Tidal array cost reduction: Testing a removable nacelle design for DeltaStream Technology

Lead Research Organisation: Swansea University
Department Name: College of Engineering

Abstract

The global tidal renewable energy sector is preparing to enter the growth stage and is estimated to reach £7bn by 2020
with 3712MW of installed capacity, demonstrating huge potential to become a serious contributor to the energy mix.
Transition from the current embryonic stage of the sector requires to overcome a number of technological barriers and
demonstrate that significant reduction of cost of energy is achievable in order to remove barriers to market penetration.
There is an urgent need to reduce the installation and maintenance costs of tidal stream turbines. The current project
proposes an effective wet-mate nacelle removal system for cost-effective installation and recovery. Swansea University
(SU) will evaluate of the mechanical interfacing of the removable nacelle which is to be integrated on the DeltaStream final
device assembly. This Work Package focuses specifically on the testing of the removable nacelle components through a
purpose built experimental test rig for a full scale space-weight prototype assembly. Support will also be provided to the
final device assembly including tribology investigations to establish requirements for the critical mechanical interfacing
surfaces for long term deployment.

Planned Impact

The partnership that has been formed between industry and academia emphasizes the importance of developing an effective wet-mate system for cost-effective installation and recovery as there is an urgent need to reduce the maintenance costs of the DeltaStream system. This important design element if addressed successfully it will bring down the cost of energy and commercialisation of tidal stream technology and improve the UK's security of energy supply. The main output of SU's study will be the evaluation of the mechanical interfacing of the removable nacelle on the support base structure.
The design and full scale testing of removable nacelle components will confirm the crane-ship 'wander' engagement envelope. The operability and reliability of the wet-mate engagement process with approach and orientation tolerances will
be verified. Key areas of impact of this work will be as follows:

UK: Targeted investment in low carbon marine energy technology provides a great opportunity to deliver industry growth benefits to remote coastal communities. At the same time investment in this emerging sector will help UK companies to become strong economic contributors to UK's growth providing jobs as well as creating international export opportunities for IP based technology and services. Furthermore, investing in renewable energy will help secure future energy needs, decarbonising the UK economy and enabling the UK Government to meet their obligations by reducing domestic Green
House Gas (GHG) emissions. Commercial scale deployment of DeltaStream will have significant and beneficial impact on the UK, stimulating its manufacturing sector. Tackling the uncertainties associated with design, manufacture, operation and
maintenance of all types of tidal energy devices will benefit TEL's DeltaStream supply chain and the wider marine energy community and the UK will therefore be better placed to become a global force. The structural engineering sector will also
be a beneficiary as the existing, yet underutilised, manufacturing facilities and expertise can be applied to the design and manufacture of TEC device installations. Building these structures within the UK will have clear benefits for the future UK
economy.

Academia: Where data gathered in the project is free of commercial sensitivity, it will also be shared with the academic community for application to research activities related to other significant projects in the marine and maritime sectors.
Importantly, the research assistant will benefit from the training and experience developed through formal training, conference visits and in collaborating with industry.

Device designers: The UK leads the world with the development and deployment of marine energy devices. This project will make significant contributions to accelerate the deployment of TEC arrays. The timescale benefits during installation will reduce overall Costs of Energy (CoE) and enable developers to reduce risk and inspire higher investor confidence. The input from the industrial collaborators, TEL and MML Marine will be significant in ensuring the findings of this project are put into practice at the first opportunity.

Energy companies, Consultants and Policy makers: The deployment of TEC arrays will lead to market growth where DeltaStream is expected to capture a considerable share both in the UK and internationally. Design improvements will reduce the cost of installation and maintenance (two of the biggest cost areas for marine tidal turbines). The overall reduced CoE of the DeltaStream design especially with regard to the foundations for fixing to the seabed will allow the energy suppliers to promote a product which is attractive to customers. Policy makers and consultants will learn important lessons in identifying best practice and will be in a better position to assess the technical, commercial and financial prospects of the tidal stream technologies in UK and internationally.
 
Description This project has shown that further careful engineering design can result in additional cost savings when applied to tidal stream turbines. The project had the opportunity to study in detail a full size turbine design. The improvements identified provide a clear route towards cost reduction.
A focus of the project was the connection system between the turbine nacelle and its support structure. This component is required to transmit significant loads when energy is generated, but easily disconnect for maintenance. Importantly, the project team had an opportunity to carry out an independent design review and technical risk analysis of the connection and make recommendations for improvements prior to the build of the unit.
A wide choice of engineering materials are available for the components making up the connection. We reviewed the resistance of these materials to corrosion and wear, providing clear commerical direction to future research in this area.
Exploitation Route The findings will help to design future tidal stream turbines. The use of a wave tank to test installation could be used by other developers to de-risk offshore operations. The risk assessment work has been published and provides a methodology for assessment of a wide range of technologies and projects operating at sea.

The turbine and the deployment site have been purchased by Cambrian Marine and the TIGER project will continue work on the site. This will further support the tidal energy industry.
Sectors Aerospace, Defence and Marine,Energy,Manufacturing, including Industrial Biotechology

 
Description The findings of the project have been used by the commercial partner to improve the reliability and design of their tidal turbine. In line with commercial value of the results, some findings are commercially confidential. As part of the experimental testing, the project has developed a method of converting design drawings to a 3D printed scale model suitable for tank testing of the installation process. These have been used to assist in the planning of offshore operations and will improve the range of sea states usable, directly reducing operations and maintenance costs. In future, the method can be used for other wave and tidal renewable energy device designs. The test rig developed was retained and additional testing was undertaken in 2019 as an MSc project. The test verified the use of video footage as a method of determining inertial properties and load estimates. The project also showed some correlation between wave height and installation time. An addition impact is the training and professional development of this MSc student. The risk assessment work package resulted in a standardised method, so that all stakeholders could have a full understanding of the risks identified for a tidal turbine installation project. Corrosion is a long term issue for tidal design - work in this area will significantly improved the lifespan of the device design.
First Year Of Impact 2016
Sector Aerospace, Defence and Marine,Energy
Impact Types Economic

 
Description Tidal array cost reduction: Testing a removable nacelle design for DeltaStream Technology 
Organisation Cardiff University
Department School of Engineering
Country United Kingdom 
Sector Academic/University 
PI Contribution This is an Innovate UK collaborative project between the three partners. We are responsible for lab scale testing, risk assessment and a research study on corrosion.
Collaborator Contribution Cardiff university have undertaken some numerical modelling tasks under a related award to Cardiff (EP/N509838/1). Tidal Energy Limited undertook the engineering design. Unfortunately, TEL went into administration during the course of the project.
Impact The project has provided a number of confidential reports to Tidal Energy Limited including a design review, a corrosion study and improvements to the design. Additionally, related papers have been published around the theme of risk assessment of economic activity in the ocean (the blue economy).
Start Year 2016
 
Description Tidal array cost reduction: Testing a removable nacelle design for DeltaStream Technology 
Organisation Tidal Energy Ltd
Country United Kingdom 
Sector Private 
PI Contribution This is an Innovate UK collaborative project between the three partners. We are responsible for lab scale testing, risk assessment and a research study on corrosion.
Collaborator Contribution Cardiff university have undertaken some numerical modelling tasks under a related award to Cardiff (EP/N509838/1). Tidal Energy Limited undertook the engineering design. Unfortunately, TEL went into administration during the course of the project.
Impact The project has provided a number of confidential reports to Tidal Energy Limited including a design review, a corrosion study and improvements to the design. Additionally, related papers have been published around the theme of risk assessment of economic activity in the ocean (the blue economy).
Start Year 2016
 
Title Corrosion study to inform tidal turbine materials selection. 
Description Within the project we undertook a research study on corrosion to identify suitable materials that had the correct structural properties and would suvive the tidal environment. The (confidential) report covered four main topic areas. 1) Understanding types of corrosion present in fast flowing sea water environments. These include: Uniform Corrosion, Galvanic or Bimetallic Corrosion, Crevice Corrosion, Pitting Corrosion, Erosion Corrosion, Stress Corrosion, Fatigue Corrosion 2) Environmental factors that influence corrosion. There are various environmental factors including: Dissolved Oxygen, Temperature, Water Velocity. The additional environmental implications of damage due to biofouling was not considered in this case, but should be a factor for long term installations. 3) DeltaStream Specific Considerations. One of the advantages of the DeltaStream prototype was the large welded steel structure and corrosion protection for this was important. Other materials were present in the design and careful choices needed to be made in a number of design detail areas. 4) Mitigation measures were recommended for long term maintenance of the effective function of the device. 
Type Of Technology New/Improved Technique/Technology 
Year Produced 2017 
Impact This methodology made a direct impact on the choice of materials and hence the fundamental design of the turbine. 
 
Title Laboratory scale testing of tidal turbine installation stability 
Description A goal of the project was to improve the installation process of the device in a number of areas. One element required for installation is an understanding of the sea states where an installation is possible. As part of this, a design process was undertaken to improve the range of sea states usable by changes to the design of the system. This concept was validated by application of a laboratory test. Swansea University has a 30m long wave flume to create scaled wave conditions and this was used for the test. The CAD design for the improved design of deltastream was "defeatured" to create a more generic shape. This was then 3D printed to make a functional scale representation of the unit. Interaction between the scale model and the waves created in the tank provides real insight into the installation process. 
Type Of Technology New/Improved Technique/Technology 
Year Produced 2016 
Impact Installation and operations and maintenance processes are the most significant cost reduction target in tidal energy (after capital cost of the turbine units). Improving these costs will significantly reduce the levelised cost of energy. 
URL http://www.swansea.ac.uk/engineering/zcce/energy-environment/facilities
 
Title Risk assessment for Blue Growth Technology 
Description A risk assessment study was undertaken and used to support the industrial partner. The goal of the risk assessment methodology was at a higher level than a typical engineering study and concerned whole project risks. This work documents the methodology used to assign the risks to various projects. A standardised methodology of risk assessment was developed comprising three core elements of the risk management process: risk identification, risk analysis and risk mitigation. This method could be applied to deployment of the tidal turbine technology in various locations and configurations, allowing all stakeholders to have a full understanding of the risks identified. 
Type Of Technology New/Improved Technique/Technology 
Year Produced 2017 
Impact By using a standardised methodology, critical risks could be identified and mitigated, allowing informed decisions to be made on the most suitable technology choices and project sites to pursue. Internal (industrial partner confidential) work was undertaken concurrently with a wider consideration of risks. The generic results were applied to a number of different technology types and published at the prestigious EWTEC conference in 2017.