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 WTGs
A 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 group
PROFESSIONAL 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 2011/2012
EDUCATION
• Diplom-Kaufmann (Business Administration)
• International MBA

Structure
1 Introduction

In offshore wind, Vattenfall operates a capacity of 840 MW and has
more 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)
Sweden (~940 MW)
Germany (>1 GW)
alpha ventus (60 MW)
• Vattenfall share: 26.25%
Egmond aan Zee (108 MW)
• Vattenfall share: 50 %
Netherlands (~254 MW)
Beaufort (279 MW)
• Development
Yttre Stengrund (10 MW)
• Extension/repowering (10MW)
in developmentUtgrunden (10 MW)
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
Thanet (300 MW)
Kentish Flats (90 MW)
• Extension of 51 MW in implementation
Trolleboda (110-150 MW)
• Development
Kriegers Flak II (640 MW)
• Development
Taggen (150 MW)
• Development
Wind farms in operation
Wind farms in planning phase / under construction
Wind farms in development
Sandbank (288 MW)
• Planning/Engineering ongoing
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 of
installation 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
120
105
80
180
Hub
height (m)
Rotor (m) Blade
length (m)
4MW
8MW
140
250
290
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 implementation
Henrik 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 chain
are 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]
Availablevessels
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 about
requirements, 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]
Availablevessels
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
120
105
80
180
Hub
height (m)
Rotor (m) Blade
length (m)
4MW
8MW
140
250
290
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 would
allow 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 no
one-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

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