Renewables

Renewables

Detail design of the substructure and topside of the substation RIFFGAT

Pile gripper design

Deck layout cable laying vessels

Detail design of the substructure and topside of the substation DANTYSK

Meerwind transformer platform

KCI can assist offshore wind developers and EPIC contactors during field development. We offer consultancy and engineering services including the design of foundations, cables, met masts and substations. Through KCI’s smart tool TILT (Transport & Installation Logistics Tool), in depth insight in the logistics process and its most stringent bottlenecks can be achieved. We support our clients during the complete life cycle of an offshore windfarm from first concept to decommissioning or life time extension.
KCI has already been involved in the design of over 15 offshore wind farms in northwestern Europe.
 
Specialties
In house design from feasibility study to detailed design of substations, substructures and foundations • own concepts for 3-and 4-legged jackets & monopiles • own design for  floating & self-installing substations • innovative logistics tool TILT • sea bed analyses to determine most efficient subsea cable routes • integrated safety analysis • onsite fabrication supervision • offshore monitoring during installation phase

Topside Offshore Substation Horns Rev C

In 2014 Danish grid operator Energinet.dk awarded the design & build contract for the topside of the Horns Rev C offshore substation to HSM. KCI won the tender to support HSM with engineering services.

The KCI scope consists of carrying out a complete design review, completing the detailed design and where required re-engineer parts of this offshore wind substation topside.

Additional services for the Horns Rev C Topside:

  • Procurement support by doing the preparation of tender packages for the equipment and instrumentation.
  • Procurement support by providing a full technical review of the bids for the various packages.

 

Phase of Development
Technical Review, Basic Design

Year of Project
2014 - 2016

Location
Offshore

Client
HSM /  Energinet.dk

Double Slip Joint (DSJ)

In 2013 KCI started a research project in cooperation with the Delft University of Technology (TU Delft) to develop a better concept for the connection between monopiles and transition pieces. Grouted and bolted connections had shown their complications and a new and cost effective alternative would be interesting for the Offshore Wind market, thus thought KCI's R&D department. The intensive reseach study ultimately has led to the development of the Double Slip Joint (DSJ).

In the double Slip Joint connection, 2 sets of rings with matching conical surfaces are integrated in the standard cylindrical tubes of the foundation pile (FP) and the transition piece (TP). The conical surfaces are tapered at about 2 degrees, providing a well-defined self-locking steel on steel connection after installation of the TP, which acts as if the rings are welded together.

Advantages of the DSJ

  • Short installation time, no waiting time needed for grout material to cure or bolts to be tightened
  • Ease of installation: self-locking system due to operational loading of WTG
  • Less handling/operations offshore
  • Ease of fabrication, cylindrical rolled plate (no cones)
  • Sharp decrease of installation costs

Phase of Development
R&D, Concept & Detailed Design

Year of Project
2013 - 2016

Location
Offshore

WTG jacket design for Hohe See Poject

KCI performed the concept and the FEED (2nd BSH) for a jacket foundation for a 6MW turbine in the North Sea.

After studying and evaluating various concepts a lightweight 3 legged pre-piled design was developed with several innovative smart features. This design results in less deck space on the installation vessel, fewer piles/ less pile driving and fewer nodes. Pre-piling and variable stick-up height makes one single design suitable for a wide range of water depths.

Other new features are its lightweight and patented transition piece and a double-boat landing which is accessible from 2 directions.

Water depth at the site is just over 40 meters, but due to the variable stick-up height of the piles, the concept can be adjusted for greater water depths. At the time the FEED was finished and the first load iteration with the WTG supplier held and the feedback incorporated in the design.

Phase of Development
Concept and Basic design

Year of Project
2011 - 2012

Location
Offshore

Client
EnBW

Recent experiences
Concept design for 3 UK projects including time series with an 8MW turbine
 

Detail design of the substructure and topside of the substation RIFFGAT

KCI completed the engineering for German Offshore wind project Riffgat in March 2013. The Riffgat (also known as OWP Riffgat) is an offshore wind farm 15 kilometers (9.3 mi) to the north-west of the German island of Borkum and north of the shipping channel in the southern North Sea. The wind turbines are built across an area of 6 square kilometers.

In April 2010, KCI was awarded the engineering for structural, utility systems and 3D interfacing design for both the jacket and the topside. Just before sail away in February 2013, KCI engineers carried out a final inspection of the topside at Hollandia’s yard. The topside set sail to the German part of the North Sea where it was successfully hooked up to the jacket foundation, also developed by KCI

 

Phase of Development
Detailed design

Year of Project
2010-2012

Location
OFFSHORE in the Southeastern North Sea within the exclusive Economic zone of the Federal Republic of Germany

Client
Hollandia B.V. and Strukton Systems B.V.

Monopile concept designs for Borssele Project

For the announced Dutch Borssele I and II projects several clients awarded KCI with the concept design of the monopile foundations. The output from KCI is typically used as input in the tenders of the clients to help them submit a competitive bid for the development of the Borssele sites.

Phase of Development
Concept design

Year of Project
2016

Location
Offshore

Client
Various

Gravity Base Foundations

For various clients and projects, KCI is assisting in the design of Gravity Base Foundations.

Where the experience and strength of KCI do not lie in the concrete parts of these foundations, KCI is very experienced in designing the steel transition pieces and secondary steel. KCI is also well aware of best industry practices and the requirements of various WTG suppliers.

Phase of Development
Concept and Basic design

Year of Project
2015 - 2016

Location
Offshore

Client
Various clients
 

Basic and Detail Design OSS Jacket Baltic Sea

KCI performed the concept and basic design (2nd BSH) for a Jacket foundation of an Offshore Substation in the Baltic Sea in 2013.

Various concepts were investigated ranging from a jacket with 4 to 8 legs, and post- and pre-piled options were studied. The final concept consisted of 6 legs and is a pre-piled jacket, which was the starting point for the basic design.

In 2014 KCI started the Detail Design (3rd BSH) for the same OSS jacket.

Phase of Development
FEED and Detailed design

Year of Project
2013 - 2016

Location
Offshore

Client
Iberdrola

Pile gripper design

Innovative pile gripper design for Geosea excelling in superb performance and low maintenance costs due to simplicity of the design.

KCI performed the concept, basic and detailed engineering of a pile gripper that guides monopiles during the lowering and driving phase of the installation. It compensates for horizontal movements in both longitudinal and transverse direction. Besides the positioning of the pile, the gripper also extracts energy from its pendulum motion during the pile lowering to seabed, preventing resonance. The pilegripper is used for piles upto 60 m long with a diameter upto 6.5 m.

Phase of Development
Concept, basic and detailed design

Year of Project
2013

Location
OFFSHORE

Client
GeoSea

Deck layout cable laying vessels

As a true back-deck specialist, KCI provides its customers a complete in-house service encompassing all prerequisites to design, engineer and manufacture equipment ranging from single components to complete marine handling systems. Customers like to involve KCI at an early stage to keep design options open so KCI’s creative and experienced engineers can come up with the best conceptual solutions. We love to spar with you from first ideas, can quickly deliver FEEDs, basic and detailed designs and can take care of fabrication & installation management.

KCI has been involved in a large number of cable lay-deck layouts. Ranging from smaller, project specific mobilisations to generic deck layouts of cable-lay vessels, such as Boskalis’ NDurance and Van Oord’s Nexus. For both vessels KCI has been involved from the conceptual stage to the detailed phase of designing equipment and vessel interfaces.

Phase of Development
Engineering aspects from concept to detailed design and shop drawings

Year of Project
2008 - 2015

Location
OFFSHORE

Client
Van Oord, Boskalis, Oceanteam, Tideway, GeoSea

R&D project XL monopiles

KCI has investigated the effects of applying monopiles in larger water depths and with bigger wind turbines.

KCI developed in-house routines to quickly assess the feasibility of any combination of water depth and wind turbine to optimize the monopiles (e.g. weights and wall thickness) for each and every monopile location.

Additional activities performed:

  • KCI performed analyses in association with Cathie Associates on the applicability of p-y and t-z curves on XL monopiles in various types of soil
  • First setup of load iteration with MVOW for V164 by exchanging stiffness matrices.
  • Prepared parametric drawing for primary steel
  • Designed typical secondary steel for XL-monopiles
  • Reviewed the general effects of soil properties on XL-monopiles
  • Assess current available designs for transition pieces in the market.

Phase of Development
R&D, Concept design

Year of Project
2014 - 2015

Location
Offshore

Client
Internal

Detail design of the substructure and topside of the substation DANTYSK

DanTysk Offshore Wind GmbH built a wind farm that is located in the North Sea west of the island of Sylt and consists of 80 wind turbines and a transformer platform. The total energy production provides energy for approximately 400,000 households.

KCI provided the detailed structural design of both the topside and the jacket.

Phase of Development
Detailed design

Year of Project
2011 - 2013

Location
OFFSHORE North sea, along the German Danish border

Client
Hollandia B.V. and Strukton Systems B.V.

Rotor Installation Engineering for BARD Wind Farm

In 2011 and 2012 KCI assisted the BARD project with the installation engineering.

The scope consisted of various parts:

  • Prepare the concept for WTG & WTG foundation installation
  • Design and analysis of lifting and upending method
  • Design and select tools and equipment
  • Prepare installation procedures

In order to execute the scope succesfully the following analyses were performed:

  • Floating Stability Analysis
  • Hydrodynamic Response (RAO)
  • Rotor Tip Wave contact Analysis
  • Workability Optimization Analysis
  • Site Specific Assessments
  • Dynamic Lifting Analysis Rotor
  • Deck Lay-out and Deck strength
  • Operational procedures
  • Rotor offloading and deck fixation

 

Phase of Development
Installation Engineering

Year of Project
2011 - 2012

Location
Offshore

Client
BARD

Princes Amalia Wind Park - Mitigating Measure for failing Grout Connection Monopiles

In 2011, during site inspections, performed on behalf of the owner of the Princess Amalia Wind Farm (Eneco), differential vertical settlements at the grouted connection between the transition piece and monopile of several wind turbine generators (WTG’s) were observed.

The grouted connection, as designed by another company, was failing and further analysis demonstrated the situation would only deteriorate as a result of the continuous axial forces.

In 2012 KCI was hired to design a mitigating measure to correct the failing connection and to provide a maintenance-free solution to transfer the vertical forces from transition piece to monopile for the remainder of the lifetime of the park.  

Phase of Development
Concept and Basic design

Year of Project
2011 - 2012

Location
Offshore

Client
Eneco
 

Gwynt-Y-Mor Offshore Substation concept

KCI performed the concept design for the self-installing substation with suction buckets for the Gwynt-Y-Mor Field for Siemens.

This field has a depth up to 28 meters for which a self-installing option was found to be a good fit. The proof of concept was delivered by the Oil & Gas projects at the P-Blocks in The Netherlands, where KCI installed this concept on five locations.

Additional services on the Gwynt-Y-Mor OWF

  • Installation planning and engineering for RWE.
    KCI performed the transport and installation engineering.
    For the logistics KCI have advised the client based on our in house developed logistics tool TILT. On basis of which vessels, barges, quay side sizing, personnel, etc. can be estimated based on acceptable risk levels. Risk assessments are carried out for uncertainties such as weather and availability of personnel, equipment and material.
  • Grillage & Seafastening design for Monopiles & Transition Pieces for RWE.
  • Grillage & Seafastening design for the Offshore Substation Jacket and Piles for Seaway Heavy Lifting

Phase of Development
Concept, Basic and Detailed Design

Year of Project
2011 - 2012

Location
Offshore

Client
Siemens

Installation Engineering Globaltech – Time-domain Installation Analysis

In 2012 KCI performed the installation support to Van Oord for the installation of the WTG foundations for Global Tech I (tripods).

  • Lifting operation simulation
  • Modelling of jack-up motions, crane motions, lifting wires & spreader
  • Installation Support on site
  • Workability Optimization
  • Smart Rigging Design
  • Stabbing Procedure

Additional activities performed:

  • Range of supporting activities relating to operations
  • Owners engineering for Global Tech I

 

Phase of Development
Installation Engineering

Year of Project
2012

Location
Offshore

Client
Van Oord

Meerwind transformer platform

The offshore wind farm 'Meerwind Süd und Meerwind Ost' consists of 80 wind turbines and one transformer platform and is located in the German Bight in the North Sea. KCI provided the basic and detailed design of the substructure of the transformer platform. The 4-legged jacket substructure features a boat landing and a total of 18 J-tubes.

Phase of Development
Basic and Detailed design

Year of Project
2010 - 2013

Location
OFFSHORE

Client
WindMW GmbH

Offshore Substation NordSee Ost

KCI was awarded the Concept, Basic and Detailed design (2nd and 3rd BSH) of the NordSee Ost topside by Siemens.

KCI performed the concept engineering for the self-installing substation layout (with suction anchors) for NordSee Ost, Germany for Siemens. An evaluation was made between self-installing and fixed structure. A final decision was made based on economics, vessel availability and finally client preferences to use a turbine foundation as OSS foundation. Water depth at the location for the substation is 25 meters.

After the Concept design, Siemens awarded the Basic and Detailed design to KCI as well.

KCI s responsibility includes for the topside steel and utility design and the integration of all (HV) systems into the platform.

Additional services on the NordSee Ost OWF

  • Owners engineering for RWE.
  • KCI provided direct support at the office

Phase of Development
Concept, Basic and Detailed Design

Year of Project
2010

Location
Offshore

Client
Siemens

Gemini Jacket design

KCI performed the calculations for the FEED and detailed design of 2 foundations for 2 offshore substations: Buitengaats and Zee-Energie in the North Sea in 2013 for Iemants. The jackets are 4-legged and be post-piled.

Water depth at the sites ranges from 30 to 34 meters.

Additional services on the Gemini OWF

  • The design of 2 helidecks for Bayards.
  • Grillage & Seafastening design for the Offshore Substation Jacket and Piles for Seaway Heavy Lifting


Phase of Development
FEED and Detailed design

Year of Project
2013

Location
Offshore

Client
Iemants

Basic Design self-installing Gravity Based Foundation concept

KCI has been contracted for the Basic Engineering of the structural steel design of a self-installing Gravity Based Foundation (GBF) concept.

This self-installing GBF is specifically developed for wind turbines with a capacity of over 6MW which need to be installed in waters deeper than 40m. The principle has been tested by computer simulation and by model testing at Marin. The next step is full scale testing. A demonstrator will be built in order for the self-installing GBP to be accepted for project financing. The target site for the demonstrator is the Borssele Kavel 5, which is specifically intended for testing new offshore wind technologies

The scope of KCI’s assignment includes the Basic Design of the steel structure, secondary steel, guiding system, ballasting system and the transport & installation procedures.

Phase of Development
Basic Design

Year of Project
2016 - 2017

Location
Offshore

Client
MonoBaseWind

Concept, Basic and Detailed Design of secondary steel Blyth

For the Blyth Offshore Wind Demonstrator project BAM will deliver 5 gravity base foundations, which are a combination of a concrete foundation with a steel ‘monopile’.

KCI has designed and engineered the complete secondary steel Concept, Basic and Detailed Design for BAM.

Concept Design – KCI prepared the concept for the secondary steel based on experience from previous projects (lessons learned) in combination with the requirements of the WTG supplier (MVOW).

Basic Design – Further development of the concept design based on the input from Client (EDF), Cable Installer, WTG supplier (MVOW), the construction team and certifying body (DNV/GL). In addition to the design and calculations, a 3D-model of secondary steel for one generic GBF location was created to facilitate communication and alignment of all the stakeholders involved.  

Detailed design – Incorporation of additional information received from fabricator and from various vendors of electrical appurtenances. KCI created 5 specific 3D models for each ‘monopile’ of all GBF locations and was responsible for the integration of all 3D models. This includes interfacing, clash detection for all vendor items and equipment from WTG supplier and in addition the alignment of ‘monopile’ and turbine tower.

Fabrication & Installation engineering

In parallel with the detail design process, KCI was responsible for fabrication assistance and prepared input for various installation options for several secondary steel items like J-tubes, external platforms and boatlanding. All engineering was approved by DNV/GL.

Phase of Development
Concept, Basic & Detailed Design

Year of Project
2016 - 2017

Location
Offshore

Client
BAM Infraconsult


 



Dirk Pulles
Manager Renewables

Tel.: +31 (0)10 427 0399
Email: renewables@kci.nl