vattenfall: challenges for next generation offshore wtgs from a developer’s point of view

Expected challenges and requirements for Installation Logistics of next generation offshore WTGsA developer’s point of view

Jan-Hinnerk Maxl

Confidentiality class: None (C1)25th November 2014

2 | Giant Offshore Wind WTGs – A developer’s point of view on Installation Logistics | Jan-Hinnerk Maxl

Executive Summary

• In offshore wind, Vattenfall operates a capacity of 840 MW and has more than 8 GW in development,

planning or construction phase.

• In the SylWin area, a cluster approach is being taken, in order to gain synergies during the installation,

but esp. during the operation phase.

• Lessons learned, derived from previous projects and current developments, will have to be challenged

again and taken as a basis for further improvement of the project implementation phase and thereby the

reduction of CAPEX.

• The component sizes will change the perception of installation logistics by project stakeholders, since

although lessons learned may have been taken into account, cost reduction will not be its strong suit,

due to the new requirements.

• Project developers have to cope with the challenges of a still or further developing branch and have to

become competitive in terms of LEC.

• Although only campaign based, a holistic approach on the entire supply chain of an offshore wind project

has to be chosen.

• Taking large scale WTGs and project sizes into account, the ‚classic‘ SC approach has to be challenged –

on a project by project basis.


Executive Summary (cont’d)

• The latest generation of installation vessels is now available and has finalised its first deployments at

projects.

• The capabilities and limitations of the installation resources are determining approx. 30% of the CAPEX.

• Recent assessments of the market suggests, that for the relevant vessel segment no bottleneck is to be

expected in the next years.

• Intensive exchange between the parties of the market about requirements, availability and feasibility of

solutions is required.

• Will the utilisation of “motion compensating systems” enable robust feeder concepts?

• Components are determining the operational limits. Addition devices may enable further reduction of

operational limits.

• A float-in barge of Logima‘s windmaster concept would allow permanent stay of the installation vessel on

site.

• Will the next generation of “floating installation vessels” provide a stable platform for WTG foundation

installation?

• Due to the individual site conditions of each project, there is no one-fits-all access strategy, which is

randomly adaptable


Structure

1 Introduction

2 Vattenfall Offshore Windpower

3 Experience from previous projects

4 Giant OW WTGs – what does that mean?

5 Supply Chain design

6 Implications for Installation Vessels

7 …and Installation Methodologies!

8 Questions / Discussion


Vattenfall Europe Winkraft GmbH, Germany - Hinnerk Maxl

Personal Introduction

CURRENT TASK• Lead Installation Logistics team of Sandbank project• Member of Marine Operations & Logistics groupPROFESSIONAL EXPERIENCE• More than 10 years experience in leadership as nautical

and diving officer as well as deputy commander• Functional and managerial responsibility in offshore wind

installation logistics and project management since 2010• Involved in DanTysk installation logistics during

procurement phase 2010/2011• Consultant for maritime issues & project management with

K2 Management in 2011/2012• Contract manager for the Installation contracts of the

Meerwind SüdIOst project (WIV, CII, OSS) in 2011/2012EDUCATION• Diplom-Kaufmann (Business Administration)• International MBA


Structure

1 Introduction









In offshore wind, Vattenfall operates a capacity of 840 MW and hasmore than 8 GW in development, planning or construction phase

Horns Rev I (160 MW)• Commissioning in 2002• Vattenfall share: 60 %

Denmark (~500 MW)Lillgrund (110 MW)• Commissioning in 2007

Sweden (~940 MW)

Germany (>1 GW)alpha ventus (60 MW)• Commissioning in 2009• Vattenfall share: 26.25%

Egmond aan Zee (108 MW)• Commissioning in 2007• Vattenfall share: 50 %

Netherlands (~254 MW)

Beaufort (279 MW)• Development

Yttre Stengrund (10 MW)• Commissioning in 2001• Extension/repowering (10MW)

in developmentUtgrunden (10 MW)• Commissioning in 2000

DanTysk (288 MW)• Commissioning ongoing• Vattenfall share: 51%

Nordpassage(~400 MW)• Development

UK (> 4GW)

Ormonde (150 MW) • Commissioning in fall 2011 East Anglia (up to 7.2 GW)• Development• Vattenfall share: 50%

Thanet (300 MW)• Commissioning in 2010

Kentish Flats (90 MW)• Commissioning in 2005• Extension of 51 MW in implementation

Trolleboda (110-150 MW)• Development

Kriegers Flak II (640 MW)• Development

Taggen (150 MW)• Development

Wind farms in operationWind farms in planning phase / under constructionWind farms in development

Sandbank (288 MW)• Planning/Engineering ongoing• Vattenfall share: 51%

Vattenfall’s offshore wind capacity

Sandbank Extension (288 MW)• Development

SylWin Cluster

Horns Rev III (up to 400 MW)• Bidding process


In the SylWin area, a cluster approach is being taken, in order to gain synergies during the installation, but esp. during the operation phase

SylWin cluster approach

• > 350 WTGs• Close vicinity of

projects/plants• Relative close distance

to service port Esbjerg• Similar geophysical

conditions• Similar geotechnical

conditions

Similar conditions and geographical vicinity of different projects/assets enable:• Further development of Installation Logistics concepts and• Bundling for the O&M logistics


Structure

1 Introduction









Lessons learned, derived from previous projects and current developments, will have to be challenged again…

Experience from previous projects

Under deck stiffening required,in order to cope with full tower weights.

(Installation) blade lifts to be thoroughly engineered in order to enable smooth operations with sufficient operational limits.


… and taken as a basis for further improvement of the project implementation phase and thereby the reduction of CAPEX

Experience from previous projects (cont’d)

Handling of large, larger and even larger monopiles is considered to constitute at least a challenge, either due to manufacturing capabilities or due to handling procedures

Detailed Daily Progress Report analysis allows identification of time consuming activities and determining a realistic approach for net installation durations per WTG


Structure

1 Introduction









The component sizes will change the perception ofinstallation logistics by project stakeholders, …

• Number of WTGs per round trip?• Availability/ accessibility of respective ports?• Availability of capable vessels? (WTG & foundations)• Further increase of operational limits?• Further reduction of cost per installed MW?

WTG size development and related challenges


…, since although lessons learned may have been taken into account, cost reduction will not be its strong suit, due to the new requirements

Development WTG components’ weights & dimensions

90

59

120105

80

180

Hub height (m)

Rotor (m) Blade length (m)

4MW8MW

140

250290

700

Tower (t) Nacelle (t)

Lenghts (m) Weights (t)

Source: MAKE 2014


Project developers have to cope with the challenges of a still or further developing branch and have to become competitive in terms of LEC

Distance to shore & water depths of European offshore windfarms

Taking experience made into account, the environmental conditions will not necessarily improve and it has to be questioned, whether learning curves can really be adapted from project to project (or have to be restarted again and again)

Source: EWEA 2011


Structure

1 Introduction









Opportunities to further reduce LEC

Although only campaign based, a holistic approach on the entire supply chain of an offshore wind project has to be chosen

Source: Carbon Trust interview 2014

“In order to make wind power affordable for the society as a global energy source, the scope of innovation has to be expended.” Innovations - Also in other parts of the value chain Industrialisation - Infrastructure has to be developed Cooperation - Is mandatory to lift wind power from the

concept level into a real life implementationHenrik Stiesdal, former CTO Siemens Wind Power

Combined with the individual needs of a project :• Standardisation of logistical means & procedures as well as• An individual adaption of the relevant tiers in the supply chainare considered as key elements for future offshore wind projects


Taking large scale WTGs and project sizes into account, the ‚classic‘ SC approach has to be challenged – on a project by project basis

Offshore Wind supply chain schemes

Manufacturers Base Harbour Offshore installation


Taking large scale WTGs and project sizes into account, the ‚classic‘ SC approach has to be challenged – on a project by project basis

Offshore Wind supply chain schemes

Offshore installationManufacturers Base Harbours


Structure

1 Introduction









The latest generation of installation vessels is now available and has finalised its first deployments at projects

3rd generation jack-ups


The capabilities and limitations of the installation resources are determining approx. 30% of the CAPEX

Number of installation vessels & crane capacity (SWL)

0

1

2

3

4

5

6

7

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

max. SWL [T]

Ava

ilabl

e ve

ssel

s

Although many new installation vessels have entered the market in the past, one has to question, taking increasing component weights and applicable contingency factors into account, if the supply will cover the industry’s demand under competitive conditions


Next generation Jack-Up Vessel supply and demand

Recent assessments of the market suggests, that for the relevant vessel segment no bottleneck is to be expected in the next years

Source: BTM Consultants “Global Evaluation of Offshore Wind Shipping Opportunity”, 2013


Intensive exchange between the parties of the market aboutrequirements, availability and feasibility of solutions is required

Projects’ requirements

0

1

2

3

4

5

6

7

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

max. SWL [T]

Ava

ilabl

e ve

ssel

s

Available installation technology

• Which technical feasible and commercial reasonable concepts can optimise the installation logistics?• How can these concepts, also taking e.g. the Owners’ point of view into account, be utilised during the life time of the offshore wind farm or in other branches?• How reliable are these solutions?• When will they be available?• Which form of exchange between the involved stakeholders is required and in how far may this be restricted due to e.g. legal restrictions?

90

59

120105

80

180

Hub height (m)

Rotor (m) Blade length (m)

4MW8MW

140

250290

700

Tower (t) Nacelle (t)

Lenghts (m) Weights (t)


Structure

1 Introduction









Will the utilisation of “motion compensating systems” enable robust feeder concepts?

Bargemaster system during offshore test

Source: http://www.barge-master.com, 2014


Components are determining the operational limits. Addition devices may enable further reduction of operational limits

Boom lock system by High Wind

Source: http://www.high-wind.eu, 2014


A float-in barge of Logima‘s windmaster concept wouldallow permanent stay of the installation vessel on site

Windmaster concept

Source: http://www.logima.dk, 2014

Utilisation of as many weather windows as possible No ‘waste’ of vessel time for transit periods


Will the next generation of “floating installation vessels” provide a stable platform for WTG foundation installation?

NorWind concept for a floating foundation installation

Source: http://www.norwind.no, 2014


Due to the individual site conditions of each project, there is noone-fits-all access strategy, which is randomly adaptable

Constraints for the installation campaign

Foundation design

Environmental conditions Time-distance relations


Structure

1 Introduction








32 | STRAAK FORUM - Schiffe für Offshore Windparks | Jan-Hinnerk Maxl

Thank you for your attention!

vattenfall: challenges for next generation offshore wtgs from a developer’s point of view

Engineering

installation resources

installation methodologies

offshore wind project

project developers

giant offshore wind

generation offshore

wtg foundation installation

project sizes