Oceanology International and Catch the Next Wave 2016
Innovations in Foundations: The Mono Bucket
Søren A. Nielsen
Who We Are and What We Do
Bonheur ASA
(listed OSE)
Offshore Drilling
Renewable Energy
Ganger Rolf ASA
(listed OSE)
Cruise
Shipping /
Other investments
Offshore Wind
51.9%
100.0%
100.0%
100.0%
Fred. Olsen
Fred. Olsen
Fred. Olsen
First Olsen Ocean Ltd.
Energy ASA
Renewables AS
Cruise Lines
(listed OSE)
Ltd.
Fred. Olsen
Windcarrier AS
Universal Foundation
Norway AS
NHST Media
Group AS
(54%)
Koksa Eiendom AS
Global Wind Service A/S
Various
165 years in shipping and energy
How We Got Into the Foundations Business
In the period to 2010 it became clear that the market required an
improved foundation concept for deeper waters and large turbines
In 2011 a majority stake in Universal Foundation was acquired
The aim was to qualify and commercialise the suction bucket concept in
parallel with building a turn-key capability within foundations
MBD Offshore Power A/S
Changes name to
Universal Foundation A/S
Today, UF designs can also be licenced to 3rd parties
60% of shares acquired by
Changes name to
Norway
Acquires further shares and now
owns 82% in Universal Foundation
Experience from more than
2,000 suction buckets installed world-wide!
Universal Foundation
- a Hybrid Design Combining the Benefits of Other Proven Concepts
A hybrid design
The design combines the benefits and main proven
aspects of a gravity base foundation, a monopile and
a suction anchor.
Competitive in 20-55 m water depth
Addressing the gap between the “industry darling”
monopile and the typically more expensive jacket.
Installed
Universal Foundation
- Suction installation process
1.The suction pump unit is attached to the foundation
2.The foundation is lowered to the seabed
3.Deadweight and gravity ensures self-penetration into the seabed
4.The pump unit enables under-pressure inside the bucket and a
water-jet alongside the skirt tip ensure local seabed liquefaction –
the combination ensures soil penetration
5.Verticality is controlled to reach required inclination tolerance (+/0,25 degrees - +/- 0,1 degrees achieved in real life average so
far)
6.The suction pump unit is recovered
Project execution track record (key projects only)
PROJECT NAME
TIMELINE
KEY ACHIEVEMENTS
FREDERIKSHAVN (DK)
2002 –
still operational
 WTG load testing and monitoring
 Comprehensive data collection
 Most researched foundation in the business
2009 –
still operational
 Floating installation concept proven
 Integrated scour protection system validated
2013 –
still operational
 Delivery of a full EPCI solution
 Installation at a UK R3 “true offshore site”
 Foundations already hit by 50year design wave (20m)
Sep. 2014–
results are
being analyzed
 Tests at Dudgeon, Dogger Bank and Hornsea
 Data collection through 29 installations
 De-risking and confirmation of design parameters
Mid. 2015-
 Early market engagement
 Detailed design of 6 foundations
 UF supporting a Vestas V90
3MW WTG
HORNS REV 2 (DK)
 Foundation supporting a met
mast
DOGGER BANK (UK)
 Foundations supporting two
met. masts
TRIAL INSTALLATION (UK)
 Installations to test soil
sensitivity and verify design
parameters
ICEBreaker – Lake Eire (US)
 Detailed design ongoing
The Mono Bucket is well past a “proof of concept” stage and is
ready for demonstration and mass deployment
2013
Market
Penetration
Strategy
2014
2015-2017
2017 - 2018
Dogger Bank
Met. Masts
Trial Installations
several sites on
east coast England
Demonstrator project
Large scale
commercial
project
COMPLETE
COMPLETE
IN PROGRESS
SECURED
Test of new
technology
Technology
qualified for use
29 successful
installations in 24 days
• Dogger Bank
• Dudgeon
• Hornsea
Proof of concept
Building
experience &
track record
Industrialization
Our final step towards
full commercialisation
2
…And continue to prove the cradle to grave approach…
Horns Rev 2 decommissioning
One met mast fully recovered
Operational since 2009
Removed July 2015
Source: DBB Jack-Up
LEEDCo ICEBreaker
– First commercial contract
LEEDCo ICEBreaker
– First commercial contract
Trial Installation (2014)
– de-risking installation and optimizing design
Trial Installation
– completed end September 2014
 Testing of scaled down Universal Foundation design as well as
“standard” bucket for benchmarking and referencing purpose
 UF structure: 8m diameter x 6m skirt
 Reference structure: 4m diameter x 6m skirt
 Campaign running across three major offshore sites in the North Sea
 Dudgeon
 Hornsea
 Dogger Bank
Trial Installation
– 29 installations completed in September 2014
 Test focus and goals
 Penetration in challenging soil conditions
 Water injection impact
 Verticality
 Forces/stress in skirt structure
 Soil leveling capability
 Verification of design parameters
 Install-ability including splash zone movement and and plug heave
measuring
 Minimum 12 installations in total
 Challenging soil conditions
 Soft clay
 Bolder Bank (with sand spikes/layers)
 Clay Crust
 Sand
Trial Installation – completed end September 2014
 Achievements


Installations:

6 on Dogger Bank

2 on Hornsea

4 on Dudgeon

+4 additional on Dogger Bank with the Reference Probe

29 installations performed in 24 days…

… resulting in a unique soil data base in offshore wind!
Data from

Click-on Pump Unit

Structural Monitoring Systems

Data for the Reference Probe system

Crane Log

ROV operation

Slash zone penetration

Daily Project progress reports
Offshore campaign - Route and Positions
Video can be
provided on request
kaj@ufoas.dk
Full seabed contact
well-within inclination tolerance at Sand Site 2
Seabed contact after seabed leveling
Installation of UF Mono Bucket in
Hard Clay Cu 200-400 kPa
Predicted
penetration
Achieved
penetration
Pump capacity
Universal Foundation
– A Fred. Olsen related company
Universal Foundation
- A hybrid design

Design verified up to 55 m.w.d. with up to 8MW WTG

Suitable for a wide range of soil profiles

Modular design, utilising existing supply chain

25% less steel than comparable monopile

No grouted connections - integrated transition piece

No seabed preparations, integral scour prevention

Single-lift or self-floating installation

Noise free installation – self-levelling

Completely removable – reducing the need for “Bank-Aval”

A solid foundation to REDUCE LCoE
Fast and Simple installation is key to success!
INSTALLATION
Monopile
UF Mono Bucket
1. Multiple lifts - multiple vessels
1. One lift – one vessel
2. Upending tools
2. Suction pump unit
3. Pile hammer 6-800 kEUR/month
4. Pile gripper
5. Marine growth removal
6. Grout spread + curing temp./time
7. Noise mitigation 2-300 kEUR/unit
8. Scour protection (another vessel)
9. Shimming plates
10. Flange correction tool
Translating to cost savings of >30% in installation
Going from a complex marine spread…
Going from a complex marine spread…
Source: IHC
… And the 160db problem…
– cost out of 20mEUR according to Vattenfall
Source: Vattenfall
… to one foundation, one vessel and one suction unit…
and noise free installation!
Spread on Brave Tern for Dogger Bank
 Click on Unit + transport frame
 Lifting yoke
 Control room
Noise free
The offshore inhabitants are already convinced…
Source: Hamburger Abendblatt, November 2014
And we continue to drive innovation…
Universal Foundation
- ALREADY BEING DEPLOYED
Project reference: Frederikshavn – Denmark - 2002
– Vestas V90 3.0MW turbine
Bucket diameter 12m, height 6m, weight 135t
Universal Foundation
- ALREADY BEING DEPLOYED
Project reference: Horns Rev 2 – Denmark - 2009
– Met Mast for biggest wind farm in Denmark
Bucket diameter 12m, height 6m, weight 165t
Universal Foundation
- ALREADY BEING DEPLOYED
Project reference: Dogger Bank 2013
– 2 met masts for the largest UK Round 3 project (7.4GW)
Bucket diameter 15m, height 7.5m, weight 350t
Universal Foundation
- ALREADY BEING DEPLOYED
EPCI Contract ”In house”
Main Contractor
Universal Foundation
Engineering
Universal Foundation
Fabrication
Harland and Wolff (a Fred. Olsen
related company)
Installation
Fred. Olsen Windcarrier (a Fred. Olsen
related company)
Topside
SeaRoc (a Fred. Olsen related
company)
Project schedule

Contract signed October 2011

Fabrication May to November 2012

Installation 1st campaign February 2013

Installation 2nd campaign September 2013
Thank you – questions ?