1. Introduction
With the rapid development of offshore wind energy in Korea, a number of high capacity OWTs are being installed, which moves towards offshore wind power generation with the goal of becoming one of the top three nations for offshore wind power generation in the world. Accordingly, OWTs with a capacity of 3 MW models were developed and commercialized, 4.2 MW and 5 MW capacity OWTs models are also being researched for completion and mass construction. The aims of the present study were to propose and evaluate a suitable substructure for a 5.5 MW wind turbine in the shallow muddy seabed on the Gunsan coast, southwest of Korea.
Nowadays, OWTs are supported by many types of foundations, such as monopile, multi-pile, SB, jacket; even a floating foundation (
Figure 1) for each type of offshore wind foundation has its priority and limitation. The type of substructure mainly depends on the water depth, turbine size, and soil conditions. Mono-pile foundations are currently the most commonly used foundation solution for OWTs, but it is impossible or too expensive to implement at some sites where the seabed consists of a shallow sandy layer lying on a rock bed. The reason for this is that mono-pile is a tubular steel pile with an outside diameter of 3-6 m and a length of 20–50 m, 40–50% of the length should be inserted into the seabed to provide resistances [
1,
2]. Multi-pile foundation (
Figure 1c) is the expansion of mono-pile foundation, but adapted to a greater water depth [
3]. This type of foundation is also not suitable for muddy and shallow geological conditions, because three smaller and lighter piles should be penetrated up to 10–20 m into the seabed. The jacket foundation can be used at a larger water depth of 10 m to 60 m. The limitation of this type of foundation is the higher cost of installation and construction. The floating foundation (
Figure 1f) is a deeper sea substructure. It allows access to deep-water sites with higher wind resources. The SB foundation is believed to be an effective alternative to this ground condition.
The advantage of the SB foundation is that their own weight and vacuum pressure causes them to become firmly embedded in the sea floor. This method eliminates the need for pile driving, and consequently, a quick installation, with no heavy driving equipment for penetration and no hammering noise [
5]. The efficiency and reliability of SB foundation was verified in numerous studies. In these studies, the lateral bearing capacity and the stiffness of the foundation are the dominant design factors. Latini and Zania [
6] investigated the dynamic responses of suction caissons, and the skirt length was found to be a significant parameter for determining their behavior. Bagheri et al. [
7] performed three-dimensional finite element analyses to evaluate the load-bearing behavior of the bucket foundations under cyclic and monotonic loading conditions. This study examined the effect of various loading conditions and foundation geometries installed in different soil properties. Aside from that, a series of studies were conducted to examine the effect of the bucket aspect ratio on the ultimate bearing capacity of the SB foundation, the influence of the sand’s relative density on initial foundation stiffness, and the dependence of foundation behavior on bucket geometry [
8,
9,
10].
Although this SB concept is continuously and widely used as one of the most promising types of foundation for offshore structures, it has a disadvantage of instability in vibration, since this substructure is mainly applied to the soft seabed of coastal areas and not fixed to the rock directly. Among the SB concepts, the tripod concept is currently the most widely used foundation solution for OWTs on the sandy seabed. The stiffness of these types of foundation mainly depends on the length of the SB. However, in case of a shallow muddy seabed, SB length is limited by the rock layer depth. For reinforcing the stiffness of the foundation, the SB diameter will, therefore, become bigger. With the larger diameter, the industrialization of this type of foundation faces a manufacturing problem. Especially for the structure on sandy ground, the increased diameter can lead to group pile effect. Moreover, offshore structures on a sandy seabed are susceptible to scour. Scour also affects bucket length and stiffness. This study focused on a 5.5 MW capacity OWT substructure located on the Gunsan coast with a shallow muddy seabed.
With this seabed condition, a new type of SB needs to be developed and verified in horizontal bearing capacity. Through a kinetic derivation, this study proposes a new foundation solution that is not only optimal in terms of horizontal bearing capacity but also saves on material costs. The influence of scouring, one of the hazards for OWTs foundations located in sandy seabed, was also examined. The finite element program software was used for the simulation. Assuming that the local scour depth occurs the same in each SB. The development pattern and speed of scour are not considered in this study. Three kinds of earthquake ground motions were selected and scaled to some peak ground accelerations (PGAs), and they were combined with the environmental wind to generate a thrust load for finite element analysis. The damage states were defined as excessive displacement at the top of SB. Seismic fragility curves were plotted by using the maximum displacement of SBs for different scour depths. The scour fragility was also obtained by defining the horizontal axis as the scour depth. All of the responses and fragility of the new SB were compared with TSB.
2. Background of SB
SB foundations, referred to as suction caissons, suction piles, or suction anchors, were first introduced to the offshore industry in 1982 [
11], and they were recognized as suitable support structures for OWTs in 2001 [
12]. Then, in 2003, a prototype wind turbine was installed in Frederikshavn, Denmark. An SB foundation is an upside-down bucket inserted into the seabed to provide resistances. During installation, a suction pump attached at the top of the bucket pumps water out of the skirt compartment to create pressure, which creates a driving force that pushes the bucket down into the seafloor (
Figure 2). The benefits of SB foundation include (but are not limited to): fast and low-noise installation, easy decommissioning, no sea-bed preparation needed, and adaptability to deeper waters as well as larger turbines. The installation of an SB is especially easy in soft clays, but recent experience proves that even the installation in dense sand is not a limitation [
13,
14,
15].
The bucket foundation was commonly designed as the mono-bucket or tripod bucket (
Figure 3). An SB is usually made of steel and has a cylindrical shape (skirt) that is closed by a steel plate at the top (lid) and an open bottom. It has an opening on the lid, which is open during the initial installation phase, where the SB penetrates the soil due to its own weight. They are fairly simple steel fabrications that can be designed with less steel than that required for the equivalent pile foundation and, therefore, might result in lower material costs. The mono-bucket foundation model was the subject of many studies. The stability of foundation and cost-effectiveness was verified. However, for higher capacity turbines, and to fulfill the high requirements in terms of the bearing capacity of the foundation, multi-pod foundations with three or more individual foundations are preferred [
17]. SBs are expected to be particularly suitable for the coast of the Republic of Korea. In December 2014, Korea initiated the installation of an offshore wind turbine supported by the TSB foundation, which was completed in October 2016; this is a 3 MW capacity wind turbine.
Figure 4 shows the four stages of the installation process of the full-scale 3 MW-class OWTs, which was designed by Doosan Heavy Industries and Construction in Korea [
18]. This site is the shallow water area with the mean sea level of around 13.6 m. This OWT with TSB includes blades with a diameter of 100 m and a hub height of about 80 m above the mean sea level; each of the TSB comprising the foundation system is about 6 m in diameter and 12 m in length. This SB, with the advantage of the fast and hassle-free installation, also reduces the total installation cost by 30% [
19].
Since the foundation cost reaches 20–40% of the total cost depending on water depth [
21], it is economically very attractive to optimize the design of SBs. Lowering foundation cost is key to reducing the total cost for OWTs. Therefore, selecting a suitable OWTs foundation type and optimal design are the most important factors to lower the cost. As an example, there are two weather towers with different types of substructures constructed by The Korea Electric Power Corporation Research Institute (KEPCO RI). The first tower (HeMOSU-1) is supported by a jacket pile foundation; whereas the second tower (HeMOSU-2) is supported by a TSB foundation. The cost analysis showed that the TSB foundation requires half of the construction cost of jacket piles for the same seabed condition. Remarkably, the penetration of HeMOSU-2 into the TSB foundation was completed in 6 h, while HeMOSU-1 took two months to install [
22]. This confirmed again that suction caissons are excellent solutions from construction and installation perspectives. Regarding the issue of cost optimization, not only the structural design of a substructure, but energy system equipment were also proposed. Mostafa Nazemi and his coworkers [
23] proposed a comprehensive analytical architecture to model, characterize, and mitigate the general HILP hazards and earthquakes, while Yushuai Li et al. [
24] investigated the adaptive and optimal control problem for a virtual synchronous generator (VSG). Using the proposed controller, the author can obtain the optimal control policy in a model-free fashion, which is the major advantage compared with the existing optimal control approaches used in VSG.
However, the cost is not the only issue concerning foundations. The development of a new concept of foundations also aims to enhance the resistance of the foundations. The bucket foundations supporting OWTs are subjected to a vertical load, horizontal load and overturning moment resulting from self-weight, wind, wave, current, etc. Hence, the vertical, horizontal and moment-bearing capacities must be investigated, and they can be determined by the simple method, the tangent intersection method [
25], as shown in
Figure 5, where two tangent lines along the initial and latter portions of the load–displacement curve are plotted, and the bearing capacity is the intersection point of these two lines. Although the foundation is not widely used in practical wind farms, its bearing capacity under variable loading conditions was investigated using model tests [
26,
27,
28] and numerical modeling [
29,
30]. Considering that some of the offshore wind farms are located in earthquake areas, the study of the seismic behavior of SB is also one of the most vital engineering issues. In this study, some analyses were conducted to understand the responses of the proposed offshore wind turbine when supporting structures under seismic loads, wind load, and both of the two under scouring conditions. Finally, the fragility curve was used to compare the seismic performance between the proposed foundation and traditional TSB foundation.
5. Conclusions
This study proposed a PSB foundation as the feasible choice of foundation solution, suitable for locations with shallow muddy seabed conditions. For the combined effect of the post-scour, earthquake, and wind load, some analysis was carried out. The following conclusions were obtained from this study:
- (1)
If the bucket size (L, D) and the space between the bucket and the wind turbine center (R) are assumed to be similar, the foundation model with the PSB is the optimal in terms of the dimensionless resisting moment;
- (2)
The scour has a minor effect on the natural frequency of the OWTs system. Specifically, with the proposed PSB model, the first natural frequency of the system is reduced by about 0.21%, even with scour depth of 4m. The effect of this is small because the lateral stiffness of the wide shallow bucket is large. This is in good agreement with previous studies;
- (3)
Under scouring conditions, the stability of the foundation deteriorates significantly. Specifically, the displacement at the SB level increases gradually as the depth of scouring increases. However, wind acting on the OWTs has a minor impact on the top displacement of SB in operating conditions, and the top displacement of SB is mainly dominated by seismic load. Additionally, the top displacement of SB caused by the seismic wind combination is clearly less than that caused by the seismic load alone;
- (4)
From the analysis, PSB clearly has a better performance compared with the TSB. PSB not only saves materials (the total mass is reduced to only 64% of TSB), but also shows a better seismic performance in bearing capacity.
Since all issues cannot be resolved in this study, other complex problems, such as the effect of the speed and development of local scour, different shallow seabed properties and other external forces, such as a wave, etc., need to be performed in order to develop a more comprehensive understanding of this foundation behavior.