015WindDays - 13thJune 2018

Double Slip Joint Innovative Pile Connection

About KCI

• Oil & Gas

• Renewables

• Equipment

• Wheels

1.3 Substations

Riffgat (Basic Design (2nd BSH), Detailed Design (3rd BSH)) DanTysk (Basic & Detailed Design) Luchterduinen (Owners engineering) Horns Rev C (Detailed engineering) Offshore Switch Yard (Elia, Belgium, Basic Design) Wikinger (Iberdrola, Germany:

Concept Design, Basic Design, Detailed Design, Fabrication support) Meerwind (WindMW, Germany, Basic Design, Detailed Design) Gemini (Iemants, The Netherlands, all jacket calculations) Riffgat (Hollandia Strukton, Germany, Basic Design, Detailed Design) DanTysk (Hollandia Strukton, Germany, Basic Design, Detailed Design) Offshore Switch Yard (Elia, Belgium, Basic Design)

Wind Turbine Foundations

GBFs Blyth Offshore Wind

Demonstrator Secondarysteel design

Further development of transition piece design Cranefree Gravity Foundation (Seatower) (undisclosed project)

Monopiles Bearing Solution MP-TP Double Slip Joint (patented)

Jackets Three legged Jacket Light Transition Piece Double boatlanding

About KCI

135 m

London Paris

324 m

Wheels – Ain Dubai(under construction)

Special relations

R&D Consortium

Installation Fabrication

Design

SIEMENS

Valuable feed-back

Question

“What do you think can be improved for TP connections ?”

8 Monopile connections (left 4 concepts are based on presentation for event Smulders 1000 TP)

Dowec ‘03

How it works

Foundation pile

Conical rings Taper angle ≈ 2⁰

ICCP anode

Transition Piece

4 m

2⁰

How it works - Sketch

• Material: St355

• Minimum machining

• Tolerance angle ± 0.1°

How it works - vertical self settling

Load

Slip

Storm 1(SW)

Storm 2(W)

Storm 3(NW)

time

locked

≈ 150mm

Pile

Self-tightened/lockedSteel on steel contact

How it works – roundness settling

How it works – roundness settling

100% settled(100% contact)

5% settled(75% contact)

Before settling(contact at 3 points)

Well defined contact between rings

Tapered rings

Bending moment is fully transferred by friction- connected as if welded

MF

How it works – Load transfer by friction

Settling by natural turbine loads- no special tools required

Tapered rings

How it works – Settling by natural loadsF

M

Attractiveproperties

Benefits – 1 of 5

Tapered rings

1) Simple, no grout or bolts, contact at conical steel surfaces

Fast: TP installation cycle 30% shorter:

• Smaller installation vessel spread

• Short offshore campaign

• Logistics of entire project speeding up

Tapered rings

2) Fast installation

1) Simple, no grout or bolts, contact at conical steel surfaces

Benefits – 2 of 5

Safe:

• The DSJ avoids the awkward unstable moment of pin-point placement of the TP on the pile

Tapered rings

2) Fast installation

3) TP instantly stable after placing it on the pile

1) Simple, no grout or bolts, contact at conical steel surfaces

Benefits – 3 of 5

Safe:

• No access to the TP required

Tapered rings

2) Fast installation3) TP instantly stable after placing it on the pile

4) Personnel access and manual work on the TP not required

1) Simple, no grout or bolts, contact at conical steel surfaces

Benefits – 4 of 5

5) Connection can be deep under water

2) Fast installation

Why is this important ?Tapered rings

3) TP instantly stable after placing it on the pile 4) Personnel access and manual work on the TP not required

1) Simple, no grout or bolts, contact at conical steel surfaces

Benefits – 5 of 5

Weight split 50%

200 ton25 m

1200 ton80 m

Typical foundation for 8 MW turbine

Bolted TP

flanges

groutskirt

40m

20m

With DSJ

700 ton45 m

700 ton55 m

Relevant for building future turbines ! 10-15 MW

Future XL foundation for 15 MW

1500 ton

1500 ton

TP installation

Tower installation

Future XL foundation for 15 MW

1. Simple connection, no grout or bolts

2. Fast installation

3. TP instantly stable on the pile

4. Personnel access and manual work on TP are not required

5. Connection can be deep under water (weight split 50%)

Five Benefits - summarized

“Plug & Go”

Test set-up

F

EquivalentMoment & force

MP clamped

TP neutral weight

M

Prototype SIF

Length 15m + 6mWeight 12t + 5 t

Scale 1:5 for 8 MW(or full scale 500 kW)

Test set-up WMC

6 ton6 ton

Test results – cyclic bending

Limit 8 mm

Limit 12 mm

125 cycles

125 cycles

Test results - irregular loads

Various rings manufacturing methods

1) Rollingconical strips 800x130 mm

2) Forging and final machining

3) Expansion first cylindrical rolling

Tolerances• wedge angle • Circumference • Ring flatness • Ring distance

Manufacturing costs

Tolerances• wedge angle • Circumference • Ring flatness • Ring distance

Manufacturing costs

Tolerances• wedge angle • Circumference • Ring flatness • Ring distance

Manufacturing costs ?

Business case – main conclusions

1. The most appealing properties: simple, robust and stable connection

2. Costs of installation are 30% lower

3. Costs manufacturing are also lower (especially with future larger turbines)

4. The installation is faster and safer, reducing the project schedule and project risks

5. No investments in the organization, supply chain or installation equipment

6. More flexibility in the employability of the installation fleet for future XL foundations.

Time line for Double Slip Joint development

Feasibility

Mini-testsWoZ medium-tests

Full scale demo

Ready for commercial use

WoZ award

1:30

1:5

1:1

futureJan 2014 (graduation TUD)

Jan 2015-2016(graduation TUD)

2017(consortium)

• Our product: foundation & connection concept

• Offshore wind farm - 2019 ?

Time line for Double Slip Joint development

Actual & Perceived risksJudging risks and returns

Use proven technologyUse the Double Slip Joint – “risks”: Returns: Use the Double Slip Joint – “risks”:• Does it work ?• Failure modes, corrosion ?• Time risks ?• Unknown risks ?

Returns:• Lower costs supply & installation• Shorter installation schedule• Lower O&M costs• No risks of bolt/grout failure

Question

• Dynamic Strength

• TP Installation speed

• Low Risk, Safety

• Cost Efficiency

“What do you think can be improved for TP connections ?”

Questions ?

Boudewijn van Gelderb.vangelder@kci.nl

Thank you !