Lead Session Chair:
Stephan Barth, Managing Director, ForWind - Center for Wind Energy Research, Germany
Jo van Montfort (1) F P Yves Van Ingelgem (2)
(1) SGS INTRON B.V., Sittard, The Netherlands (2) Zensor, Brussels, Belgium
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Presenter's biographyBiographies are supplied directly by presenters at OFFSHORE 2015 and are published here unedited
Experienced professional, being more than 25 years active in the area of building and construction materials in the international business such as offshore wind.
Experienced Large capital project manager, managing multidisciplinary projects in the field of structural steel and corrosion protection:
Project manager: “QA steel and corrosion protection 2de lock Waaslandhaven”, for Antwerp harbour (biggest lock in the world).
Main consulting manager of several multi disciplinary projects in relation to multimillion euro damages of offshore coating systems: “Stormvloedkering Nieuwe Waterweg” and “Oosterscheldekering”.
Saving costs by integrated corrosion management for offshore substructures
While in operation offshore foundations structures are subjected to dynamic loads, but equally to the hostile and corrosive marine environment. As a result: potential corrosion of the steel. All kind prevention matters are implemented to reduce the chance of corrosion problems to arise, but experience learns that corrosion never can be fully prevented. By controlling these risks, initial building costs as well as unforeseen maintenance costs of offshore structures can be reduced significantly.
The present paper will as such present a novel, fully integrated approach for risk reduction related to corrosion on and around foundation structures.
By use of fit for purpose requirements for corrosion control (systems), risks can be managed and costs can be saved. The method presented is based on knowledge, experience and supported by state-of-the-art intelligent monitoring techniques.
The approach proposed engages in various life stages of a wind farm. The following life stages are covered:
• (Pre) design
• Service & Maintenance
• End of service life
For each structure fit for purpose requirements for corrosion protection are needed. The approach of the so called “requirements pyramid” is used. Starting with general user requirements, functional and material requirements are defined by corrosion experts.
Main body of abstract
Based on fit for purpose requirements in the structural design phase, together with structural engineers, corrosion experts validate and improve design choices.
Taking into account the design of the corrosion protection system as well as the structural design, the proposed approach will include guidance and support during the building stage. Choices of coating systems and/or cathodic protection are based on sound based knowledge and predictive models instead of poor predictive performance tests. This has an effect on initial costs such as need for additional steel for corrosion allowances and type of coating system(s).
Based on the same philosophy the installation stage is supervised. In parallel with the building stage, the approach includes a tailored intelligent monitoring concept. This concept will be based on all information gathered by the experts in the phase of structural design and on the decisions made regarding the corrosion protection measures used. Risks and potential ‘hot spots’ are identified and ranked based on their likelihood and severity. This results for the service & maintenance stage in a clear scheme of continuous (online) monitoring using sensors combined with targeted and complementary inspection schemes.
The system focuses on signs of corrosion activity related to the efficiency of the corrosion prevention matters implemented, such as cathodic protection and coatings. During the building stage the sensors and monitoring units are installed and commissioned. Once the construction is completed, the approach includes the continuous follow-up of the corrosion state of the structure.
The system detects undesired corrosion issues in a very early phase. From the acquired data experts and operator extract the most appropriate approach, taking into account the detailed knowledge about the structure.
Based on the information obtained in the design as well as follow-up phase the operator will be able to propose a rapid and targeted intervention to stop or control the issue and save maintenance costs.
By combining risk reduction and specific early-stage interventions this approach leads to cost reduction from the financing phase up to the operational phase of the farm.
The audience will learn about a new and integrated way of corrosion management for foundation structures, starting in the design phase and leading to risk and cost reduction over the entire operational life.