Monitoring the New Fixed Offshore Wind Turbine Foundation...

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Journal of Ocean and Wind Energy (ISSN 2310-3604) http://www.isope.org/publications/publications.htm Copyright © by The International Society of Offshore and Polar Engineers Vol. 3, No. 1, February 2016, pp. 10–15; http://dx.doi.org/10.17736/jowe.2016.jcr38 Monitoring the New Fixed Offshore Wind Turbine Foundation in the East China Sea Ling Chen and Jifu Zhou Key Laboratory for Mechanics in Fluid Solid Coupling Systems, Institute of Mechanics Chinese Academy of Sciences, Beijing, China Jie Li, Yifeng Lin and Jianying Li New Energy Design & Research Section, Shanghai Investigation, Design & Research Institute Shanghai, China We introduced a new fixed structure supporting offshore wind turbines on the Donghai Bridge wind farm in the East China Sea. It is a high-rise pile cap foundation with a cap supported by eight steel piles penetrating soil. This foundation serves as an in-situ test model for a new structure to support offshore wind turbines. To monitor the behavior of the new structure, stress/strain monitoring instruments were installed on four steel piles and in the cap; clinometers were also installed to monitor tilt angles. This instrumentation allows in-situ measurements of the wind speed and direction as well as measurements of the stresses on the piles and cap and the inclination of the tower. From these measurements, the impact of the waves and wind on the tower stress was characterized, as was the relationship between the wind conditions and tower inclination. Additionally, the behavior of the new structure during typhoon Haikui was captured. INTRODUCTION With the increasing development of the world economy and severe environmental problems, underground fossil fuel is not a viable way of covering humanity’s vast and fast-growing energy needs. Renewable energy is one part of the broader approach needed to overcome the challenges associated with fossil-fuel- driven economies (Kaldellis and Kapsali, 2013; Zhou and Lin, 2013). Above sea level, the wind has higher velocity due to the reduced number of obstacles and smaller wind shear and turbu- lence (Farmakis and Angelides, 2011). These advantages have driven the fast development of offshore wind farms, especially in the North Sea where monopile foundations are usually applied as a result of their economic advantage in shallow water (Jonkman, 2007; Lombardi, 2010). In the last decade, the Chinese govern- ment has attached great importance to offshore wind power devel- opment. In 2010, the Donghai Bridge wind farm, the first offshore wind farm in China, was completed in the East China Sea; it con- sists of 34 offshore wind turbines (3 MW each). The wind farm is located southeast of Shanghai, approximately 8 to 13 km offshore and 1 km eastward from Donghai Bridge, as shown in Fig. 1. The wind turbines are arranged every 1000 m in the north-south direc- tion and every 500 m in the east-west direction. This arrangement is based on the prevailing wind direction, minimizing wake effects and obtaining the highest efficiency from each generator. The wind turbine blades sit at the top of the high tower, and this causes large horizontal loads and bending moments; there- fore, it is crucial to design a highly safe foundation according to hydrogeological conditions. One major design challenge of the Received July 25, 2015; updated and further revised manuscript received by the editors October 10, 2015. The original version (prior to the final updated and revised manuscript) was presented at the Twenty-fifth International Ocean and Polar Engineering Conference (ISOPE-2015), Kona, Hawaii, June 21–26, 2015. KEY WORDS: Offshore wind turbine, high-rise pile cap foundation, in- situ measurement, Donghai Bridge wind farm. offshore wind turbine foundation is to satisfy applicability and sta- bility under long-term cyclic loads (Bhattacharya, 2014; Zaaijer, 2009). The fatigue life of the structure is a critical safety compo- nent and must be fully understood. It is also important to ensure that the rotor frequencies are kept away from the system’s natural frequency to avoid resonance (DNV-OS-J101, 2004; Swagata and Sumanta, 2015). Additionally, some serious anthropogenic and environmental factors need to be considered, including the struc- ture damping of an impulse response caused by a boat impact (Koukoura et al., 2015), earthquake loading (Yu et al., 2015), and extreme meteorological events. The hydrogeological conditions in the East China Sea are quite different from those in the North Sea (Lin et al., 2007). A series of soft clay layers with a total thickness of more than 25 m covers the seabed. It is a very complex engineering problem to build offshore wind turbine structures on this soft clay. Accord- ing to environmental protection requirements, it is necessary to minimize the feedback effects on marine ecology. Therefore, the Fig. 1 The location of the Donghai Bridge wind farm

Transcript of Monitoring the New Fixed Offshore Wind Turbine Foundation...

  • Journal of Ocean and Wind Energy (ISSN 2310-3604) http://www.isope.org/publications/publications.htmCopyright © by The International Society of Offshore and Polar EngineersVol. 3, No. 1, February 2016, pp. 10–15; http://dx.doi.org/10.17736/jowe.2016.jcr38

    Monitoring the New Fixed Offshore Wind Turbine Foundation in theEast China Sea

    Ling Chen and Jifu ZhouKey Laboratory for Mechanics in Fluid Solid Coupling Systems, Institute of Mechanics

    Chinese Academy of Sciences, Beijing, China

    Jie Li, Yifeng Lin and Jianying LiNew Energy Design & Research Section, Shanghai Investigation, Design & Research Institute

    Shanghai, China

    We introduced a new fixed structure supporting offshore wind turbines on the Donghai Bridge wind farm in the EastChina Sea. It is a high-rise pile cap foundation with a cap supported by eight steel piles penetrating soil. This foundationserves as an in-situ test model for a new structure to support offshore wind turbines. To monitor the behavior of thenew structure, stress/strain monitoring instruments were installed on four steel piles and in the cap; clinometers were alsoinstalled to monitor tilt angles. This instrumentation allows in-situ measurements of the wind speed and direction as well asmeasurements of the stresses on the piles and cap and the inclination of the tower. From these measurements, the impact ofthe waves and wind on the tower stress was characterized, as was the relationship between the wind conditions and towerinclination. Additionally, the behavior of the new structure during typhoon Haikui was captured.

    INTRODUCTION

    With the increasing development of the world economy andsevere environmental problems, underground fossil fuel is not aviable way of covering humanity’s vast and fast-growing energyneeds. Renewable energy is one part of the broader approachneeded to overcome the challenges associated with fossil-fuel-driven economies (Kaldellis and Kapsali, 2013; Zhou and Lin,2013). Above sea level, the wind has higher velocity due to thereduced number of obstacles and smaller wind shear and turbu-lence (Farmakis and Angelides, 2011). These advantages havedriven the fast development of offshore wind farms, especially inthe North Sea where monopile foundations are usually applied asa result of their economic advantage in shallow water (Jonkman,2007; Lombardi, 2010). In the last decade, the Chinese govern-ment has attached great importance to offshore wind power devel-opment. In 2010, the Donghai Bridge wind farm, the first offshorewind farm in China, was completed in the East China Sea; it con-sists of 34 offshore wind turbines (3 MW each). The wind farm islocated southeast of Shanghai, approximately 8 to 13 km offshoreand 1 km eastward from Donghai Bridge, as shown in Fig. 1. Thewind turbines are arranged every 1000 m in the north-south direc-tion and every 500 m in the east-west direction. This arrangementis based on the prevailing wind direction, minimizing wake effectsand obtaining the highest efficiency from each generator.

    The wind turbine blades sit at the top of the high tower, andthis causes large horizontal loads and bending moments; there-fore, it is crucial to design a highly safe foundation accordingto hydrogeological conditions. One major design challenge of the

    Received July 25, 2015; updated and further revised manuscript receivedby the editors October 10, 2015. The original version (prior to thefinal updated and revised manuscript) was presented at the Twenty-fifthInternational Ocean and Polar Engineering Conference (ISOPE-2015),Kona, Hawaii, June 21–26, 2015.

    KEY WORDS: Offshore wind turbine, high-rise pile cap foundation, in-situ measurement, Donghai Bridge wind farm.

    offshore wind turbine foundation is to satisfy applicability and sta-bility under long-term cyclic loads (Bhattacharya, 2014; Zaaijer,2009). The fatigue life of the structure is a critical safety compo-nent and must be fully understood. It is also important to ensurethat the rotor frequencies are kept away from the system’s naturalfrequency to avoid resonance (DNV-OS-J101, 2004; Swagata andSumanta, 2015). Additionally, some serious anthropogenic andenvironmental factors need to be considered, including the struc-ture damping of an impulse response caused by a boat impact(Koukoura et al., 2015), earthquake loading (Yu et al., 2015), andextreme meteorological events.

    The hydrogeological conditions in the East China Sea are quitedifferent from those in the North Sea (Lin et al., 2007). A seriesof soft clay layers with a total thickness of more than 25 mcovers the seabed. It is a very complex engineering problem tobuild offshore wind turbine structures on this soft clay. Accord-ing to environmental protection requirements, it is necessary tominimize the feedback effects on marine ecology. Therefore, the

    Fig. 1 The location of the Donghai Bridge wind farm

  • Journal of Ocean and Wind Energy, Vol. 3, No. 1, February 2016, pp. 10–15 11

    seabeds in the region should be protected against a wide range ofsurface hardening. As a result, monopiles and the jacket founda-tion for offshore wind turbines are not applicable. Additionally,severe typhoons frequently hit this area, which place more strin-gent requirements on the structure’s strength and stability. Further-more, because there is a fairway across the wind farm, the foun-dation should be able to endure ship collisions. Therefore, a newhigh-rise pile cap foundation is proposed to this end (Lu, 2010).

    This paper focuses on the feasibility of this new foundationunder contingent conditions. The manuscript is organized as fol-lows: first, the new offshore foundation and environmental con-ditions at the wind farm are introduced; then the distribution ofmonitoring instruments is presented; and finally, the tower incli-nation and stresses on the steel piles and cap under the actionof winds and waves, particularly under the extreme conditions oftyphoons, are discussed and followed by a brief conclusion.

    SETUP OF THE HIGH-RISE PILE CAP FOUNDATIONAND CLIMATES OF THE WIND FARM

    The new fixed structure supporting offshore wind turbines con-sists of a circular platform 14 m in diameter and eight inclinedsupporting piles 1.7 m in diameter (see Fig. 2). The large cir-cular platform is the surface-piercing cap divided into two parts.The lower section is a 3-m-high cylinder, and the upper sectionis a frustum of a cone with a height of 0.5 m. The inclined pilesare evenly distributed around the bottom of the large platformcap with the common center axis and 5 m radius. The piles are84.5 m long with about 65 m below the seabed. The slope ratioof each pile is 5.5 to 1. A 78-m-high vertical tower is mountedto the platform cap with a 3 MW wind turbine fixed at its topend. A transitional steel pipe 4.5 m in diameter and 60 mm thickis used to connect the tower and cap. This new foundation hasbeen proved to take full advantage of the strong horizontal bear-ing capacity (Lang et al., 2014).

    According to the meteorological statistics, the prevailing winddirection is E-SSE, and the average wind speed at 90 m above thesea is about 8 m/s; 96% of the time the wind speed is in the 3.5–25 m/s range. The average annual wind power density is about662 W/m2.

    Typhoons represent the most hazardous weather in the EastChina Sea. The maximum wind speed of a 50-year return periodis 36 m/s. The complex and changeable environment must betaken into account during the design phase. Wang and Li (2010)analyzed the average wind speed and occurring frequency oftyphoons in the northwest Pacific Ocean on the basis of a 63-year

    Fig. 2 A new high-rise pile cap foundation for offshore wind tur-bines

    Average Average Average Designed Designed Extreme Extremesea high low high low high lowlevel tide tide tide tide tide tide

    0.23 1.86 −1034 2.55 −2009 3.68 −2093

    Table 1 The tide level of the wind farm (m)

    Surface layer Middle layer Lower layer

    Velocity Direction Velocity Direction Velocity Direction(cm/s) 45 (cm/s) 45 (cm/s) 45

    315 72 257 72 148 67

    Table 2 The designed tide currents of the wind farm

    Tp H T L C H1% H4% H5% H13%(y) (m) (s) (m) (m/s) (m) (m) (m) (m)

    50 2.83 7.76 74.1 9.55 5.81 5.06 4.92 4.24100 3.01 8.23 81.6 9.91 6.18 5.38 5.23 4.51

    Table 3 Wave parameters of 50-year and 100-year return periods

    dataset from 1945 to 2008. Both the wind speed and occurringfrequency tend to increase due to climate change. Therefore, in-situ monitoring during typhoons is very necessary.

    The mean water depth at the Donghai Bridge wind farm isabout 12 m. The average sea level is 0.23 m. Table 1 shows thecharacteristics of the tide level. The designed tide level is betweenthe average and extreme conditions. Tables 2 and 3 illustrate thedesigned tide currents and wave parameters, respectively. The sur-face current has the largest velocity of 315 cm/s, and the velocitydecreases towards the lower layer. The direction has an averagevalue of 70 with little deviation. Wave parameters of 50-year and100-year return periods are considered.

    Design Standards

    The project was designed on the basis of the following stan-dards:

    • Code of Hydrology for Sea Harbour (JTJ 213-98, 1998)• Technical Code for Building Pile Foundations (JGJ 94-94,

    1994)• Guidelines for Design of Wind Turbines (DNV/Riso, 2002)• Design of Offshore Wind Turbine Structures (DNV-OS-J101,

    2004)• Offshore Concrete Structures (DNV-OS-502, 2007)• Recommended Practice for Planning, Designing, and Con-

    structing Fixed Offshore Platforms—Working Stress Design(SY/T 10030, 2004; API RP 2A-WSD, 2000)

    • Recommended Practice for Fatigue Strength Analysis of Off-shore Steel Structures (SY/T 10049, 2004; DNV-RP-C203, 2001)

    • Wind Turbines – Part 1: Design Requirements (IEC 61400-1,2005)

    • Design Requirements for Offshore Wind Turbines (IEC61400-3, 2009)

    Natural Frequency Control

    To avoid resonance, the natural frequency should be controlledbeyond the range of the excitation frequency. In general, the exci-tation frequency is related to the rotor speed. For this 3 MW windturbine, the rotor speed ranges from 8.3 rpm to 17.3 rpm, with therated speed being 15.7 rpm. As a result, there are two dangerous

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    Fig. 3 Ranges of natural frequency allowance

    frequency ranges, one from 0.1383 to 0.2883 Hz and the otherfrom 0.4150 to 0.8650 Hz. Including an extra 5% allowance forsafety, the ranges of the allowance frequency are 0–0.1314 Hz,0.3027–0.3943 Hz, and larger than 0.9083 Hz. This can be seen inFig. 3, where 1P and 3P represent the rotor frequency and bladepassing frequency, respectively (DNV/Riso, 2002).

    MONITORING INSTRUMENTS

    Pile Wall Stress Meter

    Forty pile wall stress meters labeled BGK-4000 were installedon four of the eight piles to monitor stress. Ten stress meters wereinstalled on both sides of each pile at heights of −30 m, −20 m,−10 m, −5 m, and −1 m; their locations are illustrated in Fig. 3.Three other stress meters were installed on the transitional zone ata height of 7 m and arranged at an angle of 120 to one another.

    The specifications and technical notices of BGK-4000 are asfollows:

    Range: 0–3000 Accuracy: ± 001% F.S.Sensitivity: 100 Temperature: − 20C to 80C

    Rebar Stress Meter

    Twelve rebar stress meters (KL unbonded elastic wire resis-tance rebar strain meters) were installed on the high-rise cap tomonitor the loads (see Fig. 4). Additional stress meters, labeledDI-10, were installed nearby to eliminate the effects of temper-ature and moisture. Applying two separate stress measurementsystems allows the observed measurements to be verified and val-idated. The measurement principle is detailed in the followingthree parts:

    1. Rebar Stress

    P = a′ ×ãR× b− f ×ãZ (1)

    where P is the rebar stress (MPa); f is the sensitive coefficient(MPa/0.01%); a′ is the temperature coefficient (C/ì); b is thetemperature correction factor (MPa/C); ãR is the resistance vari-ation 4ì5; and ãZ is the resistance ratio variation (0.01%).

    2. Residual Strain

    = f ′4R−R05+ b4T − T05 (2)

    Fig. 4 Monitor distribution

    where is the residual strain 45; f ′ is the minimum monitor-ing data (MPa/0.01%); R is the resistance ratio (0.01%); R0 is theinitial value of resistance ratio (0.01%); b is the temperature cor-rection factor (MPa/C); T is the test temperature (C); and T0 isthe initial temperature (C).

    3. Modified Rebar Stress

    We acquire P and by utilizing the rebar stress meters andassistant stress meters, respectively. Then the actual rebar stresscan be obtained as follows:

    P ′ =E4b′4T ′ − T ′05− 5+P (3)

    where P ′ is the modified rebar stress (MPa); b′ is the temperaturecorrection factor (MPa/C); T ′ is the measured points temperature(C); and T ′0 is the initial temperature (

    C).

    Clinometer

    Two clinometers, labeled EL, were installed on the inside ofthe tower in the horizontal direction at a height of 9 m. One isdirected north, while the other is pointed west (see Fig. 4). In thisway, the inclination angle of the tower caused by winds can bemeasured. In the operating condition, the inclination is measured,and then the horizontal displacement can be analyzed. Throughthe use of the EL clinometers, the voltage signals are obtained,and the inclination angle can be calculated by:

    D =C5X5+C4X

    4+C3X

    3+C2X

    2+C1X

    1+C0 (4)

    where D is the inclination angle 45; X is the measuring voltage;and Ci are the voltage coefficients. (The constants vary in differentsensors and i = 0, 1, 2, 3, 4, 5.)

    RESULTS

    Tower Inclination

    The tower inclination was measured in two orthogonal direc-tions, north–south and west–east. To analyze the structure’sresponse to the wind effect, the magnitude of the inclination in thetime history was calculated and compared with the wind speed.The results are provided in Fig. 5.

    As indicated in Fig. 5, there is an obvious positive correlationbetween the wind speed and tower inclination. An increase in thewind speed generally results in an increase of the tower inclina-

  • Journal of Ocean and Wind Energy, Vol. 3, No. 1, February 2016, pp. 10–15 13

    Fig. 5 Time series of wind speed and tower inclination in February 2010

    tion angle. When the wind speed experiences a step change, thecorresponding increase or decrease of the inclination angle of thetower is much more apparent immediately. In February 2010, theinclination angle of the tower had a maximum value of about3.8 min; this is a small value compared with the design limit of18 min. The correlation coefficient for the wind speed and towerinclination from February 5 to February 25, 2010 is 0.5507; thisis calculated by:

    r =Cov4V 1 I5

    Cov4V 1V 5 · Cov4I1 I5(5)

    where Cov is the covariance, V is the wind speed, and I is thetower inclination.

    Usually, two variables are regarded to be significantly corre-lated when the correlation coefficient is larger than 0.5. Hence,the wind speed and tower inclination are significantly correlated,especially from February 5 to February 22, 2010, when the corre-lation coefficient is 0.6108. It may be noted that the wind speedis not the unique factor for the inclination, and many other factorscan be included. On February 23, 2010, a low wind speed wasmeasured while the tower inclination was relatively large. Duringthis time, the correlation coefficient was 0.494. This suggests thatother factors, such as the wave effect, can also play a significantrole in the operating condition. Once the frequency of the waveclosest to the natural frequency of the wind turbine system or asurge wave condition is considered, the vibration and inclinationof the tower cannot be predicted simply by the wind speed.

    Stress

    Stresses of Steel Piles. In-situ measurements of stress on thesteel piles from September 2009 to May 2010 are presented inFig. 6. In the early running of the wind turbine, the stresses oscil-lated significantly. At heights of −1 m and −10 m, the stressesrange from −30 MPa to −40 MPa, and the two stress lines are in

    Fig. 6 Measured stress on steel piles at four different heights

    substantial agreement except in partial turbulence. It may be notedthat the seabed is at a height of −11 m, and these two lines aremeasured above the seabed. Here the main force is found to bethe static load of the platform and upper structures due to gravity.The maximum compressive stress reached 48.4 MPa, occurring atthe junction of the cap bottom and the top ends of the steel piles.For the pile parts beneath the soil, the compressive stress is foundto decrease with the increasing depth. The positions at −20 mand −30 m are 9 m and 19 m beneath the seabed, respectively.As shown in Fig. 6, the stress at −20 m is about one-third of thatabove the seabed and larger than that at −30 m. The reason ismost likely related to the friction effect of the soil counteractingthe static load. As seen from the line of −30 m height, the stressis nearly equal to zero. Within the height range from −20 m to10 m, the bending moment is significant. In some situations, underthe influence of winds, waves, and the machines themselves, thepile surface stress will turn to tensile stress because of the largebending moment. As a result, piles in this section should havethe ability to endure the frequent changes in tensile and compres-sive stresses. A further investigation of fatigue in offshore windturbine foundation designs should be undertaken.

    Stresses of Steels in Concrete Cap. A sketch of rebar stressmeters distributed on the cap is shown in Fig. 7. Stress metersat R4 and R12 are installed in different directions to measure thevertical and horizontal stresses, respectively. In Fig. 8, time his-tories of the vertical and horizontal stresses are presented fromSeptember 2009 to May 2010. According to the measurements,

    Fig. 7 Sketch of rebar stress meter distributed on cap

  • 14 Monitoring the New Fixed Offshore Wind Turbine Foundation in the East China Sea

    Fig. 8 Measured stress at the location of gauges R4 and R12

    steel bars inside the cap bear compressive stress. A maximumhorizontal stress reached −1705 MPa, occurring at the junction ofthe bars located at the bottom of the cap. This value was observedin the early running of the wind turbine, and stress concentra-tion is relatively obvious. After running for several months, thehorizontal stress decreases and stabilizes at about −11 MPa. Thevertical stress is larger than the horizontal stress and ranges from−21 MPa to −2905 MPa. The maximum vertical stress occurs atthe junction of the cap and transitional steel pipe.

    Endurance in Case of Typhoon

    In August 2012, a strong typhoon named Haikui passed throughthe East China Sea. The pressure drop was 965 hPa, and themaximum wind recorded was over 41.5 m/s when the typhoonlanded. The minimum distance between the center of the typhoonand the wind farm was approximately 150 km. The wind speedat the wind farm exceeded 25 m/s and lasted for at least 12 h.Surge waves with a height of 4.5 m and a water depth of 11 mwere observed.

    During the typhoon, the maximum compressive stress of theinclined foundation piles ranged from 15.9 MPa to 69.5 MPa, andthe maximum tensile stress ranged from 15.4 MPa to 45.1 MPa.The material of the inclined foundation piles, Q345B steel, has anallowable compression strength of 197 MPa and a tensile strengthof 201 MPa according to the design standards. The measuredmaximum compressive stress of the steel in the inner platformcap ranged from 10.7 MPa to 32.4 MPa, while the material of theinner platform cap, HRB400 steel, has an allowable compressionstrength of 360 MPa. The maximum horizontal displacement ofthe platform cap ranged from 18 mm to 25 mm, which is muchsmaller than the designed allowance of 55 mm. This monitor-ing result suggests that the new fixed structure has a good bear-ing capacity during typhoon events and meets operational safetyrequirements.

    CONCLUSIONS

    The Donghai Bridge wind farm is the first large offshore windfarm in Asia. It has greatly promoted the development of off-shore wind energy and serves as a demonstration site in China.In consideration of the special foundation design characteristicsand technical difficulties, the new high-rise pile cap foundationbehavior has been monitored.

    For the tower inclination, an obvious positive correlation to thewind speed was found. During most of the monitoring time, thetower inclination roughly increased with the wind speed. Thisillustrates that the wind speed is the key factor affecting the towerinclination. However, at particular times, including February 23,2010, other factors, such as the wave effect or a ship collision,

    might be the cause for the large inclination at a low wind speed.The maximum inclination angle was about 3.8 min during themonitoring time, which is a small value compared with the designlimit of 18 min. From the measured stress of the steel under gen-eral operating conditions, both the piles and the concrete cap aresafe. However, in some sections of the piles, especially at thelocation of −20 m, the stress dynamic frequently shifts betweentensile and compressive. This is a key finding that must be care-fully considered in the design of the fatigue limit.

    During typhoon Haikui, the steel stress and tower inclinationwere monitored. All the measured parameters fell well withinthe material’s allowable limits, and all the monitored parametersmet the specified design requirements. Therefore, the new high-rise pile cap foundation is safe for offshore wind turbines on theDonghai Bridge wind farm.

    ACKNOWLEDGEMENTS

    We would like to express gratitude for the financial supportfrom the National Natural Science Foundation of China (GrantNos. 11232012, 11572332, and 11172307) and from the 973 pro-gram under Grant No. 2014CB046200.

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