First Foundation Stands at World’s Largest Offshore Wind Farm

Installation of the 277 wind turbine foundations has started on the 3.6 GW Dogger Bank Wind Farm which is being developed 130 kilometres off the Yorkshire coast, the UK.

The campaign to install turbine foundations at what will be the world’s largest offshore wind farm has commenced in recent days, with the installation of the first monopile and transition piece on Dogger Bank A. The installation campaign is being led by Seaway 7 supported by DEME.

The turbine foundations for Dogger Bank Wind Farm are UK-designed and feature a unique split-level transition piece, as well as a world’s-largest 8-meter flange – or projecting flat rim – to support the turbine towers.

Steel manufactured by Tata Steel in Wales and processed in Corby and Hartlepool is being used in the supporting components of the transition pieces, while South Tyneside-based Metec and Rochdale-based Granada Material Handling have also won contracts with Smulders to support this project.

Dogger Bank will be capable of powering six million UK homes annually on completion in 2026.

The project is a joint venture between SSE Renewables (40 per cent), Equinor (40 per cent) and Eni Plenitude (20 per cent).

SSE Renewables is lead operator for the development and construction of Dogger Bank Wind Farm, while Equinor will be lead operator of the wind farm on completion for its expected operational life of around 35 years.

”These foundations have been designed for what is arguably the most demanding wave environment to be encountered on an offshore wind farm and are a testament to the many companies involved in collaborating to reach this unprecedented milestone,” Steve Wilson, SSE Renewables Project Director for Dogger Bank Wind Farm, said:

”As well as the sheer scale of the foundations, we’ve incorporated a unique split-level transition piece which allows safe access for technicians directly into the turbine tower from our service and operations vessels, eliminating thousands of manual handling activities and lifting operations over the lifetime of the assets. Successful installation of our first monopiles and transitions pieces is a giant leap for offshore wind globally and will lay the foundations for Dogger Bank Wind Farm to contribute to meeting the UK’s net zero target, enabling the development of a future energy system that is cleaner, cheaper and more secure. It also demonstrates the continued innovation in our sector as we begin to install the increasingly larger and more powerful turbines that are needed to fuel our homes and businesses safely and securely in a net zero world.”

Designed by Wood Thilsted, the foundations have been optimised to tackle challenging wave loads in the Dogger Bank area of the North Sea, with installation in water depths of up to 32 metres and at a distance of 130 kilometres from shore, and provide a solid and stable base for the scale of the GE Renewable Energy’s Haliade-X turbines.

Installation of Haliade-X turbines onto each of the installed turbine foundations will commence from Spring 2023.

”Wood Thilsted is proud to be a part of making Dogger Bank Wind Farm a success. Our team faced challenges including working with the largest turbine at the time, an innovative dynamic positioning installation vessel, and some very significant wave loads,” Alastair Muir Wood, CEO of Wood Thilsted, said.

”What made success possible was the collaborative working relationship shared with the Dogger Bank team and the other key stakeholders. This project is a model of success for current and future projects.”

Over the three-year installation programme for the three phases of Dogger Bank Wind Farm, a total of 277 monopiles and transition pieces will be loaded onto installation vessels in Rotterdam ahead of transfer out to the offshore wind farm site deep into the North Sea.

Using dynamic positioning technology, the vessels will pinpoint the installation site in the seabed at which point a monopile measuring up to 72 metres will be upended and transferred to a pile gripper, before being lowered into the seabed.

A hammer will be used to drive the monopile to the design depth in the seabed before a guidance system aligns the installation of the record-breaking eight-metre flanges which act as a connection for the transition piece which is then installed onto the monopile. The foundations require 152 giant M80 bolts to secure them before a cover is inserted onto the top of the transition piece to leave it watertight.

Seaway 7 was awarded the tier one contract for foundation installation on all three phases of Dogger Bank Wind Farm, with sub-contractor DEME deploying its Innovation vessel for installation of the first foundations on Dogger Bank A. Following the DEME Innovation, the Seaway Strashnov will deploy on Dogger Bank A to continue the foundation installation.

”The successful installation of the first Dogger Bank foundation marks the start of a multi-year installation campaign for Seaway 7,” Wouter van Dalen, Project Director, Seaway 7, said.

”In good cooperation with our client Dogger Bank Wind Farm and our partners and suppliers, this complex project has been prepared for installation with a number of different heavy lift vessels, starting with DEME’s Innovation. Seaway 7 is proud to be part of the team that is constructing the Dogger Bank project and is looking forward to safely installing the remaining 276 foundations.”

DEME Offshore is also in charge of engineering, procurement, construction, and installation of the inter-array cables for all three phases of the project.

”We are extremely proud to be supporting the construction of the world’s largest offshore wind farm with foundation installation and later in the programme as inter-array cable installer,” Lucien Romagnoli, Business Unit Director Renewables at DEME Offshore, said.

”These unique foundations are huge but also, they are technically complex. This is an important moment for the offshore wind industry and the energy transition. It is wonderful to be working alongside like-minded partners with the joint goal of achieving a net-zero energy system.”

In November 2020, the consortium of Sif and Smulders was awarded the contract for the manufacture of all 190 monopiles and transition pieces for the Dogger Bank A and B phases of the wind farm, with a contract for Dogger Bank C’s remaining 87 monopiles and transition pieces awarded to the consortium in 2021.

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