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Joining of Large Components in a Harsh Environment Research Report for the Vanguard Initiative ADMA Energy Pilot – Challenges and Outlook

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Joining of Large Components in a Harsh Environment Research Report for the Vanguard Initiative ADMA Energy Pilot – Challenges and Outlook Antwerpen Technologiepark – Zwijnaarde 48 Brussel-Bruxelles BE-9052 Zwijnaarde Charleroi tel. : +32 9 395 06 97 Gent fax : +32 9 345 13 78 J1 Hasselt [email protected] Kortrijk www.sirris.be Leuven Liège date 27-11-2019 version v1.1 reference ADMA Energy Research Report for Joining of Large Components © copyright Sirris author Jeroen Tacq contact [email protected] +32 493 31 06 44 Joining of Large Components in a Harsh Environment Research report for the Vanguard Initiative ADMA Energy Pilot – Challenges and outlook Recognized under application of the Decree of 30 January 1947 1 Table of Contents TABLE OF CONTENTS ........................................................................................................................................ 2 1 INTRODUCTION ....................................................................................................................................... 4 2 APPROACH AND METHODOLOGY ....................................................... ERROR! BOOKMARK NOT DEFINED. 3 REPORT SCOPE ........................................................................................................................................ 4 4 LARGE COMPONENTS AND JOINING TECHNOLOGIES IN CURRENT DESIGNS ............................................ 6 4.1 FIXED WIND .............................................................................................................................................. 6 4.2 FLOATING WIND ....................................................................................................................................... 13 4.3 TIDAL ENERGY CONVERTORS (TEC) ............................................................................................................. 14 4.4 WAVE ENERGY CONVERTORS (WEC) ........................................................................................................... 17 5 CHALLENGES IN CURRENT DESIGNS ....................................................................................................... 20 5.1 DESIGN CHALLENGES ................................................................................................................................. 20 5.1.1 Large flanged joints ........................................................................................................................ 20 5.1.2 MP/TP connection ........................................................................................................................... 21 5.1.3 Large bolt sizes ................................................................................................................................ 22 5.1.4 Modular design ............................................................................................................................... 22 5.1.5 Segmented blades ........................................................................................................................... 23 5.1.6 Blade to hub connection ................................................................................................................. 23 5.1.7 Adhesive bonding ............................................................................................................................ 27 5.1.8 Testing and certification ................................................................................................................. 28 5.2 UNDERSTANDING AND PREVENTING DEGRADATION ......................................................................................... 29 5.2.1 Bolted connections .......................................................................................................................... 29 5.2.2 Pre-load ........................................................................................................................................... 30 5.2.3 Fatigue performance ...................................................................................................................... 32 5.2.4 Corrosion ......................................................................................................................................... 33 5.2.5 Hydrogen embrittlement ................................................................................................................ 37 5.2.6 Reliability database ........................................................................................................................ 38 5.3 INSPECTION AND MONITORING ................................................................................................................... 38 5.3.1 Bolt inspection and monitoring ....................................................................................................... 39 5.3.2 Grout inspection/monitoring .......................................................................................................... 41 5.3.3 Operational Modal Analysis ............................................................................................................ 41 5.3.4 Monitoring of composite/steel joints .............................................................................................. 42 5.3.5 Cost of Monitoring .......................................................................................................................... 42 6 STAKEHOLDER COMPANIES ................................................................................................................... 43 7 CURRENT AND PAST PROJECTS .............................................................................................................. 43 8 ADMA REGIONS’ STRENGTHS AND INTERESTS....................................................................................... 47 9 TEST SITES ............................................................................................................................................. 49 10 FUNDING OPPORTUNITIES AND GABS ................................................................................................... 51 11 IDEAS FOR COLLABORATIVE PROJECTS .................................................................................................. 54 11.1 BOLTED CONNECTIONS .............................................................................................................................. 54 11.1.1 Pre-load ...................................................................................................................................... 54 11.1.2 Bolt degradation in a maritime environment ............................................................................. 55 11.1.3 Large flanged joint...................................................................................................................... 57 11.1.4 Submerged bolted connections .................................................................................................. 58 11.2 COMPOSITE/STEEL JOINT ........................................................................................................................... 58 11.3 ADHESIVE BONDING .................................................................................................................................. 60 11.4 RELIABILITY DATABASE FOR JOINTS ............................................................................................................... 61 © Sirris ● Joining of Large Components in a Harsh Environment 2 12 RECOMMENDATIONS AND FURTHER ACTIONS ...................................................................................... 62 APPENDIX A – BIBLIOGRAPHY ........................................................................................................................ 63 APPENDIX B – STAKEHOLDER COMPANIES.................................................. ERROR! BOOKMARK NOT DEFINED. © Sirris ● Joining of Large Components in a Harsh Environment 3 1 Introduction Joining of large components in renewable energy devices has been identified by the ADMA Energy pilot as a potential topic for research, development and demonstration within a European collaboration. ADMA Energy is a pilot project of the European Vanguard Initiative in Advanced Manufacturing for Energy-Related Applications in Harsh Environments. The aim of this report, which has been ordered by the ADMA Energy pilot, is to assess the state of the art, in order to identify key issues, challenges, existing projects, lessons learned and potential for future collaboration on research and demonstration projects. ADMA aims to support companies across the entire Offshore Renewable Energy (ORE) value chain by initiating collaborative research and demonstration projects related to the joining of large components in ORE devices. The information contained in this report should allow ADMA to assess the possibility to launch one or more research and/or demonstration projects, as well as provide the necessary information to define a project scope and partnership or specify which further actions are needed in order to obtain this information. The three main chapters of this report are: - Chapter 3: Large components and joining technologies in current designs - Chapter 4: Challenges in current designs - Chapter 10: Ideas for Collaborative projects In chapter 3 an overview is given of the different offshore renewable energy technologies and what the focus points are in terms of joining technology. Chapter 4 takes a closer look at the specific challenges related to joining of large components in a harsh environment. In chapter 10, the challenges are translated into ideas for collaborative projects.
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