Trelleborg Marine & Infrastructure unveils the IRIS: A breakthrough in offshore wind sealing systems
As the offshore wind industry evolves, the demand for innovative and efficient solutions to improve performance and sustainability has never been greater. Trelleborg Marine & Infrastructure is proud to introduce the IRIS, a pioneering airtight platform (ATP) seal, designed to revolutionize offshore wind foundation sealing. With its advanced foldable design and elimination of the need for a traditional landing ring, the IRIS sets a new standard for efficiency, safety, and cost savings in offshore wind projects. Trelleborg’s commitment to innovation that supports the scalability of the renewable wind energy market has driven the development of this breakthrough technology, which underwent extensive field testing to validate its performance.
A game-changing new approach
The IRIS offers a range of advantages that set it apart as a revolutionary offshore wind sealing system. One of its most significant innovations is that it eliminates the need for a welded landing ring, a staple of traditional airtight platform (ATP) seals. By removing this requirement, the IRIS simplifies the monopile design, significantly reducing fabrication complexity and associated costs. This streamlined design not only saves time and resources but also enhances the overall efficiency of offshore wind projects.
Designed to deliver over 30 years of maintenance-free performance, the IRIS provides exceptional operational reliability. Its long-term durability reduces the risk of unexpected downtime and costly repairs, ensuring a safer and more consistent energy output. The foldable mechanism of the seal further contributes to improved safety and efficiency, allowing for easier handling and installation while minimizing safety risks during deployment.
The performance of the IRIS has been rigorously validated through comprehensive testing. These tests confirmed that the seal effectively protects offshore platforms from hazardous gases and external elements, maintaining a secure and airtight environment.
Additionally, the seal’s innovative design supports the offshore wind industry’s commitment to sustainability. By improving installation efficiency and reducing material requirements, the IRIS not only enhances project economics but also contributes to a more sustainable energy future.
Field-tested for unmatched reliability
The Empire Wind Offshore Wind Farm (OWF) is a transformative renewable energy project located within the lease area OCS-A-0512, acquired through an auction by the Bureau of Ocean Energy Management (BOEM) in 2016. Spanning 80,000 acres of federal waters, approximately 20 miles south of Long Island and east of the Rockaways, the project could deliver clean energy to over a million homes in New York.
The development is taking place in two phases. Phase 1 will feature 54 wind turbine generator (WTG) units, each with a generation capacity of 15 MW, contributing to a total installed capacity of about 810 MW. Phase 2 will build on this with a combined installed capacity of approximately 1200 MW. To support these massive turbines, the project utilizes offshore monopile (MP) foundations, driven into the seabed with transition pieces (TP) installed on top to create a stable, airtight platform.
During a rigorous simulated test conducted at the Empire (OWF), the IRIS was subjected to real-world offshore conditions. These included installation trials, airtightness assessments through light and water tests, and long-term storage evaluations. The results confirmed the seal’s ability to withstand extreme environmental forces, while maintaining its structural integrity and airtight performance over time.
The Empire Wind OWF simulated test provided clear validation of the IRIS’s robust design and superior functionality. Over the course of rigorous trials, the seal demonstrated its airtight performance through multiple light tests, each confirming the absence of external leakage. By providing a secure and efficient sealing solution for these structures, the IRIS plays a critical role in protecting offshore platforms from hazardous gases. In addition to offshore safety and operational efficiency considerations, it also provided exceptional water protection. Minimal water ingress was observed during water column testing, highlighting the seal’s ability to withstand significant pressure differentials without compromising its integrity.
In addition to its sealing capabilities, the IRIS's installation process proved to be optimized and efficient, with deployment techniques refined to ensure smooth integration into future offshore wind projects. The mock-up test also confirmed the seal’s enhanced durability, as it withstood long-term exposure to harsh environmental conditions without any loss of structural integrity. These findings underscore the IRIS's reliability and readiness to contribute to the advanced infrastructure that is needed to help scale the productivity of the offshore wind industry.
Global reach, local expertise
The IRIS isn’t just a product; it’s a testament to Trelleborg’s drive to push the boundaries of offshore wind technology. By combining cutting-edge engineering with a commitment to sustainability, the IRIS sets a new standard in offshore sealing solutions. Its innovative design simplifies installation, reduces costs, and enhances safety, creating lasting value for offshore wind developers. As the demand for clean energy accelerates, the IRIS offers a forward-thinking solution to meet the unique challenges of offshore wind projects.
With over 100 years of polymer engineering expertise and more than 6,000 offshore wind seals delivered since 2007, Trelleborg continues to be a trusted partner in offshore wind innovation. Our global network ensures localized support, offering seamless project execution and installation assistance for offshore developers worldwide. Trelleborg remains dedicated to empowering the industry with solutions that not only support today’s renewable energy ambitions but also lay the foundation for a cleaner, more sustainable tomorrow.