STORM Connector

About

Summary The study aims to employ greener material solutions for producing greener energy. Wave, tidal and offshore floating wind arrays could supply a significant amount (up to 20%) of the UK's energy needs. However, current weaknesses in mooring lines present a major barrier for developers who are attempting to harness and exploit this energy source. This project is focused on investigating the feasibility of producing state-of-the-art multi-material hybrid end and in-line rope connectors. The components will incorporate a higher strength, lightweight corrosion resistant recycled metal core with a market leading high wear resistant nylon surface. Project Status The materials have been fully optimized and characterized form mechanical properties and microscopic features. A new design has been developed that is lightweight, easily assembled and highly durable, that aims to increase the life of a mooring system from 20 to 30 years. 5 prototypes of the component have been manufactured at an industrial scale in industrial environment (TRL 5). Description The innovative connectors have the potential to increase the lifespan of mooring ropes from 20 to 30 years, is 50% lighter and 1/7th the cost of super duplex stainless steel mooring connectors and devices which are now in use. Three innovative elements are included in the STORM connector: A new design easy to deploy and assemble and service in full compression load; A new multi-material solution 50% lighter and 1/7th the cost of super duplex stainless steel mooring connectors Full use of recycled aluminum for the core material. This avoids 95% of the energy and GHG emissions associated with primary Al production. Oilon (CF072) a low friction material (0.089μ compared with 0.74μ for steel) developed by Nylacast that can increase the life of a rope by 1/3. For offshore renewables energy devices this will result in increased deployability, increased reliability and longer in-service times thus yielding an increase in energy output and improvement in safety. Benefits The benefits of the newly designed connector are: Raw material cost (1/7th of super duplex stainless steel) Manufacturing costs (near net shape vs. machining resulting in a 30% reduction) Weight reduction (50% compared with stainless steel) Reduced deployment cost (£2500 per deployment) Ease of assembly (saving ½ day) Improved corrosion behavior (life span of component from 20 to 30 years) Low friction (1/10 stainless steel - life span of rope from 20 to 30 years) At least 30 years design life