A Review of The Technical Challenges Faced in
A Review of The Technical Challenges Faced in
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The Plymouth Student Scientist - Volume 13 - 2020 The Plymouth Student Scientist - Volume 13, No. 1 - 2020
2020
Hill, O.
Hill, O. (2020) 'A review of the technical challenges faced in floating offshore wind turbine
deployment', The Plymouth Student Scientist, 13(1), p. 238-252.
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The Plymouth Student Scientist, 2020, 13, (1), 238-252
Oliver Hill
Abstract
The cost-effective deployment of floating offshore wind turbines is faced with a multitude of
technical challenges. Several key areas of the life-cycle of floating offshore wind turbines
have been discussed within this work. The key challenges and potential solutions have been
presented, with state-of-the-art literature summarised to enable further work to build off. It is
concluded that all areas of the use of this technology requires further maturing to de-risk this
technology to entice wide-spread commercial use.
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Introduction
The utilisation of offshore wind energy is one of the most important sources of
renewable energy currently in development around the Globe, with Europe noted to
have the largest amount of potential floating wind capacity, at 4,000 GW [1].
Studies have found floating substructures for wind turbines to provide greater
advantages over the fixed-base platforms in water depths between 60m and 100m
[3]. Therefore, the maturing of Floating Offshore Wind Turbines (FOWTs) may be the
key to unlocking this increased availability of wind.
The increased size of turbines possible in FOWT systems has been also found to
lower the LCOE of the project, due to the increased turbine blade area [7].
Studies have found that LCOE of a 500MW FOWT farm at 50m water depth to be
lower than that of a fixed- bottom foundation wind farm in shallower waters [8], but
without physical installations, these estimations cannot be verified. However, the
scaling up of this technology should be conducted slowly, with small scale test sites
used to evaluate the performance of the technology before large-scale deployment of
arrays is conducted, de-risking designs, and allowing for unforeseen costs to be
discovered before it is a major problem, which could be catastrophic for large-scale
deployments.
Outlined by Crown Estate Scotland [9], the cost of the support infrastructure and the
availability of seabed rights are just two risks to mitigate for this technology, however
with suitable management this is possible. However, the proportion of the cost of the
turbine is lower for offshore projects than in land-based installations, decreasing
further as FOWTs are considered, due to the rising cost and complexity of the
foundation technology required for these locations [4]. It has been reported that for a
FOWT, only 21% of the cost is attributed to the turbine, with a further 67% for the
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platform, compared to 45% and 33% for the turbine and foundations in land-based
applications [3]. This lower proportion of cost for the turbine in floating platforms may
lead to additional development opportunities for other wind turbine designs, such as
the Vertical Axis Wind Turbine (VAWT) discussed later.
Presented in Table 1 are the different locations and their respective foundations for
wind turbine installation, including their respective costs and power output [10]. It can
be observed that the capital expenditure and LCOE of FOWTs is predicted to be
over 4 times that of a land-based installation, indicating this technology to be cost
prohibitive. Yet, another source indicates that an installation of 100 Tension Leg
Platform (TLP)-based FOWTs would have an LCOE of $124 (£95)/MWh, competing
with the fixed-base offshore wind turbine LCOE of $179/MWh [11]. The first FOWT
farm to be installed has been reported to have a net capacity factor of 65% over the
first 3 months of operation [12], as well as other sources reporting predicting capacity
factors of greater than 50% for FOWTs [9]. This range of results indicates the current
difficulty in calculating the costs associated with this technology, requiring a
considerable range of factors utilising many assumptions for the LCOE to be
determined [13]. Nevertheless, the significant cost increase for FOWTs over land-
based systems is still a hurdle for developers.
It has been noted that a saving of 50% is possible for operation and maintenance
activities, which has been noted to comprise of one third of the cost of the energy
produced [14], with only 14.7% expected in construction and manufacture of load
bearing components [15], displaying the gap in knowledge of operating FOWTs
effectively, which is to be expected due to the lack of commercial installations
currently in operation. Also noted in Table 1 are the embodied CO2 amounts required
to manufacture and install a wind turbine in each location [16]. The shallow water
installations tend to have the highest CO2 requirement, noted to be due to the
machinery and materials used in the monopile installation for the foundation of the
turbine. This shows an advantage of FOWTs over their shallow water counterparts,
where they can be fully installed onshore and then towed into position for costs an
order of magnitude less than that of fixed-bottom offshore installations [1].
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Increasing the turbine blade length has been shown require exponentially greater
mass [7], therefore better materials and construction techniques are required to
reduce this, possibly also aiding in the reduction of oscillatory forces, which are
detrimental to the fatigue life of the turbine.
Horizontal-Axis Wind Turbines (HAWT) have noticeably been the popular choice for
wind power generation over the past 20 years, resulting in a reducing LCOE as this
technology is matured. However, the LCOE reduction required to incentivise the
creation of FOWTs has be found to not be likely using HAWT [18].
Although most of the development in wind turbines has been used to mature the
“conventional”, horizontal design, research has also been conducted into the
feasibility of other designs, such as VAWTs [19]. As noted previously, the lower
proportional cost of the turbine within the FOWT system may lead to further
development opportunities for other turbine designs such as the VAWT, which may
lead to a lower LCOE for FOWTs.
The power generation capacity of VAWTs has not been increased to the same level
of HAWTs, with the largest found to be only 5MW [19]. With a lower centre of gravity
and simper design, the size (and therefore cost) of the platform required for stability
could be decreased [20], possibly increasing its attractiveness as a technology.
However, due to its lower maturity, there are more risks, with fewer case studies to
use, restricting the funding sources for this design, in favour of more mature
technology, HAWTs [20].
Table 1: Cost of Installations in Different Locations [9]
Turbine Type Capital Capital Operational Levelised Net Capacity CO2 Payback
Expenditure Expenditure Expenditure Cost of Factor (%) Period
($/kW) ($/MWh) ($/MWh/year) Energy (Months) [15]
($/MWh)
Land-Based 1,590 34.9 14.4 49 41.0 6
(2.16MW)
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Currently there are three main types of floating platform used in FOWTs, focusing on
their simplicity for ease of manufacture; the TLP, Spar buoy and the semi-
submersible [1] [9] [23]. Table 2 shows the general capabilities of these three types.
The maximum water depth for fixed offshore wind turbines to be economically viable
has been noted to be 50m [2], with floating platforms found to be more desirable for
operation in water depths greater than this. This depth increase allows for greater
siting of installations to take advantage of the increased wind resource in previously
uneconomic locations.
Designs incorporating multiple turbines within one floating platform have also been
discussed, reducing the individual moorings and foundations required. However, the
larger scale of structures required for this system would require much larger capital
investments, resulting in a stagnation of development whilst adequate funding
sources are realised. Smaller developments however have been possible, with a
recent manufacture of a 1:6 scale dual-turbine model of the W2POWER, scheduled
for deployment in May 2019, with the project envisioned to utilise two 10-12MW
turbines at full scale [24].
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The design of moorings has been a large area of study for the station keeping of all
marine-based power generation technologies. Mooring design literature has
discussed the optimal designs currently theorised for FOWTs, with work by
A. Campanile et al. [26] stating that 6-line mooring systems were the most suitable
for the station keeping of FOWTs at water depths of 50-350m, whilst providing the
greatest balance of lifetime cost, weigh and redundancy, when compared to 3 and 9-
line systems [26]. The use of wire ropes was found to not be a reasonable design
choice, due to the larger horizontal distances required when compared to chain
cables at depths around 100-250m [26]. This spacing problem is one area where the
requirements of this technology is different to that of the oil and gas industries, where
the spacing of FOWTs is much closer than that seen for oil rigs. Therefore, a hybrid
of cable chains and wire ropes has been identified as an area of further development
to possibly rectify this. However, the use of synthetic ropes has also been identified
as a low-cost alternative to wire ropes, due to their proven track record in the
offshore industry.
As stated by The Carbon Trust [1], the most likely source of failure in the FOWT is
expected to be from fatigue or corrosion, with the welding processes for the steel
structures used in wind turbines likely to influence the crack growth behaviour
significantly. Fatigue problems in turbine blades is a known problem, with ongoing
research into simulation and modelling of fatigue propagation. The inclusion of
additional forces present FOWTs, in the form of waves and more extreme weather
conditions heightens this problem for designers [27], where even the sway of the
floating platform may increase cyclic loading on the structures. For this reason, the
extended use of Fluid-Structure Interactions (FSI) and other tools is required to fully
evaluate systems placed into this extreme environment. Although the development
of such analysis processes is required to ensure adequate evaluation is conducted
[15].
This protection can take many different forms, from the passive protection given from
a coating to active protection, such as an Impressed Current Cathodic Protection
(ICCP), to reduce corrosion. Price and Figueira [28] also highlights how a
combination of both passive and active systems should be employed to protect a
structure from corrosion, for example, the ICCP system may be able to mitigate
corrosion in areas where to passive coating layer has been destroyed. Where
possible, these protective coatings should be applied thoroughly on land before the
structure is installed, with it noted that on-site repair of coatings on marine structures
is up to 50 times higher the original cost of application, €1000/m2, once logistics of
labour, materials and delays due to weather conditions are considered [29].
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Manufacture
Wind turbines are complex structures, comprising of several subsystems atop a steel
tower, utilising composite turbine blades for weight-reduction. Ever increasing in
size, offshore commercial installations currently utilise 6MW turbines, with the
development of turbines of 20MW predicted [15] [30].
As mentioned previously, fatigue is a critical issue in the operations and
maintenance of a wind turbine. One area of research is the effect of the
manufacturing process of the composite blades in its fatigue characteristics [31]. An
example of this variation includes the use of infusion resin, designed to reduce the
amount of inclusions present within the component. However, during the curing
process, the low viscosity resin used for this process can move around within the
mould, due to small variations such as mould tension, causing areas of uneven
thicknesses, which can reduce the structural performance of the overall component,
as described by the National Research Council [32], highlighting the need for
improvements in the manufacturing process to limit this movement.
The design of the Floating Offshore Wind Platforms (FOWPs) relies heavily on the
experience gathered by the oil and gas industries for deep water operations [33].
This design reuse jump-starts the maturity in this industry, de-risking this technology
and increasing the funding channels of the project, when compared to other novel
designs that have not been used commercially by other industries. The use of design
standards developed by the oil and gas industry for floating structures will aid
significantly with the maturing of FOWP designs [34]. The performance of steel and
concrete FOWPs have been evaluated, each with their own advantages. Although
ultimately key design decisions should be based on project- specific factors, such as
the available construction infrastructure and weather conditions. The proximity of
ports to the installation location, as well as their size are key factors in determining
the best platform design and manufacture techniques to use.
Noted in work by Lindenberg [35], turbine material usage is predominantly steel, with
Glass-Reinforced Polymers (GRP) used for rotor blades. However, other key
materials such as carbon fibre will need significantly increased production capacities
to reach the future needs of turbines, with Lindenberg [35] stating that just the need
for carbon fibre in turbines within the United States will reach nearly 100 million
pounds per year. The only other material constraint noted by Lindenberg [35] was
the number of furnaces available for the curing of the GRP turbine blades. However,
it is expected that this requirement will be coupled with the need for even larger
ovens to cater for the ever-increasing size of turbines, especially employed by
FOWTs. Looking at the UK however, [9] reports all areas if the UK supply chain as
being ready, or having a clear path to readiness for FOWT manufacture [9]. The
integration of a FOWP into the FOWT system has been noted by the International
Renewable Energy Agency [36] as being a technical and commercial risk, however
close working with supply chains may mitigate the risk of use of this technology,
where communication of key risks and design challenges is paramount to the swift
discovery of solutions.
Although design simplicity is favoured for manufacture, only the spar-buoy and semi-
submersible FOWPs have been noted as particularly suitable for high- volume
production, necessary for the large-scale utilisation of this technology at a suitable
LCOE, with the TLP failing in comparison to these types [37].
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To reduce the increasing pollution of the oceans, new materials and manufacturing
techniques should be developed to reduce the environmental impact, one key
example being the issue of micro-plastics and the electromagnetic fields created by
the power cabling, although additional habitats for marine life and birds could be
created by the installations, with additional fishing exclusion zones created by the
wind farm sites [30] [38].
Installation
The installation steps required for a FOWT can be summarised as follows [39]:
1. Float Out – Hook up to tug boats and float out from the launching site
2. Transit – Towing to the installation site
3. Installation – Mooring and ballasting operations conducted
4. Cable Installation – Laying of power cables to the new turbine and testing
procedures conducted
5. Termination – Connection to the power grid and disembarking FOWTs
6. Return – Transit of installation equipment and workers back to port
Ports with adequately deep harbour basins are a necessity for efficient construction
of FOWTs, for without this, transport to the sea would be time consuming and
prohibitively costly. The chartership of vessels and crews have also been noted to be
the main cost drivers for installation [39], depending highly on the proximity of the
port to the installation location, as well as the weather conditions.
Owing to the non-permeant nature of a floating platform over the fixed-base types,
the possibility of location adjustment is now possible. This moveable nature of the
FOWT has led to the development of technologies such as detachable electrical
connections for these devices [40], providing uninterrupted power distribution to
neighbouring devices, whilst allowing individual devices to be connected or removed
as required, possible for servicing or movement to more desirable areas. In doing so,
technologies such as this may lead to the ability for the cabling infrastructure to be
installed throughout an entire wind farm at once, without the need for individual cable
laying at the time of each FOWT’s installation, possibly leading to a cost decrease,
whilst simultaneously increasing the adaptability of the wind farm.
The installation of FOWTs excels in deep waters, negating the need for expensive
piling and construction vessels needed for fixed base installations. The installation of
wind turbines in conventional fixed-base structures involves the fabrication of
typically a mono-pile foundation. Yet, the viability of these structures is usually
limited to operating water depths of below 30m [2]. Below this depth, it has been
found to not be economically viable due to the restriction on maintenance and
maximum diver depths, as well as the size of structure required [2]. The use of a
floating base structure for a wind turbine has currently allowed for operating depths
of 100m, providing a significant operational advantage over conventional systems for
the location of new installations, with the floating nature of this technology allowing
for greater depths as further analysis and development is conducted [2].
Analysis into the effect of misaligned wind and wave loads on FOWTs has been
conducted by [7], finding additional considerations into the location and construction
of the system is required. The more extreme conditions present in deep waters, as
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well as making operating conditions worse for the FOWT, operation of the cable-
laying and maintenance vessels may also be impeded by these increased conditions,
incurring additional costs. However, the ability for larger turbines in these
environments may outweigh the additional costs incurred. FOWTs require only
towing to the installation location, whereas fixed-base structures require the use of
large vessels to install the structure into its final location. As noted previously, the
use of larger wind farms would allow for a reduction in LCOE, with the larger space
availability of deep water off-shore arrays allowing for the correct spacing of turbines,
as so to reduce the effect of wakes and inter-turbine interactions, further increasing
the efficiency of the wind farm. One key issue highlighted with the use of deep-water
offshore turbines, is the longer distances of cabling required for connection [41].
Cabling is expensive due to the material, installation and maintenance requirements,
therefore if this expense can be covered by a larger array of turbines they would be
more economically viable.
Parametric design tools have been developed for the whole life cost modelling of
offshore wind farms, including the installation of these devices, particularly useful in
the estimation of cable lengths required for connections to the substation [42],
however the results of models such as these have been noted to be particularly
sensitive to several factors, such as the site’s location and capacity of the installation.
Therefore, further development of these tools is required to provide higher accuracy
results for development. This is presumed to improve over time, as more FOWTs are
installed, providing more data points for these tools to be compared to.
Literature reveals several projects that look to provide automated analysis of images
of turbine blades for surface cracks, which could lead to structural damage if not
properly maintained. Work into monitoring blade structure health, internal turbine
health and position monitoring of the structure are being developed, all working to
monitor the condition of separate sections of the turbine’s components [31] [44]. The
use of these sensors allows for the turbines health to be monitored remotely, with
data sent to monitoring stations, where structural failures could be predicted, and
suitable preventative measures assigned. As deep-water offshore installations are
more isolated than other deployments, a higher level of automation is required to
reduce the costs needed for physical assessments that may be costly to reach the
remote locations FOWTs are installed in. Systems such as those proposed by
Friedman et al. [45] allow for the monitoring of significant areas of the turbine system
using multiple technologies to identify a fault. However, the fault will still require
rectification, meaning that maintenance crews would still need to be assigned,
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battling the remoteness and adverse weather conditions of the installation site each
time.
The failure rates of the different components of a fixed-base offshore wind turbine
have been evaluated in literature, electrical systems to have the highest annual
failure rates more than 0.5 in some cases, with an average downtime of around 2
days per failure [46]. However, due to the infancy of FOWTs, reliable data is not yet
available on failure rates or their effect on downtime. It is hypothesised that the
floating nature of FOWTs, coupled with their higher distances from shore will result in
more difficulty in accessing the components, increasing the downtime of installations.
The preventative strategy of replacing components before failure has also been
theorised, where components falling into different age groups may be replaced at the
same time as other repair procedures, minimising the visits required to a wind
turbine for maintenance [47]. Strategies such as this will aid in the minimisation of
maintenance procedures for FOWTs, where the remote nature of these installations
incurs high costs from maintenance crews. However, some maintenance procedures
cannot be performed on location, requiring the towing of the FOWT back to shore.
Blade maintenance is an example of this, where work to ensure structural integrity of
the blades is critical to the functionality of the turbine. Studies have confirmed that
the blades of a turbine are the most critical components of the system, “susceptible to
failure due to initiation and propagation of subsurface damage in a number of forms”
[48], therefore the development of monitoring tools is paramount to ensure safety
and structural integrity of FOWTs if the design and manufacture of these
components cannot be improved to reduce these issues.
The use of sensors and evaluation of the ambient noise have been noted to be of use
in the detection of damage in turbine blades for offshore installations [49], with other
work using novel techniques such as turbine blade crack detection using drones [43].
Novel techniques such as this could be developed to allow for greater automation in
the monitoring of remote FOWTs, however this technology requires maturing before
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Conclusion
This paper has presented a review of the technical challenges present in several key
areas in the deployment of floating offshore wind turbine technology. Based on the
current level of technology maturity in each of the area, the unique challenges and
potential solutions have been identified where possible. These key challenges
include the validation of the economies of scale predictions for large FOWT farms,
the development of improved construction materials to reduce the mass of the
increasing size of turbines, improved analysis techniques for the combined wind and
wave loading present on FOWT installations, the adaption of current manufacturing
techniques to improve the performance of large components such as turbine blades,
optimisation of the power cabling connections to reduce the large costs associated
with the long lengths needed for deep water offshore operations, and finally, the
development of innovative solutions to reduce the operational and maintenance
costs associated with the remote operation of these systems will enable cost
reductions noted to be up to 50%.
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