Integrated solution for installation of over 300 piles on major wind farm

05 Apr 2023

MENCK MHU 4400S hydraulic hammer being used to install over 300 piles on a major wind farm in Southeast Asia.

Project overview

Project name

Major offshore wind farm

Location

Southeast Asia

Developer partners

Global offshore wind operator

Water depth

27–38 m

Solution

Integrated pile installation solution

A global offshore wind operator required an integrated solution to monitor and install 349 piles, 111 wind turbine generator (WTG) jackets and two offshore substation (OSS) jackets at a major Southeast Asia offshore wind farm.  

One integrated approach

Installing 349 large-diameter jacket piles, the highest number on a single renewable project to date, demanded a creative and integrated approach to address large pile diameters, complex soils, strict noise constraints and demanding installation tolerances. 

Our solution

01Efficient installation solution

Efficient installation solution

To support this critical jacket installation phase, we delivered a fully integrated solution combining subsea cutting, piling operations, structural monitoring, and real-time positioning. The project leveraged the combined strengths of UTEC, Acteon’s geo-services business line, Menck, Acteon’s marine foundations business line and the engineering expertise of 2H, Acteon’s engineering consultancy. During early-phase testing, we used our water-abrasive cutting tool combined with an internal lifting tool to cut and recover six piles in a single offshore operation. This allowed the operator to trial future decommissioning processes.

We supplied and operated MHU 4400S hydraulic hammers, supported by an underwater noise reduction unit (MNRU) and live penetration monitoring system to ensure efficient, safe and environmentally compliant pile installation.

For precise alignment and interface with other systems, we designed a bespoke pre-piling template. Alongside this, we installed a fully redundant real-time kinematic (RTK) positioning network, developed with a regional partner, to guide accurate pile installation across the site.

Structural monitoring systems were deployed across foundations, delivering real-time data and insight into strain, inclination, displacement, and corrosion. This coordinated approach combining our experience and advanced equipment integrated ensured safe, efficient and cost-effective delivery at scale, supporting long-term asset integrity and minimising environmental impact.

UTEC installing monitoring instrumentation on wind turbine foundations for a major wind farm in Southeast Asia.
02Innovations in action

Innovations in action

  • Live depth penetration monitoring paired with GNSS-equipped hammers ensured real-time precision
  • Fully autonomous RTK stations, powered by solar and remotely controlled, reduced offshore manpower needs
  • NX2 digital platform integrated structural and anode monitoring data, enhancing visibility and supporting smarter O&M planning
UTEC installing monitoring instrumentation on wind turbine foundations for a major wind farm in Southeast Asia.

The result

Our integration of smart digital sensors ensured all 349 piles were driven without a single pile run. Real-time digital monitoring ensured installation remained on schedule, with minimal downtime, consistently meeting critical tolerances without the need for rework.  

By installing structure and corrosion monitoring sensors, we enabled remote asset condition tracking, reducing subsea inspection costs and environmental impact as well as supporting an optimised operations and maintenance (O&M) interventions programme. This creative and customised solution facilitated a safe and insight-driven delivery across all the phases of the development. 

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