double slip joint - winddays...2018/06/13 · cranefree gravity foundation ( seatower) (undisclosed...
TRANSCRIPT
Westpoint Building 2 | De Brauwweg 60 | 3125 AE Schiedam | The Netherlands | www.kci.nl | [email protected]
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 [email protected]
Thank you !