Opportunities for anti-corrosion solutions in the Offshore Renewable Energy sector

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1 Opportunities for anti-corrosion solutions in the Offshore Renewable Energy sector The NESSIE project Jeroen Tacq

2 The NeSSIE project North Sea Solutions in Corrosion for Energy Goal: Development of three demonstration projects related to innovative anti-corrosion solutions for ORE in the North-Sea Basin EU funded project Offshore Renewable Energy (ORE): Wave, Tidal and Wind energy Reduce the LCoE by tackling the corrosion challenge Develop 3 demo projects Related to corrosion In the North Sea Basin Higher TRL levels, solutions ready for commercialization Check

3 The NeSSIE project Project partners

4 The NeSSIE project State-of-the-art Solutions currently in use Remaining technical challenges related to corrosion Innovative corrosion solutions and materials Company surveys Economic opportunities report Roadmap for ORE Demonstration projects 3 demo projects, project developers selected Looking for solution providers Opportunities for cross-sector knowledge transfer!

5 Corrosion in Harsh Environments What makes an environment harsh? Humidity Temperature (both high and low) Presence of aggressive species Salts: mainly chlorides and sulphides (seawater, road salts, etc.) Gasses: especially sulfurdioxide (SO 2 ) Chlorines Erosion Dirt, dust particles and other deposits Presence of bacteria and bio-fouling Local variations in environmental conditions (ex. partially burried or submerged structures) Cleaning products (ex. food industry) Acidity (ph) dwinirestu.wordpress.com

6 Corrosion in Harsh Environments Typical harsh environments CUI Industrial environments Marine Underside of bridge Waste water treatment Livestock buildings Source: corrosionpedia.com Source: Source: videostock.com

7 Corrosion in Harsh Environments Typical harsh environments CUI Industrial environments Marine Underside of bridge Waste water treatment Livestock buildings Source: 112brabant.nl Source:

8 Corrosion in Harsh Environments Seeing the cross-sector opportunities Corrosion is not necessarily sector specific. Source: MarineTraffic.com Source: Source: news.wjct.org Source:

9 Corrosion in Harsh Environments Seeing the cross-sector opportunities Corrosion is not necessarily sector specific. Source: TripAdvisor Source: MarineTraffic.com Source: Source: news.wjct.org Source:

10 Corrosion in Harsh Environments Seeing the cross-sector opportunities Source: ihmusedparts.com Requirements can be different. Lifetime Possibilities for maintenance Cost: CAPEX vs. OPEX Environmental/sustainability considerations Repair and application conditions Source: Source: Source:

11 Corrosion in Harsh Environments Find the opportunities for two-way growth! Source: ihmusedparts.com Source: Source: Source:

12 Offshore Wind Energy Atmospheric zone Splash zone Submerged zone Burried zone

13 ORE Coating Solutions Coating systems currently in use Strongly influenced by guidelines and standards (NORSOK M-501, ISO , ISO 20340, DNVGL-RP-0416) Differentiation between submerged, splash and atmospheric zones A typical example for the splash zone: ZnR or EP Primer/2-3 EP based coats/pur topcoat Total DFT: 450 to > 1000 µm Use of metallizing is increasing Zn-based (often as a primer for subsequent organic coatings) TSA: Arkona (2017), CROWN project

14 ORE Corrosion Challenges Primary steel vs. Secondary steel Primary: Structural components such as the foundation and tower. Failure of a primary steel component could threaten integrity of the entire structure. Secondary: Components which are important, but whose failure will not result in a total collapse of the structure

15 ORE Corrosion Challenges Primary steel corrosion challenges Atmospheric zone: no significant corrosion issues have been reported Splash zone: coating damage and corrosion is observed Almost invariably linked to mechanical damage or improper coating application Flexible and damage tolerant coatings as a solution (polyurea, powder coating)? Reduction of LCoE through single layer systems (reliability?)

16 ORE Corrosion Challenges Primary steel corrosion challenges Submerged zone: Currently Cathodic protection (with/without coating) Weld seams often coated A lot of questions: MIC? Mudline? Corrosion inside MP? Are coatings a solution? Damaged during installation? (MP guiding system, scour protection, scraping of soil)

17 ORE Corrosion Challenges Secondary steel corrosion challenges Boat landing CBPC, corrosion allowance Repair issues Acces zones Railings, platform borders, hatches Polyurea (inspection?), powder coating Source: OWEZ_R_Results corrosion inspection offshore wind farm egmond aan zee

18 ORE Corrosion Challenges Secondary steel corrosion challenges Critical areas Bolted connections Corners, difficult to reach areas, crevices Filmgalvanizing, thermoplastic cover coatings, filling foams, caps and shields (BoltShield) Accessories Source: OWEZ_R_Results corrosion inspection offshore wind farm egmond aan zee Source: OxiFree Source: BoltShield

19 ORE Corrosion Challenges O&M Maintenance and Repair difficulties Surface preparation (difficult + regulations) Wet surfaces, Temperature, Salinity, Humidity Drying times (ladders, boat landing, multilayer systems) Window of opportunity Environmental considerations Submerged structures O&M Inspection and Monitoring Monitoring techniques reducing need for manual inspection Improved inspection techniques to avoid undiscovered damages Drones?

20 ORE Corrosion Challenges Company surveys, NeSSIE: Technical challenges; New anti-corrosion coatings Non-toxic anti-corrosion solutions More (time) efficient coating application processes avoiding coating flaws Coatings more resistant to damage More effective coating repair procedures/materials (lifetime of structure) Repair coatings tolerant to humid/wet substrates, increased salt concentrations, lower application temperatures and imperfect substrate preparation. Reducing CAPEX of coating systems (single layer, reliability) Anti-fouling coatings: long lasting, performant and environmentally friendly Wind vs. wave/tidal

21 ORE Corrosion Challenges Company surveys, NeSSIE: Technical challenges; New anti-corrosion coatings Non-toxic anti-corrosion solutions More (time) efficient coating application processes avoiding coating flaws Coatings more resistant to damage More effective coating repair procedures/materials (lifetime of structure, window of opportunity) Repair coatings tolerant to humid/wet substrates, increased salt concentrations, lower application temperatures and imperfect substrate preparation. Reducing CAPEX of coating systems (single layer, reliability) Anti-fouling coatings: long lasting, performant and environmentally friendly Wind vs. wave/tidal

22 Market entry How to gain market access? Need track record for new-builds (min. 5 years) + go through certification schemes Easier to get in as a repair solution Some non-critical components (secondary steel) are also subject to less stringent regulations Current opportunities: NeSSIE demonstration projects JIP - Demonstration of ORE Coatings

23 NeSSIE Demonstration projects Three lead companies selected for demo cases: European Maritime Energy Centre (EMEC) Scottish and Southern Energy (SSE) Simec Atlantis Energy (ATLANTIS) Now looking for solution providers Expression of Interest (EoI) on NeSSIE webpage ( EoI also for general issues described earlier!

24 NeSSIE Demonstration projects General challenges identified by NeSSIE Key Challenges Cathodic protection Experience and unknowns Novel product risk Design Quality control Preparation and applying coatings Maintenance difficulties and repairs Inspection Examples Hydrogen embrittlement, cathodic disbondment Regulation, knowledge transfer between sectors, corrosion below the mudline after installation Consolodation of the market, variance in test data/reliability tests Unable to protect/coat certain designs, material selection, use of high strengh construction steels Unrealistic demands, inspection criteria and procedure not well defined Preparation of surface to get required roughness bring difficulties: not all areas can be blasted, thicker paint layer more susceptible to cracking (welds/corners) Locations that are more susceptible to damage (boat landing, flanges, edges and corners), weather windows, application conditions (wet surfaces, temperatures too low) Costly, undiscovered damage Specific Challenges identified by demo project developers

25 NeSSIE Demonstration projects European Maritime Energy Centre (EMEC), Orkney Islands, UK Open sea demonstration facility Project: development of solutions for marine energy converters, subsystems and connectors

26 NeSSIE Demonstration projects European Maritime Energy Centre (EMEC), Orkney Islands, UK Open sea demonstration facility Project: development of solutions for marine energy converters, subsystems and connectors Key focus: floating technologies (wave and tidal) Highly exposed, oxygenated environments Limited access for O&M Specific challenges still to be defined, but may include Bio-fouling Anti-corrosion coatings for aggressive splash zone Coatings for connectors

27 NeSSIE Demonstration projects Scottish & Southern Energy (SSE), Greater Gabbard and Beatrice, UK Offshore wind farms Greater Gabbard, in operation Beatrice, under construction Source: sse.com/whatwedo/ourprojectsandassets/renewables/greatergabbard

28 NeSSIE Demonstration projects Scottish & Southern Energy (SSE), Greater Gabbard and Beatrice, UK Offshore wind farms Greater Gabbard, in operation Beatrice, under construction Key focus: innovations in corrosion management and remediation Specific (repair) challenges: Boat landing fenders (reactive paint or air/water tight wrap solutions) General TP corrosion remediation (ex. from contact with floating objects) Hook-on points for personnel, requires frequent repair (problems with high salinity) Major component corrosion in nacelle Corrosion at interfaces

29 NeSSIE Demonstration projects Simec Atlantis Energy (ATLANTIS), Pentland Firth, UK Tidal energy developer (technology and sites) MeyGen project Source: simecatlantis.com/projects/meygen

30 NeSSIE Demonstration projects Simec Atlantis Energy (ATLANTIS), Pentland Firth, UK Tidal energy developer (technology and sites) MeyGen project Particular challenges: Turbines need to be services opening of flanged joints problems with recoating to the same level of protection Account for flow effects (accelerate corrosion) on required cathodic protection Stainless steel components act as anodes for rest of the structure and accelerate corrosion. Require improved understanding and mitigation measures Cathodic disbondment on carbon fibre tidal blades

31 NeSSIE Demonstration projects Sign in on the Expression of Interest To contribute to the demo cases (specific & general challenges) To propose solutions for the general challenges outlined today To be included in a database of solution providers for corrosion in harsh environments To have a chance at being selected for one-on-one meetings by the project developers (demo cases) at the NeSSIE Conference in Glasgow on Expression of Interest on NeSSIE webpage:

32 NeSSIE Demonstration projects Also for the general challenges!! Questions? Contact me

33 JIP Demonstration of ORE Coatings Development project JIP Offshore test site (ex. Blue Accelerator) 5 years Representative coating application conditions Test piles or other representative structure (i.e. no coupon testing) Very rough cost estimation Design and installation: Exploitation: /year Coating inspection:??/inspection

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35 Dr. Ir. Jeroen Tacq Senior Engineer

36 #sirris