Comment: Robots are transforming offshore wind farm maintenance

The UK's offshore wind sector is poised for unprecedented growth. With the UK Government committed to decarbonising the country's electricity system by 2035, plans are in place to quadruple offshore wind power production by the end of the decade. This ambitious target presents not just opportunities, but significant challenges, particularly in the realm of infrastructure maintenance and inspection.

According to the Climate Change Committee's recent report to Parliament, the number of new offshore wind installations each year needs to triple if the UK is to meet its net zero target. This rapid expansion demands a radical rethinking of how we approach the inspection and maintenance of offshore energy infrastructure.

Traditional methods, relying on large crews and vessels, are increasingly viewed as unsustainable - both economically and environmentally. They're not only costly and carbon intensive but also struggle to keep pace with the sector's growth. This is where cutting-edge technology is stepping in, promising to transform how we inspect and maintain our offshore wind farms.

Enhancing safety

Across the industry, engineers and researchers are developing a suite of innovations to meet these challenges head-on. A key focus is on automating inspection and maintenance processes, which not only improves efficiency but also significantly enhances safety by reducing the need for human divers to work in dangerous underwater environments.

Robotic systems, including Remotely Operated Vehicles (ROVs), Uncrewed Surface Vessels (USVs) and autonomous underwater robots, are at the forefront of this transformation. These machines can operate in conditions that would be hazardous or impossible for humans, working at greater depths, for longer periods, and in more challenging weather conditions.

Among the many technological advancements in this field, three key innovations stand out for their potential to revolutionise offshore inspections.

The chicken head problem

The first of these innovations tackles a problem whimsically named after barnyard poultry. The “chicken head problem” has long pecked at the minds of underwater robotics engineers. Just as a chicken can keep its head stable while its body moves, robots need to maintain precise positioning in turbulent seas. Current breakthroughs in control systems are allowing underwater robots to do just that, keeping steady even as they are buffeted by strong currents. This stability is crucial for tasks like measuring the corrosion rate of underwater structures, where consistent contact is essential.

Equally impressive is the advent of advanced 3D mapping and reconstruction technologies. Modern underwater robots are now capable of creating detailed, three-dimensional models of subsea infrastructure. These ‘digital twins’ allow engineers to monitor the accumulation of marine life on turbine foundations or identify potential structural issues, all from the safety of onshore control rooms. By combining visual data with sonar readings, these systems can operate effectively even in murky waters, significantly expanding the conditions under which inspections can be carried out.

Coordinating robots

The third groundbreaking development is the coordinated use of USVs and ROVs. This tag-team approach is revolutionising how we conduct offshore inspections. USVs act as mobile base stations, deploying and coordinating with underwater ROVs to perform comprehensive inspections of wind farm infrastructure. Advanced AI and control systems enable these robotic teams to navigate complex underwater environments with increasing grace and efficiency.

These three advancements, while remarkable in their own right, are part of a broader technological ecosystem evolving to meet the demands of the expanding offshore wind sector. From AI-empowered predictive maintenance systems to drones that can monitor above-sea infrastructure, the industry is embracing innovation at every level.

The potential impact of these technologies is substantial. Early estimates suggest that automated robotic inspection systems could reduce fuel consumption for maintenance missions by up to 97% - from 7,000 litres per day to just 200 litres. This dramatic reduction not only slashes operational costs but also aligns perfectly with the environmental ethos of the renewable energy sector.

Around the clock

Moreover, these technologies promise to expand the operational window for inspections and maintenance. Traditional methods are often limited by weather conditions and daylight hours. In contrast, robotic systems can potentially operate 24/7, in a wider range of sea states, maximising the uptime and efficiency of offshore wind farms. Even better, they don't suffer from seasickness like humans do.

Of course, the journey from laboratory to commercial deployment is not without its challenges. Ensuring reliability in harsh offshore environments, managing power requirements for extended missions, and integrating these new systems with existing infrastructure are all hurdles that need to be overcome. Moreover, developing protocols for these autonomous systems to operate safely alongside other crewed vessel traffic is a critical consideration, requiring advanced collision avoidance systems and clear regulatory frameworks.

Towards 2030

Yet, as we look towards 2030 and beyond, it's clear that these technological advancements will play a crucial role in maintaining and expanding our offshore wind capacity. They promise to make this vital renewable energy source more efficient, safer, and more environmentally friendly – a key step in our transition to a sustainable energy future.

The next time you glimpse the distant silhouette of an offshore wind farm, consider the unseen revolution happening beneath the waves. A future of cleaner, safer, and more efficient offshore energy infrastructure is emerging, driven by the invisible hands of artificial intelligence and robotics and, crucially, guided by humans.

David Morrison is Project Manager at the National Robotarium