current catcher© support frames · 2015. 2. 4. · current catcher© support frames by donald h....

Current Catcher© Support Frames By

Donald H. Gehring President

Marine Energy Corporation 1302 Waugh Drive, PMB #465

Houston, Texas 77019 USA Phone: +1-832-654-4003 - USA www.marineenergycorp.com

[email protected]

February 4, 2015 1

http://www.marineenergycorp.com/

Current Catcher© Support Frames With Fixed

or Weathervaning Current Generators

Marine Energy Corporation has patented frames that support as many current generators as practical maximizing economies of scale and minimizing support costs including: structural, fabrication, HU&C, transportation, installation, umbilical, maintenance, operations, etc. 1. The frames can be fixed to the seabed or to another structure or can be a buoyant floating

frames moored in any manner known to those familiar with the art of mooring systems. 2. The frames can support fixed or weathervaning current generators. 3. The entire frame can also be free to weathervane. 4. The frames can be installed in relatively shallow water tidal or river locations, to ultra

deep water open ocean locations. 5. The current generators can be replaced with a plug and play current generator

replacement device like the one illustrated later in this presentation or the whole frame, with its generators, can be replaced and taken to shore for maintenance.

6. The frames can optional support wave generators, which improves economics. 7. The frames can be horizontally connected to other frames in a Current Catcher© farm

allowing the whole farm to help supported highly loaded individual current catchers. 8. The frames will be located below the water’s surface and cannot be seen from shore

causing no visual pollution and not subjecting the frame to boat damage, high wave loading or splash zone corrosion.

2

Patent Approved Dec. 5, 2014

3

Shallow Water Current Catcher© Frames With or Without Wave Generators (Shrouds Can Be Added In Relatively Low Current Velocity Locations)

6

Turbine blades at the bottom of the

current diverter housing

Low drag coefficient center diverter

housing

Outer current shroud housing is

mounted to the vertical column

The middle horizontal braces provide

low drag coefficient shroud bracing.

The top pivot bearing will likely

house the electrical swivel

The bottom pivot bearing

Insulated electrical cables are run through

the interior of the frame’s pipe tubulars. Two Dimensional Frame Pipe Tubular Frame

Current Catcher© Frame Mounted To A Fixed Platform (Current generators can be fixed or can weathervane 360 degrees inside the frame)

7

Current Catcher© Frame Mounted To A Fixed Platform (Current generators can be fixed or can weathervane 360 degrees inside the frame

(Shrouds Can Be Added In Relatively Low Current Velocity Locations)

8

Marine Energy Corporation’s 14.4 MW 3-D Generator Support Frame

Supporting 24 - .6 MW MCT Turbine Generators

• Marine Energy Corporation has designed an ocean current generator support frame for 150 meters of water for a site located approximately 2 kilometers offshore with approximately 2m/sec of current. The frame is buoyant and moored enough below the ocean’s surface to avoid cyclonic wave forces, boat collision and visual pollution yet near enough to the water’s surface to catch the highest velocity ocean currents and to optionally support wave generators.

• The frames are designed to be mass produced in existing offshore platform fabrication yards located all over the world. The frames are designed to be loaded out, transported and installed using conventional offshore platform equipment. One frame can probably be installed in one day.

• The frame allows the current generators to naturally weathervane with the currents

• 24 - MCT’s 600kW turbines were assume with 16m diameter blades for the initial frame sizing. The frames can support many types of current generator, including helical generators.

• Each generator has an in air of 28 metric tonnes and a submerged weight of approximately 18 metric tonnes.

• OIL’s frame analysis work was based on the following simultaneous inline environmental conditions of:

Current = 2.0 meters/ second across the frame

Hmax wave = 25.2 meter / 13.4 second period

• The support frames can be completely removed by reversing the installation process allowing safe refurbishment and upgrade work to be done onshore.

• The frames are designed using offshore platform design methods allowing them to be used possibly for 100s of years.

10

Marine Current Turbines’ 16 M OD .6 MW Generator

11


12


13

Submersible Heavy Lift Transport Vessels (HLV), like the one

shown below, is planned to be used to transport and install the

current and wave generator support frames.

HLV shown transporting an 18,000 MT offshore platform’s topside. 14

Heavy Lift Vessels (HLVs) submerge their cargo decks so that

structures can be floated on and off

Bla

ck M

arl

in

Tra

nsp

ort

er

157m

of

availab

le d

eck l

en

gth

il

130m

of

availab

le d

eck l

en

gth

15

These buoyant generator frames can be built in existing offshore

platform fabrication yards located all over the world. The current

frames have been sized to fit on the most common HLVs for easy

loadout and fast transport to site and float off offloading. The

frames will probably be offloaded in a still water location near site

and then towed to site by a tug.

120m

80m Cross Section During

Loadout

Skidded Loadout

from Fabrication

Yard to HLV

16

These buoyant generator frames can be built in existing offshore

platform fabrication yards located all over the world. The current

frames have been sized to fit on the most common HLVs for easy

and fast transport to site and float off offloading. The frames will

probably be offloaded in a still water location near site and then

towed to site by a tug.

120m

80m

Cross Section During

Transport

Cross Section During

Offloading

14.4m

Tug

17

1. The Heavy Lift Vessel (HLV) will be

moored in a still water location near site.

2. Tug’s lines will be connected to frame

3. The HLV will submerge.

4. The buoyant frame will float free from

the submerged HLV.

18

5. The tug will pull the buoyant frame away

from the HLV.

6. The HLV will demob

7. The tug will tow the frame to site

19

8. The tug connects the frame to

pre-laid moorings.

Pre-laid moorings

Pre-laid moorings

Prevailing Current

Tug

Tug

20

9. Tug reduces tow line tension

until the pre-laid mooring lines

become tight and pull the

buoyant frame underwater in

the prevailing current.

Pre-laid moorings Prevailing Current

21

10. The tug1 pulls the buoyant frame

into the vertical and tug 2 installs

the second set of up-current pre-

laid mooring lines.

Tug 1 Tug 2

Prevailing Current

22

11. The tugs install the remaining down

current pre-laid mooring lines.

Prevailing Current

23

12.The tugs then install the pre-laid

power cable vessels and ROVs

make power cable tie-ins.

ROV makes power cable tie-ins

Power cable

Prevailing Current

300m

80m

30m

190m

190m

190m

190m

270m

Max Upper Leg

Mooring Line

Load = 1200 MT

Max Lower Leg

Mooring Line

Load = 1700 MT

24

Deep Water Current Catcher© Frame Weights

Weight of the support frame in 300 Meters Water Depth = 1800 MT

Weight of 24 MCT .6 MW generators in air = 672 MT

Total weight of the support frame and generators = 2472 MT

Total weight of tendons and anchors legs* = 1400 MT

Note:

*Based on conventional neutrally buoyant steel pipe TLP type tendons.

*Base on preliminary frame design subject to combined 100 year storm wave

and current loading.

25

MCT 600 kW Generators

Current Catcher© Support Frame Supporting 24 - .6 MW MCT Turbine

Generators-300 Meters of Water

26

MCT 600 kW

Generators

Pivot Pin and

Electrical Bearing

14.4 MW 3-D Generator Support Frame Supporting 24 -

.6 MW MCT Turbine Generators

Max Lower Leg

Mooring Line

Load = 1700 MT

Max Upper Leg

Mooring Line

Load = 1200 MT

Max Mooring Leg Axial Load-45 Degree 2 m/s Current and 100 Year Storm Waves

0 Degree

Current and

Wave Direction

Max Mooring Line Load in Lower Legs = 1700 MT

Max Mooring Line Load in Upper legs = 1200 MT

Florida Straits : An Ideal Example Of A High Velocity Unidirectional Current Area

Offspring International Ltd

Unit 1

Oak Street

Quarry Bank, Brierley Hill

West Midlands DY5 2JH

Tel: +44 (0) 1384 415540

Email: [email protected]

White Polyester Rope Mooring System

Neutrally Buoyant Polyester Mooring Rope Imposing Min Load On Frames

30

The System Philosophy 1. Use buoyant open truss fixed offshore platform steel pipe frames to support

as many underwater turbine generators as possible.

2. Use a large heavy lift vessels to transport the frames with generators.

3. Use proven offshore platform design, fabrication, transport and installation

techniques so the system will last for 100s of years

4. Use offshore platform installation techniques that allow the frames to be

installed in high current locations.

5. Use a plug and play current generator replacement robot systems that

allows safe offshore replacement of individual turbine generators.

6. Shared control and power distribution infrastructure with other marine

power generations system like wave power generation systems and wind

power generation systems.

7. Locating the frames initially in near constant unidirectional high velocity

locations should provide the most power production at the lowest costs.

8. The current catchers can also allow their current generators to weathervane

to align naturally with the highest velocity currents maximizing their

efficiency in locations where current flows change direction.

9. The frames can also serve as a foundation for wave generators which can

also provide additional buoyant support for the frame.

10. Additional buoyant top support can be provided minimizing frame tubular

members sizes, minimizing drag and improving generator performance. 31

Current Generator Replacement

Device Concept

March 29, 2013

Revised November 24, 2013

This is just one current generator replacement concept that illustrates how

a current generators in such a frame can be replaced. Other replacement

device concepts are possible.

The following slides illustrate the device concept and the last slide contains

a text description of how this device is installed on the current generator

support frame, how the device removes a current generator, how the device

brings the old current generator to the surface and how a refurbished

current generator is installed.

32

Underwater View of the Current Generator Replacement Device (CGRD)

Current Generator Support Frame (CGSF)

Current Generator Replacement Device (CGRD)

33

Underwater View of the Current Generator Replacement Device (CGRD)


Current Generator Replacement Device (CGRD)

34

Side View of the Current Generator Replacement Device (CGRD)

Current Generator

Support Frame

(CGSF)

Current Generator

Replacement Device

(CGRD) 35

Side View of the Current Generator Replacement Device (CGRD)

hydraulic jack pulls

generator out of housing

current generato

r

roller

supports


Current Generator

Replacement Device

(CGRD)

Current

generator

housing

36

Upcurrent View of the Current Generator Replacement Device (CGRD)


Cu

rren

t G

en

era

tor

Rep

lacem

en

t D

evic

e

(CG

RD

)

37

45o View of the Current Generator Replacement Device (CGRD)


Cu

rren

t G

en

era

tor

Rep

lacem

en

t D

evic

e

(CG

RD

)

38

1. The Current Generator Support Frame (Frame) is located below the water allowing dynamically positioned (DP) surface maintenance vessels to DP moor above the current generator support frame.

2. The generators will be locked in the vertical bay where the Current Generator Replacement Device (Device) will be lowered to avoid possible generator blade damage. This can be done from a remote control panel or by the DP Vessel.

3. After the DP vessel moors above the Frame, the DP vessel will lift, position and lower the Device onto guides on the Frame and lower the Device to the desired current generator needing replacement.

4. The Device will unlock the generator from its housing and pull the generator out of its housing onto its transport rollers.

5. The Device will lock the generator on its transport rollers and the DP vessel will lift the Device with the current generator to the surface and onto the deck of the DP vessel.

6. The crew of the DP vessel will remove the old current generator from the Device and replace it with a refurbished current generator.

7. The DP vessel will lower the Device to the empty generator housing. 8. The Device will push the refurbished generator into the empty generator housing and lock the generator. The

locking press physically secures the generator into its housing and electrically connects the generator to the Current Generator Support Frame’s electrical cabling system.

9. The Device is again lifted to the surface for subsequent additional current generator replacements or will return to base.

10.When the Device is finally removed from the vertical bay, where the old generator was replaced, the generators will be unlocked and allowed to again produce electricity.

11.The DP vessel will likely be on site replacing many generators in the same mobilization with supply vessels transporting refurbished generators to the DP vessels and returning the old generators to an onshore shop for refurbishment and eventual reinstallation.

Current Generator Replacement Device (CGRD) Operation Description

39

40

Current Catcher Design Development Plan

Phase 0 – Concept Acceptance In Principle • Design Basis / Power Capacity Assumptions • Site Assumptions • Environment Criteria Assumptions • Base Case Concept Assumptions and Layout • Design Rules and Regulations Assumptions • Conceptual Assumptions (Fabrication, installation, HU&C & Operation) • Sizing Analysis Assumptions • Global Motions Analysis • Naval Architecture: Stability, Structural Design • Mooring Design: Anchor, Mooring Legs and Connectors • Preliminary Costs and Economics • Preparation for Phase 1 Engineering

41


Phase 1 -Concept Design Development Phase (Pre-Feed) • Design Basis / Power Capacity Requirements • Permitting and Site Selection • Environment Criteria Development • Base Case Concept Selection and Layout • Design Rules and Regulations Determination • Conceptual Assumptions (Fabrication, installation, HU&C & Operation) • Sizing Analysis • Global Motions Analysis • Naval Architecture: Stability, Structural Design • Mooring Design: Anchor, Mooring Legs and Connectors • Preliminary Costs and Economics • Preparation for FEED Phase

42


Phase 2 - Feed Design Phase • Component Designs • Develop Component Design Loads and Design Criteria • Develop component design rules and regulations • Design weights and loads from all components • Frame Layout For Components • Frame Sizing • Mooring System Sizing For Loads • Structural Design For Fame Sizing and Loads • Frame Motion Analysis Based On Final Frame Sizing and Loads • Model Tank Testing • Fabrication Planning and Costs Estimates • Transportation and Installation Planning and Cost Estimates • Final Costs Estimates and Economic Analysis Including Permitting • Contract preparations and negotiation in preparation for contract award • Final Investment Decision

43


Phase 3 - EPCI Phase Of Prototype or Full Scale Current Catcher • Contract awards • Detailed designs and drawing of all components • Fabrication of components • Fabrication of Current Catcher Frame • Installation, HU&C of Components on Current Catcher Frame • Pre-commissioning and Quayside Testing • Transport to Site • Installation At Site • Export Power Cable installation and connection • Start-up and First Electricity

current catcher© support frames · 2015. 2. 4. · current catcher© support frames by donald h....

Documents