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Description
The project will develop an innovative light-weight pressure casing (cylinder) for a pre-tension system of a wave energy converter (WEC) in order to improve energy efficiency and lower the energy cost. The development includes manufacturing of a set of prototype cylinders which will undergo thorough testing. The final result of the project is a full-scale certified pressure casing ready to be installed on an operational WEC and demonstrated in the ocean after the COMPACT project. The project''s main objectives are: 1) To improve the performance and reduce the price of wave energy technology, thus contributing to its quicker commercialization; and 2)To actively contribute to the Portuguese Industrial Strategy for Ocean Renewable Energies and promote jobs and growth in the region.
Summary of project results
CorPower Ocean (CPO) and OPS Composite solutions are spearheading the ‘industryadvancing’ initiative combining world-class WEC (Wave Energy Converter) design knowledge with vast experience in composite pressure vessels for offshore applications. . In essence, it will see the development of new technology to address two common challenges experienced in state-of-the-art wave energy technology – weight and price. The team will design, test, and manufacture an innovative lightweight (composite) pressure cylinder, which is one of the key components of CPO’s Wave Energy Converters (WECs).
The key findings from the project are summarized below:• A novel barrel design was developed that allowed efficient manufacture in composite material. This design and subsequent manufacturing process of a scaled prototype barrel has been endorsed by DNV.• The design and manufacturing process were assessed using a burst test, in which the barrel was pressurized until failure. The barrel failed close to 700 bar – which was around 80% of the intended maximum design load (900 bar). With minor adjustments in design it will be possible to manufacture a barrel that can reach the required 900 bar.• Several different materials were tested for the barrel liner using wear tests. There are currently no available solutions for the liner material that meet all of CPO’s requirements. Further work is required to develop solutions for this before a final PTC barrel concept can be developed.
The project has successfully proven promising design concepts that will be essential for manufacturing the PTC barrel in composite in the future. This has the potential to unlock significant weight and cost reductions, which is critical for delivering lower cost renewable wave energy to the grid – and subsequently open up a new renewable market.
Summary of bilateral results
Shared knowledge was developed between CPO and OPS, including:1 Developing winding techniques and understanding for manufacturing of the final design2 Developing and understanding the possibilities and drawbacks for the flange connection of large bolts embedded within a pressurized, wound composite structure3 Developing a sealing solution for the transition between a wound composite vessel and the stiff steel flange4 Developing a solution for minimizing bolt yielding/fatigue due to bending moments from expansion of the pressure vesselThe successful collaboration and the relationship that has been developed between OPS and CorPower Ocean mean that is very likely that the two organisations will continue to collaborate in the future