FORCE Technology. Wind Power Services. Leiv Låte. Safeguarding life and assets in a sustainable manner

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1 FORCE Technology Wind Power Services Leiv Låte Safeguarding life and assets in a sustainable manner 0

2 About FORCE Technology FORCE Technology is: One of the leading technology, consulting and service companies on the international market. We: Are independent Are a non-profit company Have a development budget > MEUR 30 We transform highly specialized engineering knowledge into practical and value-creating solutions for a broad spectrum of sectors and industries. forcetechnology.com

3 FORCE Technology Norway AS 55 persons Integrity Management & Materials and Corrosion 30 persons Structural Integrity Management 80 persons NDE and Visual Inspection 20 persons NDE and Welding Training 30 persons Structural Monitoring

4 Group Business Areas INTEGRITY MANAGEMENT SENSORS & NDT INNOVATION DESIGN & ENGINEERING HYDRO- & AERO DYNAMIC SERVICES TESTING & MONITORING ENERGY, CLIMATE & ENVIRONMENT MATERIALS & WELDING METROLOGY

5 Wind Power References Siemens Wind Power

6 Wind Farms Integrity Management FORCE Technology Package Inspection services Specialized personnel and tools Inspection products and technologies - Visual inspection (UAV helicopter) - Scanners (ATS-2, MWS-6) Inspection data Inspection plan Corrosion management - Materials technology - Coating and corrosion - Cathodic protection - Corrosion monitoring services Corrosion data Inspection and maintenance planning Software tool: MANIFER Required struct. analysis Monit. data Monitoring data Structural integrity - Structural reliability assessment of turbine components (loads/ resistance analysis) Structural reliability Monitoring - Load/response sensors (strain, accelerations, inclination, etc.) External data (complementary information) - Monitoring data about the condition of other turbine components (e.g. rotor, electrical systems) - Production forecasts

7 Wind Power Non-Destructive Testing (NDT) Our NDT equipments to the wind power industry covers: Blades - In production Automated track scanner (AMS-14, AMS-57) Ultrasound crawling scanner (AMS-46) Ultrasound manual scanning (MWS-6) - On site Visual inspection (UAV helicopter concept) Portable ultrasound scaner (ATS-2) Ultrasound manual scanner (MWS-6) Towers - In production Fast automated ultrasound (AMS-41) Flexible ultrasound scanner (AGS-2) - On site Efficient ultrasound scanner (AGS-1) Other efficient equipment for NDT of plastic and composites Reliable automated NDT inspection services reduces costly repairs and downtime

8 On-site inspections (onshore & offshore) Blade Scanning and inspection UAV - Drone Blade inspection Blade Scanning Tower - Weld inspection Automated UT Scanning - Tower Subsea inspection Automated UT Scanning - Subsurface

9 Corrosion control of offshore wind farm monopile foundations

10 Marine media corrosion protection Corrosion allowance Coatings Cathodic protection

11 Design of corrosion control Design life years Closed compartment Expect very low rates, corrosion allowance Internal or external J-tube DNV-OS J101: Internal submerged Either cathodic protection (CP) or corrosion allowance (CA) - with or without coating in combination Difficult in practice to obtain completely sealed and airtight Tide induced variations of the internal water level.

12 Wall thickness and localisation by UT Internally or externally wall thickness estimates Manual UT Automated UT, subsea also possible

13 Wall thickness varies, random and localised Examples of UT wall thickness data same foundation Prevailing water level Localised pitting corrosion. Min. wall thickness above/below waterline: 50.3 / 48.7mm. Average: 51.0 mm => Max variation: 0.7/2.3 mm. Localised general corrosion. Min. wall thickness above/below waterline: 49.7 / 49.3 mm. Average: 49.9 mm => Max variation 0.2/0.6 mm

14 Options to control corrosion Corrosion allowance Coating CP (cathodic protection) Design differently Corrosion inhibitors? Material selection

15 Corrosion protection by coating + CP Control of CP necessary, anode replacement /ICCP Design criteria under development current demand, location

16 Anodes installed on TP for external CP

17 Future challenges Low corrosion rates in fully closed compartments with no renewal of nutrients Corrosion rate estimates in partially closed vary from 0.02 to 0.5 mm/yr, but uncertain data Localised corrosion is likely corrosion fatigue a concern Corrosion protection is possible by CP but.. What is the actual current demand? Risk of hydrogen embrittlement (H 2 S, stress) Risk of explosions ventilation Mud zone complications Future designs fully closed or open?

18 Closed compartment CP Which current demand should be used for design? Oxygen free conditions, DNV-RP-B401, 20 ma/cm 2 Internal monopile, 20 m length, 5.5 m diameter, 20 years 1 ring X 6 anodes Max Underprotected 2 rings X 3 anodes Max. -852

19 Open design ~ anode distribution Oxygenated conditions, DNV-RP-B401 Internal monopile, 20 m length, 5.5 m diameter, 20 years 2 rings X 16 anodes Max -761, min Underprotected 4 rings X 8 anodes Max -939 min -1022

20 CP in closed compartments Galvanic anodes Zn or Al, distributed correctly Current drain to buried parts depends on sediment resistivity Oxygen will be used quickly, H 2 and H 2 S likely produced Hydrogen gas accumulation safety issue Overprotection: H2 ingress, risk of cracking in highly stressed details Microbial growth, H 2 S: poisonous, explosive at 4 %, recombination poison H ingress, corrosive

21 Aluminum ladder unintentionally acting as anode

22 CP Inspection Accurate Field Gradient Measurements FiGS

23 Stay in control Step change in CP integrity for structures, pipelines and flexibles: FiGS will: Detect coating damages on exposed and buried pipelines Accurately measure anode performance Help optimise CP retrofitting, offering substantial cost savings Reduce inspection time Be a proactive tool for structural integrity

24 The FiGS Measures the strength and direction of electric fields, enabling accurate calculation of anode and cathode current densities Reference cell drift is eliminated, yielding very high sensitivity The detection limit is times better than any of the alternative methods Robust and reliable in operation A coating damage of 3-5 cm² can be detected at 30 cm distance

25 Applications Structures: Reliably measure current density and coating damages Measure current output from anodes and establish remaining life Use measured values in CP models and retrofit designs Measure current drain to mooring and buried structures like wells and piles Pipelines Detect coating damages on exposed and buried pipelines Measure current output from anodes Use measured values in CP models and retrofit designs Flexibles Detect coating defects and exposure of tensile armour/stress armour

26 Case study: Jacket life extension Old structures normally have very low current densities: Typical design current density: 90 ma/m² Actual current densities: ma/m² q By using FiGS, the actual current densities can be documented and used in the retrofit design. q By also applying computer modelling, substantial cost savings are possible. Typical benefits from the use of FiGS: q Design code: Replace 70% of the anodes in 4 years q FiGS/Model: Replace 15% of the anodes in 9 years

27 Integrity Management Division FORCE Technology Norway AS Hornebergveien Tel Fax info@forcetechnology.no 0