1. Introduction
Renewable energy has proven to be an extremely important direction of study to achieve carbon peaking and carbon neutrality goals while ensuring energy security. Wind energy is generally considered to be one of the cleanest sources of various types of renewable energy [
1]. As an important component of wind energy, offshore wind energy has more advantages than onshore wind energy and has great development potential. In recent years, the installed capacity of offshore wind energy has been growing rapidly. According to statistics, by 2025, its share of new installed capacity in the world will rise to 21% from 6.5% in 2020 [
2]. China is rich in offshore wind energy reserves and is the most important growth point of global offshore wind energy. In 2021, China added 12.689 MW of new installed capacity, with a total installed capacity of 19.7 GW, making it the world’s largest offshore wind energy market [
3]. However, the utilization of offshore wind energy faces more challenges than that of onshore wind energy. One of the challenges is that the installation of an offshore wind turbine (OWT) is more costly and risky. Based on NREL’s statistical data for the 2019 reference project which has been operating for 25 years, the Levelized Cost of Energy (LOCE) for the assembly and installation of offshore wind turbines is 1.5 times that of onshore [
4]. Meanwhile, the unstable and harsh marine environment leads to more complex loads on the OWT structures, especially those in contact with water, which makes offshore operations riskier. In addition, the components of the OWT need to be installed within certain tolerances; as a result the weather windows for installation operations are very limited [
5]. Therefore, dynamic response assessment is of great importance in the construction planning phase for the installation of offshore wind turbines.
The foundation of an offshore wind turbine is a critical structure that supports the OWT and protects the superstructure from waves. Sea depth is one of the most important factors in the utilization of offshore wind energy because the cost of foundations increases significantly with depth [
6]. The fixed foundation forms mainly include gravity foundation, monopile foundation, tripod foundation, triangle pile foundation, and suction bucket foundation, which are primarily used in water depths below 50 m [
7,
8]. Monopile foundations are the most widely used foundations and are mainly installed in shallow waters below 30 m. However, as the water depth and the size of the OWT increase, the diameter and length of the monopile foundation increase, leading to an increase in material and installation costs. [
9]. Jacket foundations are suitable for installation in 30–50 m deep or even deeper seas, and are subjected to smaller wave and current loads compared to other structures [
10]. Finally, jacket foundations are the most economical solution for large-capacity offshore wind turbines [
11].
Compared to the jacket foundation used for offshore oil and gas, the jacket foundations for OWTs are smaller in weight and size. Therefore, a lifting operation is usually used for the installation of the jacket foundation of an OWT. The lifting process of the jacket foundation usually includes several steps: transportation, lift-off, lowering, docking, and concrete pouring; crane vessels are essential construction equipment. At present, the crane vessels used for the construction of offshore wind farms mainly include floating crane vessels and jack-up vessels. Jack-up vessels can provide a stable construction platform. However, due to the rapid growth of offshore wind energy in China, the supply of jack-up vessels is insufficient. Moreover, their use is more flexible due to the ability to float crane vessels to transfer quickly between foundations [
5]. Therefore, the floating crane vessel is selected for the installation of the jacket foundation, and the lowering of the jacket foundation is highlighted in this study.
The lowering system of the jacket foundation is complex. For such offshore operations, time-domain simulation is required. Li et al. [
12] used the time-domain simulation method based on an external connection library (DLL) to compare and analyze the influence of the vessel-shielding effects on the lowering operation of the monopile foundation and the jacket foundation of offshore wind turbines. Zhu et al. [
13] studied the responses to and allowable sea state for the static and dynamic process of the lowering of the tripod foundation in the frequency domain and time domain, and the results showed that time-domain simulation is necessary for such problems. Zhang et al. [
14] studied the dynamic characteristics of the coupling lifting system of the vessel-three-bucket jacket foundation during the lowering process. The hydrodynamic characteristics of the crane vessel were calculated in the frequency domain, and then the feasibility of the lowering operation was analyzed by time-domain simulation for a specific sea area. The slamming load, the lowering speed [
15,
16], and the change in added mass [
16] for the bucket jacket are also of concern. However, there are few dynamic analyses for lowering traditional pile-jacket foundations for OWTs.
To reduce the risk of offshore operation, it is important to carry out risk management of the critical events which have the potential to affect safe operation during the planning and design stage, and to derive offshore operating extreme conditions for construction decision-making. Acero et al. [
17] proposed a general method based on the extreme conditions of marine parameters for offshore operations, which can be used for various offshore operations which are affected by the environment. There are generally two critical steps in the process of assessing allowable sea states for operations using this method: defining critical events and the associated parameters, and evaluating extreme responses. Both of these critical steps require extensive dynamic response analysis using numerical simulations. Based on the numerical simulation data, the extreme response values are evaluated by mathematical methods. Zhao et al. [
18] carried out the simulation of single-blade installation of an OWT, and the extreme value was evaluated based on the mean up-crossing rate method and Poisson probability distribution. The frequency spectrum analysis is used to calculate the extreme values of operation and maintenance of the OWT [
19] and the lifting operation of a tripod foundation for the OWT [
13]. In addition, time-domain simulation and extreme value distribution model are also used in offshore piling [
20] and installation of an OWT [
21]. Thus, numerical simulations and dynamic analysis are performed and statistical analysis of the data is carried out to analyze the response of the lowering system and obtain the preliminary allowable sea states.
In this study, the dynamic responses of a four-pile jacket foundation lowering system under different random wave actions are studied and a method to define the extreme response and the allowable sea state is established, which has been rarely discussed in the installation of jacket foundations of OWTs. The frequency-domain and time-domain simulations are carried out by AQWA [
22,
23]. The frequency domain hydrodynamic analysis of the floating crane vessel is first carried out, and the responses of the free-floating vessel under different wave directions are obtained. A multi-body coupled model of the jacket lowering operation is established, which includes a floating crane vessel, wires, a spreader bar, slings, and a jacket. The jacket is established by the tube element. Based on the results of hydrodynamic analysis, the time-domain simulations are performed. First of all, a nonstationary time-domain simulation [
24] of the whole lowering operation with the winches paying out [
23] at a given rate is performed. In addition, several preliminary critical vertical positions of the jacket, which are determined by the vertical position of the bottom of the jacket leg1, are found by looking at the time series of tension in the sling and wire. Then, the response maxima or minima in different wave realizations (defined by wave seeds) [
5] are obtained by using steady-state time-domain simulation in irregular waves. The extreme values of the responses, which include the tension of the sling and the wire, as well as the motion of the jacket, are evaluated as extreme responses by an extreme-value distribution model. Besides, the Dynamic Amplification Factor (DAF) is defined as the ratio of the extreme value of the tension to the static tension, which is also called the extreme response. Thus, the most critical vertical position of the jacket is determined by comparing the extreme responses of the preliminary critical vertical positions. Thirdly, the natural periods and eigenvalues of the motion of the lowering system are obtained by ANSYS-AQWA [
23]. Based on these results, spectrum analysis is carried out to analyze the dynamic characteristics of the lowering system. Finally, the extreme responses are used for environmental parameter analysis. The environmental parameters include wave direction, the significant wave height (
Hs), and the spectral peck period (
Tp). Moreover, the preliminary allowable sea states described by
Tp and
Hs are forecast by comparing the calculated DAF with the extreme value DAF specified by the accepted standard.
3. Model of the Lowering System
The numerical simulation code was run on a computer with Windows 64-bit operating system, AMD Ryzen 7 2700 Eight-Core Processor, 3.20 GHz of processing frequency, and 32 GB of memory. For accurate numerical simulation, a multi-body coupled model that is almost identical to the actual operation was built. The side and front views of the lowering system of the jacket are shown in
Figure 2. The lowering system arrangement and the Centre of Gravity (COG) of the jacket are given. The multi-body lowering system in this study included 15 degrees of freedom (DOF), the vessel and jacket were considered 6-DOF, and the spreader bar was limited to three rotational degrees of freedom.
The numerical model and the determined data of the global coordinate system for the lowering system are shown in
Figure 3. The global coordinate system is a right-handed coordinate system with the following directions:
X-axis points to the bow,
Y-axis points to the port, and
Z-axis points up. When the vessel is stationary, the origin is at [midship section, midline, still waterline].
The jacket in this study is a four-pile jacket for a 7 MW offshore wind turbine. The main frame is composed of multiple steel pipes, and the main body height of the jacket is 42 m without legs. The bottom end of the jacket has four legs with stabbing cones, which insert into the steel pipe pile pre-drilled on the seabed during docking. The arrangement of the four legs is given in detail in Figure 8 in Chapter 5. The footprint of the jacket is 28 × 28 m, and the total mass of the jacket is 1050 t. The main parameters of the jacket are shown in
Table 1. The Z-direction COG of the jacket is relative to the bottom of leg1; the COG of the other directions is relative to the origin of the global coordinate system.
The construction vessel used for the jacket installation was a double-arm luffing floating-crane vessel, as shown in
Figure 2.
Table 2 shows the main features of the floating crane vessel. The crane vessel has four main hooks with a single main hook lifting capacity of 800 t. For the lowering operation of the jacket, tow hooks are used. In actual operation, the crane tips and the hooks are connected by wires, and the hooks and the spreader bar are connected by short ropes. Because the rope is too short, this study ignores the connection between the hooks and the spreader bar, instead regarding the hooks and the spreader as a structure, and adds the mass of the hooks to the spreader bar. Therefore, there are two wires in this operation. The spreader bar is cylindrical. The total mass of the spreader bar and the two hooks is 72 t. In addition, the vessel is positioned by eight mooring lines, shown in
Figure 3. Each mooring line is 800 m long and consists of two parts, the part connected to the anchor is the anchor chain, and the upper part is the wire rope; the parameters of the mooring lines are shown in
Table 3.
In addition, the jacket is lifted by four slings, which connect the spreader bar and the jacket. The arrangement of the slings is shown in
Figure 2. The COG of the spreader bar is aligned with the COG of the jacket in the vertical direction. The vertical distance between the spreader bar and the lift point in the jacket is 45.9 m. The slings have fixed lengths during the lowering operation, whereas the length of the wires increases as a function of time. The main parameters of the wire and the sling are shown in
Table 4.
7. Preliminary Allowable Sea States
The simulations were carried out for different wave directions for
Hs = 1.5 m and
Tp = 7 s. The extreme values of responses are summarized in
Figure 16. As can be seen from the figure, under the action of beam sea, the x-direction motion of the jacket in leg1 and pitch were the lowest, and the maximum tension in sling1 and wire1 was the largest compared to the other wave directions due to the roll motion of the vessel. In general, it was safer when the maximum tension was small and the minimum tension was large;
Figure 16c–f show the same phenomenon, that is, when the maximum tension was large, the minimum tension was small. However, it is worth noting that the minimum tension value of wire1 under beam sea was 0 kN, which is not allowed. Therefore, operation in beam sea was excluded.
Without considering beam sea, the smallest pitch motion of the jacket occured in the head sea, followed by the quarter head sea, the following sea, and the quartering sea, which was mainly caused by the wave-induced motion. The motion of the jacket leg1 x direction was caused by the vessel surge motion and the pitch of the jacket, which, in the quarter head sea, was smallest, followed by the head sea, the quartering sea, and the following sea. Wire tension was smaller under the action of the following sea and the head sea, which is mainly because the wire tension is affected by the vessel roll; therefore, the closer the wave direction was to the beam sea, the greater the wire tension. Sling tension was dominated by several factors, including jacket pitch, jacket roll, and vessel pitch; thus, sling tension is smallest under the quarter head sea, followed by the head sea. On the other hand, the maximum wire tension was larger than the sling tension, which is more dangerous. Therefore, the wire tension was chosen as the most critical response for the subsequent analysis. Considering the results comprehensively, the head sea was selected as the optimal wave direction.
Under the optimal wave direction, three significant wave heights of
Hs = 1 m, 1.5 m, and 2 m were selected, and the extreme responses of each significant wave height in different periods were calculated and are shown in
Figure 17. As shown in the figure, the responses increased with the increase in the significant wave height, and, especially, the motion of the jacket leg1 and pitch were more sensitive to the significant wave height. According to the results of response spectrum analysis, under the considered wave environment, the surge motion and wire tension of the jacket were mainly caused by waves; therefore, the jacket leg1 motion and wire tension increase with the increase in wave period. Sling tension was affected by the motion of the jacket pitch. When the wave spectrum peak period approached the natural period of the jacket pitch (6.2 s), the response became larger, and of course, it was also affected by wave load. Thus, it can be seen from
Figure 17b,d that the pitch of the jacket and sling tension will decrease in
Tp = 8 s, and then increase with the increase in the period.
The allowable sea states are often determined by comparing the extreme values of the critical responses and the defined operational criteria [
35]. This study focuses on the lowering operation of the jacket. The tension in the wire is considered the critical response due to the tension of the wire being larger than that of the sling. DNV-OS-H205 [
38] suggests that the dynamic amplification factor should be considered when dynamic load analysis is conducted. DNV-OS-H205 gives the guiding values of DAF according to the static load. In this study, the static tension in the single wire was 4467.04 kN, and the corresponding DAF was 1.20. Because the steady-state time domain simulation results are conservative [
39], the extreme value of DAF can be appropriately relaxed. According to the calculation results, it is considered safe when DAF is less than 1.22 in this study.
The DAF was calculated by the ratio of the extreme value of the maximum tension to the static tension.
Table 10 summarizes the DAF under different sea states. In the sea states considered in this paper, the extreme sea states were obtained by comparing the calculated DAF with 1.21. The sea states below the extreme sea states are the allowable sea states. The preliminary allowable sea states are marked in a light green background in
Table 10.
8. Conclusions
In this study, a method to evaluate the extreme responses and forecast the allowable sea states is used in the installation of the jacket foundation for OWT. A multi-body coupling system with 15-DOF for the lowering operation of the jacket foundation was addressed. Based on ANSYS-AQWA, the hydrodynamic analysis of the floating crane vessel was carried out, and the RAOs of the first-order wave excitation force and the motion of the vessel are calculated. Based on this, the nonstationary and steady-state time-domain simulations were carried out for Hs = 1.5 m, Tp = 7 s, and Dir =45 deg. The Gumbel distribution model was used to evaluate the extreme responses, and the most critical vertical jacket position was obtained. The eigenvalue analysis and spectral analysis were performed to obtain the natural periods and to clarify the dynamic characteristics. The allowable sea states of this operation were preliminarily predicted. The following concluding remarks were drawn:
- (1)
From the hydrodynamic analysis, it can be seen that the seakeeping of the crane vessel is good, and the first-order wave excitation force and motion RAO of the vessel are sensitive to wave directions and wave periods;
- (2)
When using the method in this study to evaluate the extreme values, the appropriate seed number may be different for different offshore operations. Fifty seeds are suitable for this system to obtain reliable results. In addition, it is the most dangerous when the brace of the jacket enters the water (JL1-Z3) during the lowering operation;
- (3)
The results show that there is a strong coupling between the structures in the lowering system, and the coupling between the vessel and the jacket in heave and pitch has a great influence on the lowering operation. Additionally, the floating crane vessel and the jacket will have low-frequency resonance in surge motion. The vessel and the jacket resonate easily in the motions of pitch, heave, and roll. As this will cause a great response, it should be avoided as far as possible;
- (4)
The optimal wave direction of the system is the head sea. With the wire tension as the critical response, the preliminary extreme sea states are obtained: Hs = 1 m, Tp = 10 s; Hs = 1.5 m, Tp = 8 s; Hs = 2 m, Tp = 6 m. Construction in allowable sea states (lower than extreme sea states) is considered to be safe.
It should be noted that only the preliminary allowable sea states of the lowering operation of the jacket foundation were obtained in this study, and more sea states need to be considered. The method used in this paper can also be used in other marine structures and offshore operations, such as a novel integrated mating operation of the OWT [
40] and floating wind turbines considering aerodynamic loads [
41], and it is a later goal of the authors to obtain the operation probability [
19,
39] by combining the statistical data of the marine environment. The limitation of the distribution modes is that it does not analyze the reliability of different distributions as in [
33]. Moreover, since the steady-state simulation of the critical position was performed, the results obtained may be a little conservative. The present time-domain simulations are based on the use of AQWA, which directly solves the convolution integrals using the Cummins equation and, thus, is time-consuming. Future studies are recommended to establish a more efficient time-domain model based on the use of a state-space model, namely the constant parameter time-domain model [
42,
43]. In this way, extensive dynamic analyses can be efficiently conducted to identify the most reliable allowable sea-states for offshore lift operations of the OWT jacket foundation.