GEODIS develops innovations for the Floating Offshore Wind industry

GEODIS is a world leader in transport and logistics, with widely acknowledged expertise in all aspects of the supply chain. As a growth partner for its customers, GEODIS is committed to supporting their development while minimizing the environmental impact of their logistics.

Since 2019 the dedicated Offshore Wind division of GEODIS Project Logistics has participated in various projects around the globe and developed solutions for the offshore wind market.

A frame of reference of the Offshore Wind Technologies

The first offshore wind farm (OWF) was installed in 1987 and since then it has become a mature industry with well-known technologies, constantly looking for cost reductions and innovations to accelerate its growth. So far, most of the OWF is bottom-fixed (wind turbines assembled on fixed foundations) but current trends indicate a strong push towards floating OWF (wind turbines assembled on floating foundations). Installing at deeper locations present some significant technical and financial challenges, but also many benefits: higher and steadier wind available, very low visibility from shore, access to new areas for OWF development…

To reduce the LCoE (Levelized Cost of Energy) of offshore developments, the industry is evolving towards bigger wind turbine generators (WTGs). OEMs (Original Equipment Manufacturers) have already designed and tested 15 MW turbines and are even working on 20 MW models. However, transporting and installing such turbines (and their foundations) present major technical difficulties, and space constraints. The supply chain of the floating offshore wind industry isn´t established yet, and only a few prototypes or pilot projects have been installed so far around the world.

That is why GEODIS collaborates with technology designers and installation companies to develop innovations that could solve some of the critical issues in this sector.

Launching of floating foundations.

Floating foundations are designed with very large weights and dimensions to minimize movements induced by waves, currents, and wind. For instance, an 8 MW prototype could reach 3000 tons and 80m length x 20m high and scale up to 15 MW would mean estimated weights of 7000 tons (steel) and dimensions of 90-100m length x 25-30m high. Weight is significantly higher for concrete floaters.

Transferring these massive structures from their fabrication or storage yard up to their location at berth, floating and ready for WTG assembly, is called a launching operation. Floating docks, semi-submersible vessels, and skidding or lifting systems are various ways to perform such operations. Unfortunately, the lack of versatility of existing launching solutions (either technical or financial) impedes full operability and limits their use to specific types of floaters. Therefore, GEODIS has taken up the challenge to design its own semi-submersible structure, with the following characteristics:

Beam enabling long-distance transport without major overhang and reducing significantly wave slamming loads

Deck bearing capacity and structure suitable to support massive weights of both steel and concrete floaters

Sufficient ballasting capacity and submersible draft adapted to all kinds of float-off operations

Daily charter rates in line with existing semi-submersible vessels of lower capacity

Strong focus on energy consumption and environmental impact reduction

Developers, Contractors, and Government agencies have shown widespread interest in this solution and recently the consortium EUROPORTS – GENIE WIND – GEODIS was awarded funding by the French Agency for Ecological Transition (ADEME) to produce further technical and commercial studies towards commercialization of this solution.

WTG Installation onto floating foundations

As explained previously, a constant increase in wind turbine generation capacity also means larger dimensions and heavier components (approx. 800 tons) to be installed higher from sea level (up to 150m). This is increasing the costs and the technical challenges of installing and servicing wind farms as current installation methods require ever larger, more expensive, and specialized vessels and cranes, many of which are not yet built or available.

That is why GEODIS decided to join the project SENSEWind in 2020 and develop this solution for floating offshore wind. SENSE is a Self-Erecting Nacelle and Service System that installs, services, and decommissions large wind turbines without extra-large special cranes or crane vessels. SENSE allows the full nacelle and rotor assembly to be lifted at a low level to a frame attached near the base of the tower. The system then raises the assembly to the top of the tower on tracks integrated into the tower and tilts for installation. SENSE can be used for all onshore and offshore turbines, on taller towers or otherwise inaccessible sites.

In 2022, the UK’s Department for Business, Energy, and Industrial Strategy (BEIS) has granted £10 million to Technology Partners SENSEWind, Glosten and Subsea Micropiles, as well as six Delivery Partners (including GEODIS) to continue the design and development of their disruptive technologies and test a 2 MW SENSE turbine demonstrator onshore.

With its strategy to develop innovative solutions for the offshore wind industry, GEODIS once again demonstrates its commitment to being the growth partner of its clients.

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