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Offshore wind farms are important contributions to the growing need for the generation of renewable energy. The number of offshore wind farms is growing, and multiple projects are under planning and construction around the world. One key element for a profitable and sustainable operation of offshore wind farms is that the installations are protected with the most cost-effective corrosion protective solution for the entire lifetime of the offshore wind farm. In practice, this means that today’s projects are planned with an estimated lifetime of a minimum of 35 years without major maintenance of the corrosion protective solution. To achieve this it is instrumental that the entire lifetime cost is considered when a corrosion protective solution is selected.
The offshore Oil&Gas industry started in the early 1970’s on the Norwegian Continental Shelf. Some of the first jacket installations were first applied with traditional epoxy coating systems. However, good experience with glass flake reinforced polyester coatings in the early 1980's convinced operators to apply these high build coating systems for all new structures, as well as refurbishing several existing structures during offshore maintenance campaigns. Glass flake reinforced polyester coatings have now been used for more than 35 years under offshore conditions on the Norwegian Continental Shelf. High film thickness and highly abrasion-resistant coatings have proven to be highly durable in the tidal/splash zone of offshore constructions.
Following the worlds growing need for sustainable energy solutions, offshore wind farms are important contributions to the generation of renewable energy. One key element for a profitable and sustainable operation of offshore wind farms is that the installations are protected with the most cost-effective corrosion protective solution for the entire lifetime. In practice, this means that today’s projects are planned with an estimated lifetime of a minimum of 25 years without major maintenance of the corrosion protective solution.
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Offshore is a very corrosive environment with a high corrosion rate. The offshore coating service life is relatively short and extremely expensive to apply maintenance coatings onsite. A new accelerated coating corrosion test method is proposed.
Cathodic protection (CP) is routinely applied to the external surfaces of offshore wind turbine monopile foundations to minimize corrosion. When the monopile internals are free-flooding, and therefore also exposed to oxygenated seawater, again, cathodic protection may be applied. In cases of unplanned water exchange through cable entry seals, a small additional surface area, in a gap between the seal and the ‘cable entry hole’ through the steel monopile is then exposed to flowing seawater. Cathodic protection calculations were undertaken to assess whether protection (either applied externally or externally and internally) could penetrate into the small gap and prevent corrosion.