infrastructure access report · 2019. 5. 2. · infrastructure access report: tidalsensors rev. 02,...

Infrastructure Access Report

Infrastructure: FH-IWES Offshore Field Test Facilities

User-Project: Tidalsensors

Testing of biofouling survivalability of TidalsenseDEMO sensors in marine environment

EnerOcean SL

Marine Renewables Infrastructure Network

Status: Final Version: 02 Date: 03-Mar-2015

EC FP7 “Capacities” Specific Programme Research Infrastructure Action

Infrastructure Access Report: Tidalsensors

Rev. 02, 03-Mar-2015 of 15

ABOUT MARINET MARINET (Marine Renewables Infrastructure Network for emerging Energy Technologies) is an EC-funded network of research centres and organisations that are working together to accelerate the development of marine renewable energy - wave, tidal & offshore-wind. The initiative is funded through the EC's Seventh Framework Programme (FP7) and runs for four years until 2015. The network of 29 partners with 42 specialist marine research facilities is spread across 11 EU countries and 1 International Cooperation Partner Country (Brazil). MARINET offers periods of free-of-charge access to test facilities at a range of world-class research centres. Companies and research groups can avail of this Transnational Access (TA) to test devices at any scale in areas such as wave energy, tidal energy, offshore-wind energy and environmental data or to conduct tests on cross-cutting areas such as power take-off systems, grid integration, materials or moorings. In total, over 700 weeks of access is available to an estimated 300 projects and 800 external users, with at least four calls for access applications over the 4-year initiative. MARINET partners are also working to implement common standards for testing in order to streamline the development process, conducting research to improve testing capabilities across the network, providing training at various facilities in the network in order to enhance personnel expertise and organising industry networking events in order to facilitate partnerships and knowledge exchange. The aim of the initiative is to streamline the capabilities of test infrastructures in order to enhance their impact and accelerate the commercialisation of marine renewable energy. See www.fp7-marinet.eu for more details.

Partners

Ireland University College Cork, HMRC (UCC_HMRC)

Coordinator

Sustainable Energy Authority of Ireland (SEAI_OEDU)

Denmark Aalborg Universitet (AAU)

Danmarks Tekniske Universitet (RISOE)

France Ecole Centrale de Nantes (ECN)

Institut Français de Recherche Pour l'Exploitation de la Mer (IFREMER)

United Kingdom National Renewable Energy Centre Ltd. (NAREC)

The University of Exeter (UNEXE)

European Marine Energy Centre Ltd. (EMEC)

University of Strathclyde (UNI_STRATH)

The University of Edinburgh (UEDIN)

Queen’s University Belfast (QUB)

Plymouth University(PU)

Spain Ente Vasco de la Energía (EVE)

Tecnalia Research & Innovation Foundation (TECNALIA)

Belgium 1-Tech (1_TECH)

Netherlands Stichting Tidal Testing Centre (TTC)

Stichting Energieonderzoek Centrum Nederland (ECNeth)

Germany Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E.V (Fh_IWES)

Gottfried Wilhelm Leibniz Universität Hannover (LUH)

Universitaet Stuttgart (USTUTT)

Portugal Wave Energy Centre – Centro de Energia das Ondas (WavEC)

Italy Università degli Studi di Firenze (UNIFI-CRIACIV)

Università degli Studi di Firenze (UNIFI-PIN)

Università degli Studi della Tuscia (UNI_TUS)

Consiglio Nazionale delle Ricerche (CNR-INSEAN)

Brazil Instituto de Pesquisas Tecnológicas do Estado de São Paulo S.A. (IPT)

Norway Sintef Energi AS (SINTEF)

Norges Teknisk-Naturvitenskapelige Universitet (NTNU)

http://www.fp7-marinet.eu/


Rev. 02, 03-Mar-2015 of 15

DOCUMENT INFORMATION Title Testing of biofouling survivalability of TidalsenseDEMO sensors in marine environment

Distribution Public

Document Reference MARINET-TA1-Tidalsensors

User-Group Leader, Lead Author

Pedro Mayorga EnerOcean SL

User-Group Members, Contributing Authors

Infrastructure Accessed: FH-IWES Offshore Field Test Facilities

Infrastructure Manager (or Main Contact)

Hanno Schnars

REVISION HISTORY Rev. Date Description Prepared by

(Name) Approved By Infrastructure

Manager

Status (Draft/Final)

01 10/2014 First Draft Javier Fernández Draft

02 02/2015 Final Draft Pedro Mayorga Final Draft


Rev. 02, 03-Mar-2015 of 15

ABOUT THIS REPORT One of the requirements of the EC in enabling a user group to benefit from free-of-charge access to an infrastructure is that the user group must be entitled to disseminate the foreground (information and results) that they have generated under the project in order to progress the state-of-the-art of the sector. Notwithstanding this, the EC also state that dissemination activities shall be compatible with the protection of intellectual property rights, confidentiality obligations and the legitimate interests of the owner(s) of the foreground. The aim of this report is therefore to meet the first requirement of publicly disseminating the knowledge generated through this MARINET infrastructure access project in an accessible format in order to:

progress the state-of-the-art

publicise resulting progress made for the technology/industry

provide evidence of progress made along the Structured Development Plan

provide due diligence material for potential future investment and financing

share lessons learned

avoid potential future replication by others

provide opportunities for future collaboration

etc. In some cases, the user group may wish to protect some of this information which they deem commercially sensitive, and so may choose to present results in a normalised (non-dimensional) format or withhold certain design data – this is acceptable and allowed for in the second requirement outlined above.

ACKNOWLEDGEMENT The work described in this publication has received support from MARINET, a European Community - Research Infrastructure Action under the FP7 “Capacities” Specific Programme.

LEGAL DISCLAIMER The views expressed, and responsibility for the content of this publication, lie solely with the authors. The European Commission is not liable for any use that may be made of the information contained herein. This work may rely on data from sources external to the MARINET project Consortium. Members of the Consortium do not accept liability for loss or damage suffered by any third party as a result of errors or inaccuracies in such data. The information in this document is provided “as is” and no guarantee or warranty is given that the information is fit for any particular purpose. The user thereof uses the information at its sole risk and neither the European Commission nor any member of the MARINET Consortium is liable for any use that may be made of the information.


Rev. 02, 03-Mar-2015 of 15

EXECUTIVE SUMMARY The Tidalsensors testing project, supported by MARINET, has been a key element in achieving the objectives of the full project FP7 TIDALSENSE DEMO, assuring the survivability of the sensors and environmental resistance of the sensors bonding system and reconsidering the materials selection for the sensors encapsulation design. The solutions tested and validated had allowed this later demonstration to be a success in achieving several World Firsts. The SME team is the first in the world to use ultrasonic guided waves to monitor composite structures for underwater use. Secondly, one of the energy collector tested – a tidal sail – is the first of its kind to be fully engineered, in full size. And thirdly, the workshop tests were run while continuing the monitoring until the structure started to fail due to controlled overloading, this is not known to have been done before in tidal energy. EnerOcean was one of the leading SMEs and none of those objectives should have been possible without the confirmation by the Marinet Tidalsensor access of the seaworthiness of the encapsulation design and materials selection.


Rev. 02, 03-Mar-2015 of 15

CONTENTS

1 INTRODUCTION & BACKGROUND ....................................................................................................................... 7

1.1 INTRODUCTION.............................................................................................................................................. 7 1.2 DEVELOPMENT SO FAR ................................................................................................................................... 7 1.2.1 Stage Gate Progress ............................................................................................................................... 7 1.2.2 Plan For This Access ............................................................................................................................... 8

2 OUTLINE OF WORK CARRIED OUT ....................................................................................................................... 9

2.1 TEST PLAN ................................................................................................................................................. 9 2.2 RESULTS .................................................................................................................................................... 10 2.3 CONCLUSIONS ............................................................................................................................................. 12

3 MAIN LEARNING OUTCOMES ............................................................................................................................ 13

3.1 PROGRESS MADE ......................................................................................................................................... 13 3.1.1 Progress Made: For This User-Group or Technology .............................................................................. 13

3.2 KEY LESSONS LEARNED .................................................................................................................................. 13

4 FURTHER INFORMATION .................................................................................................................................. 14

4.1 SCIENTIFIC PUBLICATIONS .............................................................................................................................. 14 4.2 WEBSITE & SOCIAL MEDIA ............................................................................................................................ 14

5 APPENDICES ...................................................................................................................................................... 14

5.1 STAGE DEVELOPMENT SUMMARY TABLE ........................................................................................................... 14


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1 INTRODUCTION & BACKGROUND

1.1 INTRODUCTION Tidal currents are being recognized as a resource to be exploited for the sustainable generation of electrical power. The high load factors resulting from the fact that water is 800 times denser than air and the predictable and reliable nature of tides compared with the wind makes tidal energy particularly attractive for electric power generation. Condition monitoring will be key for exploiting it cost- efficiently. “TidalSense Demo” project has supposed the demonstration of the results obtained in TIDALSENSE project, in order to clear the pace of these technologies towards commercial maturity. The original project, TidalSense supposed the development of a condition monitoring system for tidal stream generator structures that started in September 2009 and finished in August 2011. The new project, TIDALSENSE DEMO has comprised the industrialization of the developed sensors for monitoring elements manufactured using modern composite materials, the study of their feasibility as condition monitoring equipment in several tidal energy converters (TEC), including different ones to those used as reference. As part of the industrialization of the sensors we have identified the testing of biofouling survivability of TidalsenseDEMO sensors in marine environment as a key test that can be carried on only in real sea conditions as in the Helgoland, Westmole facility.

1.2 DEVELOPMENT SO FAR

1.2.1 Stage Gate Progress Previously completed: Planned for this project:

STAGE GATE CRITERIA Status

Stage 1 – Concept Validation

Linear monochromatic waves to validate or calibrate numerical models of the system (25 – 100 waves)

Finite monochromatic waves to include higher order effects (25 –100 waves)

Hull(s) sea worthiness in real seas (scaled duration at 3 hours)

Restricted degrees of freedom (DofF) if required by the early mathematical models

Provide the empirical hydrodynamic co-efficient associated with the device (for mathematical modelling tuning)

Investigate physical process governing device response. May not be well defined theoretically or numerically solvable

Real seaway productivity (scaled duration at 20-30 minutes)

Initially 2-D (flume) test programme

Short crested seas need only be run at this early stage if the devices anticipated performance would be significantly affected by them

Evidence of the device seaworthiness

Initial indication of the full system load regimes

Stage 2 – Design Validation

Accurately simulated PTO characteristics

Performance in real seaways (long and short crested)

Survival loading and extreme motion behaviour.

Active damping control (may be deferred to Stage 3)

Device design changes and modifications


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STAGE GATE CRITERIA Status

Mooring arrangements and effects on motion

Data for proposed PTO design and bench testing (Stage 3)

Engineering Design (Prototype), feasibility and costing

Site Review for Stage 3 and Stage 4 deployments

Over topping rates

Stage 3 – Sub-Systems Validation

To investigate physical properties not well scaled & validate performance figures

To employ a realistic/actual PTO and generating system & develop control strategies

To qualify environmental factors (i.e. the device on the environment and vice versa) e.g. marine growth, corrosion, windage and current drag

To validate electrical supply quality and power electronic requirements.

To quantify survival conditions, mooring behaviour and hull seaworthiness

Manufacturing, deployment, recovery and O&M (component reliability)

Project planning and management, including licensing, certification, insurance etc.

Stage 4 – Solo Device Validation

Hull seaworthiness and survival strategies

Mooring and cable connection issues, including failure modes

PTO performance and reliability

Component and assembly longevity

Electricity supply quality (absorbed/pneumatic power-converted/electrical power)

Application in local wave climate conditions

Project management, manufacturing, deployment, recovery, etc

Service, maintenance and operational experience [O&M]

Accepted EIA

Stage 5 – Multi-Device Demonstration

Economic Feasibility/Profitability

Multiple units performance

Device array interactions

Power supply interaction & quality

Environmental impact issues

Full technical and economic due diligence

Compliance of all operations with existing legal requirements

1.2.2 Plan For This Access The Tidalsensors testing project has supportted the objectives of the full project TIDALSENSE DEMO, assuring the survivability of the sensors and environmental resistance of the sensors bonding system and reconsidering the materials selection for the sensors encapsulation design.

- Main objective: To define the most appropriate bonding solutions for the attachment of the sensors and their encapsulation and the best material or surface treatment for the sensors in order to reduce possible biofouling and microbiological induced corrosion. The systems have being tested under hydrostatic pressure during the design and the material selection has being prepared using only pressure resistance and chemical degradation criteria, now we want to select the best solution adding the effects of biofouling and microbiological induced corrosion to the equation.


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2 OUTLINE OF WORK CARRIED OUT

2.1 TEST PLAN The proposed test plan comprised the installation of a set of three different samples for each combination of encapsulation material, bonding adhesive and sealant. The initially forecasted number of combinations was three sets. The working plan started with a test design meeting for the preparation of the formats (GFRP substrate, simulating the surface of a tidal turbine blade) of the samples to be submerged under intertidal level at Helgoland pier. Once the combinations of solutions were defined, in-situ samples preparation, including the internal humidity sensors installation was organised, once all the materials and parts were manufactured.

Figure 1 – The generated samples installed in December 2012

The generated samples were installed in December 2012. At the end of June 2013, the samples were removed at the pier and after visual inspection, will be installed again for additional long term testing. At the end of the year 2013 further checking was performed and the best solution were finally identified.


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2.2 RESULTS Data acquisition of humidity sensor in installation is shown in Table 1:

Table 1 – The generated data December 2012

Status Material Number Date Hour Supply

Voltage

Sensor

Voltage

Estimated

RH (linear )

Notes

Out of Cap Sensor PVC 1.1 28 oct 2012 19:37:10 5.03 2.24 46.4%




Out of Cap Sensor Delrin 2.1 28 oct 2012 19:58:06 5.03 2.21 45.4%




Out of Cap Sensor Arnite 3.1 28 oct 2012 20:11:08 5.03 2.28 47.7%




Assembled Sensor PVC 1.1 1 nov 2012 11:56:13 5.02 2.09 41.5%




Assembled Sensor Delrin 2.1 1 nov 2012 12:45:12 4.99 2.175 44.3%




Assembled Sensor Arnite 3.1 1 nov 2012 17:15:32 4.99 2.13 42.8%




Pre-Installed at Helgoland Sensor PVC 1.1 19 dic 2012 12:00:00 PM 5.10 2.213 45.5%




Pre-Installed at Helgoland Sensor Delrin 2.1 19 dic 2012 12:00:00 PM 5.10 2.519 55.4%




Pre-Installed at Helgoland Sensor Arnite 3.1 19 dic 2012 12:00:00 PM 5.10 2.268 47.3%


Pre-Installed at Helgoland Sensor Arnite 3.3 19 dic 2012 12:00:00 PM 5.10 4.23 110.5% Out of Range


Installed at Helgoland Sensor PVC 1.1 20 dic 2012 12:00:00 PM 5.10 2.253 46.8%




Installed at Helgoland Sensor Delrin 2.1 20 dic 2012 12:00:00 PM 5.10 3.653 91.9% Very High: Water Inclusion

Installed at Helgoland Sensor Delrin 2.2 20 dic 2012 12:00:00 PM 5.10 3.408 84.0% Very High: Water Inclusion

Installed at Helgoland Sensor Delrin 2.3 20 dic 2012 12:00:00 PM 5.10 2.343 49.7%

Installed at Helgoland Sensor Delrin 2.4 20 dic 2012 12:00:00 PM 5.10 2.375 50.7%

Installed at Helgoland Sensor Arnite 3.1 20 dic 2012 12:00:00 PM 5.10 2.300 48.3%

Installed at Helgoland Sensor Arnite 3.2 20 dic 2012 12:00:00 PM 5.10 2.261 47.0%

Installed at Helgoland Sensor Arnite 3.3 20 dic 2012 12:00:00 PM 5.10 2.288 47.9% It was out of range: careful follow up

Installed at Helgoland Sensor Arnite 3.4 20 dic 2012 12:00:00 PM 5.10 1.242 14.2% Very Low: damaged becuase of water inclusion


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In June 2013 the samples were inspected again, unfortunately a falling of the supporting structure destroyed the signal boxing of the PVC samples tearing down the cables, stopping any option for further data collection. Delrin samples were all defective. The test followed due to the interest of assessing marine growth.

Figure 2 – Details of marine growth on PVC encapsulations in June 2013

Figure 3 – Details of marine growth on DELRIN encapsulations in June 2013

Figure 4 – Details of marine growth on ARNITE encapsulations in June 2013


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In December 2013 the samples were finally removed after being inspected again, massive marine growth over all the composite plate and on the connection boxes.

Figure 5 – Details of marine growth on PVC encapsulations in December 2013

Figure 6 – Details of marine growth on DELRIN encapsulations in December 2013

Figure 7 – Details of marine growth on ARNITE encapsulations in December 2013

2.3 CONCLUSIONS PVC encapsulation, one of the bonding glue options as glue and a protective sealant is the solution selected. This is the solution adopted in 12 of 16 sensors installed in the second DEMO, and 8 of 16 in the First DEMO of three DEMOS carried on in the Tidalsense DEMO project, due to the lack of feedback of this project at the time of installation (The samples were still underwater at Helgoland) and although we had no problems related to the encapsulation, better cable protection was identified as a need, and the validation of the selected configuration will give higher confidence for the future.


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3 MAIN LEARNING OUTCOMES

3.1 PROGRESS MADE

3.1.1 Progress Made: For This User-Group or Technology Based in the results of the tests, modifications to the deployment procedures for the sensors and their encapsulation were put in place. The results of Tidalsensor testing project inside MARINET framework has supported the following long term objectives of our TIDALSENSE DEMO Project:

1. To provide industrial validation to the TidalSenseDEMO as a complete Condition Monitoring System for key elements of tidal energy converters (TECs) manufactured with composite material using long range ultrasonic transducers (LRUT). This industrial validation will be carried on with full size, working elements and in real sea conditions, through a set of trials of enough duration and with different TECs.

2. To demonstrate maintainability, as well as the repeatability and reproducibility of the system, by performing transducer replacement over working elements and through comparison and analysis of the resulting data before and after the maintenance operation.

3. To perform a feasibility study and cost-benefit analysis that will demonstrate the applicability of the novel sensor-based condition / structural health monitoring system developed in the preceding SME RTD project TidalSense to a representative selection of tidal energy devices at real use conditions.

The solutions tested and validated in TIDALSENSOR had allowed this later demonstration inside the FP7 TIDALSENSE DEMO Project to be a success in achieving several World Firsts. The SME team is the first in the world to use ultrasonic guided waves to monitor composite structures for underwater use. Secondly, one of the energy collector tested – a tidal sail – is the first of its kind to be fully engineered, in full size. And thirdly, the workshop tests were run while continuing the monitoring until the structure started to fail due to controlled overloading, this is not known to have been done before in tidal energy. EnerOcean was one of the leading SMEs and none of those objectives should have been possible without the confirmation by the Marinet Tidalsensor access of the seaworthiness of the encapsulation design, materials selection and installation procedures..

3.2 KEY LESSONS LEARNED We obtained several learnings:

The importance of partial test of your selected manufacturing elements before full assembly is critical to assure a seamless deployment.

Difficulty overpassed thanks to the project: Be careful of "almost sure working" solutions, not all compatibility tables between bonding solution and substrate are reliable.

The "simple access" without continuous visit to the infrastructure helped us significantly, it is very important the support of the facility.

As technical achievements:

We had our Installation Procedure for our sensors validated thanks to Tidalsensor. We learned that once you have a validated procedure follow it without any modification. This has allowed us to successfully test with NAUTRICITY Prototype at EMEC nursery site and later with Aqua Energy Solutions in Cádiz.

We tested 3 different materials for sensor encapsulation, and obtain: o A PVC based solution (original design) o A High temperature alternative solutions for process integration o 4 combinations of adhesives and sealant tested combined with the 3 materials (12 options)


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o 2 combination of elements approved, installation procedure validation.

4 FURTHER INFORMATION

4.1 SCIENTIFIC PUBLICATIONS List of any scientific publications made (already or planned) as a result of this work:

An overview paper with a first summary of these results obtained here, together with the rest of initial results of the project TIDALSENSE DEMO, has been submitted to an international conference EWTEC2013, although finally it was not possible to present it there.

EnerOcean showed the testing plan and previous results of testing in previous phase in the MARINET users conference held in ROME MARINET USERWORKSHOP 6th of November 2013.

Part of these results has been published in the Technical deliverables of Wp2 and Wp4 of FP7 TIDALSENSEDEMO project, expressing the support received by MARINET and the EU.

A presentation in the Spanish APPA Marina session in Genera Energy conference held in Madrid in February 2013 shown part of the results, “Energías de las Corrientes, potencial existente en España y tecnologías auxiliares: TidalsenseDemo”, in Spanish.

A presentation called” TidalsenseDemo, from Theory to Demonstration” was made at the European Ocean Energy Conference 2013 in Edinburgh, October 30th, In this presentation the support of MARINET to TIDALSENSOR was presented as part of the activities developed.

4.2 WEBSITE & SOCIAL MEDIA Website: www.enerocean.com

http://www.tidalsensedemo.eu/ YouTube Link(s): http://youtu.be/QDu5pcY867Q

5 APPENDICES

5.1 STAGE DEVELOPMENT SUMMARY TABLE The table following offers an overview of the test programmes recommended by IEA-OES for each Technology Readiness Level. This is only offered as a guide and is in no way extensive of the full test programme that should be committed to at each TRL.


Rev. 02, 03-Mar-2015 of 15

infrastructure access report · 2019. 5. 2. · infrastructure access report: tidalsensors rev. 02,...

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