Rajesh Panicker October 2013 Wind Turbine Installation Vessels – Classification Concepts...

Rajesh PanickerOctober 2013

Wind Turbine Installation Vessels – Classification Concepts

Supporting Sustainable Energy

© Det Norske Veritas AS. All rights reserved.

October 2013

Agenda

Introduction

Offshore Wind Developments

Classification Concepts

WTI Vessel concept – Driver for Rule and Flag requirements

DNV Rules for Wind Turbine Installation vessels

Class notations + Considerations

In-operation phase

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October 2013

DNV GL – The leading Classification society

InnovationHigh dedication to, and investment in, research & development

NetworkA world leading classification society with a dense station network across more than 80 countries

ExpertiseCombined leading technological expertise across all ship segments

ServiceWider and deeper service offering across all ship segments


October 2013

Electricity Generating Costs in EU, 2015 and 2030

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October 2013

Offshore Wind potential – new installations The European Wind Energy Association (EWEA) increased its 2020 target to 230 GW

wind power capacity, including 40 GW offshore wind (March, 2009)

To reach 40 GW of offshore wind capacity in the EU by 2020

Average growth in annual installations of 28% - from 0.4 GW in 2008 to 6.9 GW in 2020.

Assumption - 1 vessel installs 100 turbines per year, each turbine = 4 MW

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+ maintenance and repair

20-25 vessels needed in Europe

MarketUK 50%Germany 25%Rest 25%


October 2013

Europe Wind Potential

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October 2013

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WTI units in the market

>60-70% can not be used for future offshore developments- Insufficient crane capacity or - Insufficient size of vessel to support a large crane- weather restrictions

- Can not cope with the offshore environment – to much motions- No self propulsion or slow speed

May be used for support, maintenance and close to shore operation


October 2013

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WTI units in the market

During 2012 a number of new installation vessels were delivered, including.

• Northwind Installer by NorWind

• Pacific Orca by Swire Blue Ocean

• Seajacks Hydra and Zaratan by Seajacks

• Seafox 5 by Seafox Group

• Friedrich Ernestine by RWE Innogy

• Innovation by HGO InfraSea Solutions

Bold Tern by Fred Olsen Windcarrier

These purpose-built vessels, therefore, both reduce the number of harbour to wind farm site trips required during the installation process and increase the “weather window” during which offshore work can be carried out.


October 2013

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Growth in size of commercial wind turbine designs


October 2013

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October 2013

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Wind Turbine Foundations – Fixed


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Summary

Purpose built vessels are the future for Offshore Wind

Huge investment is required for construction and maintenance of fleet

Decommissioning of old offshore wind platforms to start from 2020.

About 20 new vessels under construction/ delivery 2012-13 - € 2.5 billion investment.

Douglass Westwood forecasts average € 15 billion per year investment over next ten years (2013-2022) in offshore wind sector.

UK Round 3 provide sufficient scale for this size of investment

US Offshore Wind Potential – Assessment in Progress


October 2013

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Classification as a concept

Classification is required when building a flagged vessel such as a WTI unit

Classification has gained world wide recognition as an adequate level of safety and quality process which provides a sound basic safety standard

Classification serves as a verification system for a number of parties who have special interest in the safety and quality of MOUs, such as:- National Authorities- Insurance underwriters- Owners- Building yards and

sub-contractors- Finance institutions- Charterers


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Owner, OperatorOwner, Operator

DNV-Class

Work ScopeWork Scope

Req

uir

emen

tsR

equ

irem

ents

Flag, Shelf, other

Classification Scope - Verification of Requirements

Clarification:

What is applicable for a wind turbine installation unit?

Statutory services based on delegated authority

from flag state


October 2013

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Classification of WTI vessels – dependant on how they operate

Type A)

”Ship shaped” Mobile Units


October 2013

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A) Mobile Operation - Features Designed both for transportation and installation of equipment.

Upload equipment at delivery port and sail fully loaded at high speed to installation site.

Effective propulsion and Dynamic Positioning system both for- Self propulsion - Positioning before jacking up

The vessel is designed to perform the complete installation cycle without assistance.

Main Characteristics

Ship-shaped hull.

Good/reasonable forward speed capabilities (+10 knots).

Unrestricted seagoing capabilities (without equipment).

May not be designed to survive heavy weather at site in elevated condition.

May choose to jack down and escape heavy weather.


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Classification of WTI vessels – dependent on how they operate

Type B) Stationary


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B) Stationary Operation Vessel stays continuously at the installation site

May be non-self propelled or have DP system, but then only for - Accurate positioning - Shorter field moves

Wind Turbine equipment are supplied to site by feeder vessels

WTI equipment installation implies offshore lifting

Long voyages of WTI vessel only by support of tugs or on deck of heavy lift transporter

Characteristics

Triangular or box shaped

Limited forward speed capabilities

Limiting/restricted seagoing capabilities

Capable of surviving heavy weather at site in elevated condition


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Offshore Unit or a Maritime Vessel in DNV?

Different type of offshore vessels or units

- Self Elevating Unit

DNV-OS-C104STRUCTURAL DESIGN OF SELF-

ELEVATING UNITS (LRFD METHOD

- Column Stabilized Unit

DNV-OS-C103STRUCTURAL DESIGN OF COLUMN

STABILISED UNITS (LRFD METHOD)

Ship Shaped Vessel

DNV-OS-C107SHIP SHAPED DRILLING AND

WELL SERVICE UNITS

Self elevating or Column Stabilized?

YesNo

Offshore StandardsShip Rules

DNV-OS-C104DNV-OS-C103DNV-OS-C107

or DNV Ship Rules Requirements related

to exploration and production of

HydrocarbonesX

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Definition of Class Rules & Statutory Certificates

i) Offshore Support/Crane Unit

• Offshore Rules• MODU code

ii) Self-elevating ”Cargo Ship”

• Ship Rules• MODU + SOLAS

+

The vessel will be a mix of the two regimes

Regime based on planned

operation.Decision by Flag State

+ SPS

”Stationary”

”Mobile”







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Definition of Class Rules & Statutory Certificates

Type A) Ship-shaped ”Mobile” Operation

”Cargo vessel” with self-elevating capabilities.

Enters ports to pick up equipment on regular basis.

DNV Rules for Classification of Ships to be used for all ship related items.

MODU code for the elevating phase

SOLAS certificates required because of the operation as a cargo ship.

Type B) ”Stationary” Operation

Well known concept from Oil & Gas Industry.

Designed and operated as a conventional Support/Crane Unit.

Can be designed according to MODU Code and DNV Offshore Standards.

SOLAS certificates may not be required, but this cut put limitations on how the vessel can be operated.







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Principles of classification WTI vessels

May not be designed to survive a 100y storm at location.

Then additional operational procedures to be established and followed:- Continuous monitoring of weather forecast- Preparedness for jack-down and escape

Robustness of jacking system to guarantee successful jack-down


October 2013

DNV Notation 1A1 Self-Elevating Wind Turbine Installation Vessel/ Unit

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Service notation introduced by DNV (October 2009) – OSS-101

Main motivation To provide a set of technical requirements. Recognition of vessels operational capabilities.

The requirements for the notation shall capture the primary functions and operations that are typical for these vessels.

May combine this with ”Crane Unit” This makes it easier for designers to meet our

requirements and for us to undertake the classification of the units.


October 2013

Ship-shaped self-elevating wind turbine installation vessels

Class assumptions:

Mix of offshore jack-ups and cargo ships

NO Oil & Gas in scope and price!!

Design assumptions

Vessels carry out repeated operations in restricted waters

Established practice is to allow for limited design conditions (unlike the design and class requirements for vessels used in the offshore oil and gas business).

The design requirements needs to be consistent in order to ensure robust designs that are capable to withstand the relevant design loads for all design/operational conditions,

or being able to escape in case of bad weather.

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October 2013

Basic principle

Hull & structure DNV OS-C107

(Section 1 A101)

DNV-OS-C104

The hull strength may be assessed according to DNV Rules for Classification of Ships Pt.3 Ch.1 for all transit and operational conditions.

Jack-up specific items (legs, jacking gear, guides, steel categorization, elevated conditions, overturning stability, preload capacity, fatigue)

Electrical systems DNV OS-D201 Same as DNV Ship rules Part 4 Chapter 8, hence no difference.

Marine and Machinery systems

DNV OS-D101 Same requirements as for ships Offshore refers back to Ship Rules Pt. 4

Preloading and piping arrangement, water intake

DP systems SHIP Rules

Pt.6 Ch. 7

Same requirements for ship and offshore

Instrument systems Ship control systems, engine control, ballast, bilge etc there are no differences between ship and offshore

Stability & watertight integrity

DNV OS-C301 Same requirements for ship and offshore

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Self-Elevating Unit


October 2013

Basic principle

Hull & structure DNV OS-C103 DNV Ship rules not relevant

Electrical systems DNV OS-D201 Same as DNV Ship rules Part 4 Chapter 8, hence no difference.

Marine and Machinery systems

DNV OS-D101 Same requirements as for ships but adjustments for Semi-specific items (ballast).

Offshore refers back to Ship Rules Pt. 4

DP systems SHIP Rules

Pt.6 Ch. 7

Same requirements for ship and offshore

Instrument systems: DNV OS-D202 Ship control systems, engine control etc there are no differences between ship and offshore

Ballast & bilge special for Semi design

Stability & watertight integrity

DNV OS-C301 Special for Semi design

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-

Column Stabilized Unit


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DNV Class Notation ”Wind Turbine Installation Unit”

May be assigned to different types of vessels- A) Semi-submersible type- B) ”Stationary” Self-elevating units- C) Ship-shaped self-elevating units - D) Ships with crane or other equipment specialised for WT Installation

Purpose of the new notation is to identify the main function of the unit and to develop classification rules which cover this function

Specific DNV ”WTI” Rules developed – first release October 2010, covering self-elevating units (B+C).


October 2013

Jacking system

Extended fatigue requirements to the jacking system because of many load cycles. (10 years operations x 100 moves per year)

Design and construction of jacking system should ensure the possibility for the vessel to go into a floating condition and escape from site.

It is a requirement to conduct an FMECAs (Failure Mode and Effect Criticality Assesment) with involvement of Class to highlight the critical issues with regard to jacking down and escape.

Specific Accidental Load criteria may be defined through the FMECA.

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October 2013

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Requirements to the jacking and control system

DNV-OS-D202 AUTOMATION, SAFETY, AND TELECOMMUNICATION SYSTEMS

Ch.1 Sec.1 208 An essential system A system supporting equipment, which needs to be in continuous operation or continuous available for on demand operation for maintaining the unit's safety. (Example propulsion and steering)

Ch.1 Sec.1 209 An important system A system supporting functions in order to perform in accordance to class equirement

B 500 Repairable systems (R3)501 A system serving a function of category R3 shall be designed to provide restoration of the function within a repair time specified for R3 in case of system failures .

Guidance note:Restoring a function may involve a number of manual operations, including minor replacements or repair of equipment.


October 2013

Hull Strength

Transit criteria

For the normal transit condition we advice the hull strength to be adequate for un-restricted operations – i.e. designed for a 20-year North Atlantic storm criterium.

This is in line with the +1A1 notation which is relevant as many vessels need to - Sail long distance from i.e. construction site in South East Asia to Europe. - Also the vessels may sail longer distances to operate in new geographical areas or the

voyage they travel for picking up equipment to the wind farm may be substantial.

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October 2013

Strength considerations

Deck strength

Large cargo weights require special strengthening of deck storage area.

Future increase in wind turbine weights should be accounted for.

Localized loads from cargo seafastening may apply.

Deck box often designed in consideration of moderate draught combined with large vessel width and long span between legs. Global bending and torsional stability of deck box to be documented.

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October 2013

Strength considerations due to Crane loads

For Crane Notation – crane must be certified by DNV.

Large crane loads must be accounted for in global analysis of vessel and combined with relevant environmental loading (waves, wind, current)

All relevant crane positions to be checked for.

Location of main crane around one leg will imply that this legs will see the highest utilization.

Interaction between crane, leg and jack house to be investigated and accounted for.

Insufficient stiffness of deck hull/jack house will imply that crane loads are supported/taken by the leg.

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October 2013

Design and construction of legs

Leg solutions vary substantially

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Circular legs Truss legs Square legs


October 2013

Leg design con’t

Vessels designed for restricted waters are also weight and strength optimized.

Fabrication tolerance requirements (as for ordinary jack-up legs)

High strength materials used in legs.

Welding qualification is important (procedures, testing etc).

Wear and tear from repeated jacking operations is important.

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October 2013

Spudcan design

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• Spudcan design affects the leg design and also the design of the hull.• Larger spudcans requires larger recess in the hull but implies less

seabed penetration.• Solution becomes a compromise.


October 2013

Statutory Compliance

SOLAS compliance needed for vessels operating between ports.

Large non-maritime crew requires additional SPS requirements to be fulfilled. This implies stronger requirements to stability and life saving.

MODU code requirements still valid for the elevated condition.

Flag state to decide level of compliance

DNV will assist in communication with flag state.

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October 2013

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Bringing the unit into operation – focus of Class Support

Drivers : Flexibility and Zero downtime

In operation:- Vessel is continuously mobilized with full crew and service personnel onboard - Operations costs are running…..

Concerns raised by owners:- They do not want to be constrained by a prescriptive survey schedule.

In order for DNV to support our client’s success factor we have developed and implemented suitable survey procedures

that can be done “on location” and without interrupting planned operations.

In order for DNV to support our client’s success factor we have developed and implemented suitable survey procedures

that can be done “on location” and without interrupting planned operations.

The most important success factor for the MOU or WTI unit owners: “zero downtime”

The most important success factor for the MOU or WTI unit owners: “zero downtime”


October 2013

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Increased Client Focus

Dedicated rig-coordinator for each unit (Germany/Holland/Norway/UK)- Available - acts as a single point of contact - Takes lead in initiating, planning, executing and controlling surveys- Acts as a part of a wide network that benefits Owner and DNV- Able to decide and resolve issues efficiently- Manages approvals related to modifications and upgrades

Dedicated fleet responsible for the owner in the head office (located in Oslo)

Reduced interruption to the operation.

Renewal survey on location if necessary

Continuous survey scheme (Hull, Jacking System, Crane..) – no surprises'

Approved Service Suppliers (NDE, chain, radio surveys…)

Bottom surveys


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Risk of Down time may be because of a too marginal design:

Down time or waiting time due to limitations in:- Elevated storm capacity- Jacking capacity- Sailing capacity- Deck payload capacity - Speed limitations- Vessel Stability- Capacity of crane

Robustness and design according to a well established design specification is a key to success.

Less may cost more….


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Improved Availability and Reliability – Class SupportHow can Class contribute?

Design phase Early involvement in design phase – review of Design Basis Specific class notation considering operational requirements Assist on clarification of Flag and other essential design requirements

In-service phase Optimized In-service Inspection Program – included in class fee (IIP) Systemize knowledge and sharing Class integrating with the owners maintenance scheme Partnership with the owners in developing new inspection methods Alternative risk based approaches


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Service

Thank You

Questions??


October 2013

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Service

Designs & Concepts


October 2013

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DNV Recent and Ongoing Projects

Fred Olsen Windcarrier – Brave

Tern & Bold Tern

MPI Adventure & Discovery

DDW Batam

2 units

1 unit

A2SEA Sea Installer

1 +1 unit


October 2013

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New projectsInwind – Stavanger

Yard selection in progress

Concept Approval

MPI - Holland

2 newbuilds at Cosco Nantong

Option for 2 more considered

Van Oord - Holland

Another NG-9000 unit

Quotation given to IHC Merwerde yard - Holland?

Züblin – Germany

1 newbuild


October 2013

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New designs

Houlder (Gaoh) – UKApproval in PrincipleDNV London

Ulstein Sea of Solutions - Holland

Approval in Principle


October 2013

Existing Wind turbine installation units

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Knud E. Hansen –

Hull length 161.2 m Hull width 42.00 m Hull depth 7.40 m Hull draft 6.20 m Leg length max. (incl. spud-can) 70.00 m

MPI Resolution

Hull length 130.5 m Hull width 38.0 m Hull depth 8.0 m

Leg length max. (incl. spud-can) 70.00 m


October 2013

GustoMSC designs

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NG-5300-HPE



NG-7500-HPE


NG-9000-HPE


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Huisman SWATH

Approval in Principle to be undertaken by DNV

• Structural strength• Vessel motions• Stability


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WTI R&D project in France

Independent verification of concept• Structural strength• Hydrodynamic analysis• Global motions• Vessel stability

Project delivery:”statement of feasibility”


October 2013

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Safeguarding life, property and the environment

www.dnv.com

Rajesh Panicker October 2013 Wind Turbine Installation Vessels – Classification Concepts...

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