Nordsee Ost Offshore Wind Farm - WINDFORCE · PDF fileRWE Innogy 6/16/2014 PAGE 1 Nordsee Ost...

RWE Innogy 6/16/2014 PAGE 1

Nordsee Ost Offshore Wind Farm Lessons learned and outlook Marcel Sunier Project Director WINDFORCE 2014, Bremen 18th June 2014

RWE Innogy 29 April 2014 PAGE 3

NSO – Nordsee Ost Offshore Wind Farm RWE Innogy – The energy to lead

Content

The Project - General - Location - Layout - Facts and Figures

HSE&S UXO Meteorological Mast Foundations (FOD)

Inter Array Cables (IAC) Offshore Substation (OSS) Logistics (LGS) O & M Overall lessons learned Project Partners Outlook



The Project General

48 Wind Turbines, each 6.15MW installed on jacket foundations with a hub height of 96.5m LAT

1 Offshore Substation on a jacket foundation

~ 63 km infield cables

1 Met Mast

Total output 295 MW ~ supplying electricity for 310.000 households

Investment appr. 1.3 billion Euros



The Project Location

35 km north from Heligoland and 40 km west of Amrum, area of 42 km²

Water depth: 22 – 26 m

Soil condition: sand with clay

Neighboring wind farms are “Meerwind” to the South and “Amrumbank West” to the North

Nordsee - Ost



The Project Layout

600

m 914 m

Nordsee Ost Offshore-Substation

TenneT Converter Station

Met Mast NSO

N

48 Wind Turbine Generators 1 Offshore Substation 1 Meteorological Mast − Voltage level within park: 33kV AC

Connection to the grid provider: 155kV AC Helwin Alpha Converter Station (Grid provider offshore converter station to onshore converter station in Büsum: 155kV DC) Interconnectors Wave buoys

Wave Buoy

Wave Buoy



The Project – Facts and Figures Size Comparison

∅126m

Wind turbine incl. foundation (ca. 238m)

Airbus 380 (70m)

Cologne Cathedral (height: 157m)

Seabed

Mean water level

Access plattform

0 m

25 m

- ca. 25 m

- ca. 30 m

During the foundation installation our vessels have covered a distance of almost 80.000 nautical miles 3.6 times around the world !!



HSE&S Principles

WE WANT TO AVOID EVERY ACCIDENT! WE ONLY WORK WHEN IT´S SAFE TO DO SO!



HSE&S Project Policy

These primary principles are binding and apply to all project members at all levels.

HSE&S Policy

Our approach

Our commitment

Our objectives



HSE&S Targets

HEALTH and SAFETY have

ABSOLUTE PRIORITY and

we are ALL RESPONSIBLE!

Project Target for 2014:

LTIF ≤ 4.6 (currently 4.2 ) (Lost Time Incident Frequency)



HSE&S Concepts during Construction

Rescue Concept

Provision of rescue helicopter (Sikorsky S-76, supplied by Wiking ADAC, stationed at Wilhelmshaven)

Provision of emergency coordination and rescue resources by Marine Rescue Coordination Centre (MRCC)



UXO Unexploded Ordnance

During World War II millions of tons of explosives like bombs or mines were dumped, but not marked on charts, in the North-, Baltic- and Mediterranean Sea.

Experts estimate that there are 1.6 million metric tons of conventional and chemical ammunition in German territorial waters alone, unexploded time bombs lying in or on the sea floor.(dpa)



UXO Preparation of UXO Clearance

Survey and Clearance works to expose finding. (Remote Airlift, ROV, Divers) Detonations if necessary with more required actions.



UXO Findings at NSO

German/ American/ British 500 – 1000lbs Bombs, anchor mines with

mine chairs and one Torpedo



UXO Facts

Surveyed Area 26 km2

Detected targets above threshold

457

UXO targets 77 total; 64 cleared Targets detonated 21



Lessons Learned UXO

Lesson: 1. Time consuming both

scanning and clearance

2. Area to be cleared increased during the campaign

Learned: 1. Ensure supplier is equipped

with large enough vessels to carry out the job also in slightly bad weather to avoid any installation delay

2. Clearly define clearance area for all activities with the involved contractors before financial close and include this in the relevant contracts



LIDAR device for wind measurement up to 200m

92.59 m

86.30 m

69.44 m

47.44 m

32.00 m

Hinged booms

Triangular shape of lattice tower

Standard 20ft container with energy supply and communication equipment

96.50 m

Wave Radar

Met Mast (MET) Main Layout Features I



Lessons Learned MET

Lesson: 1. Data communication to / from

mast not working or not stable by the time of installation

2. One EPCI contract for both the monopile and met mast incl. equipment and installation made co-ordination easier for NSO. But weather risk excluded

Learned: 1. Test entire communication

setup prior installation and allow plenty of time for IT to establish data communication into secure net

2. Engage with experienced contractror for entire work for smooth execution and clear risk allocation incl. weather risk



Met Mast (MET) Impressions

Victoria Mathias visiting Webcam shot

nice weather not-so nice weather = Hurrican „Xaver“ (Dec 2013)



Foundation (FOD) WTG Substation

Cable Deck

10 x J-tubes

Spiral

Boat Landing

Standard Boat

Landing

Transition Piece

2 x J-tubes

Boat Landings

Pile Catcher

Pile Gripper

Pile Sleeve

Mud Mat



Lessons Learned FOD - Design

Lesson: Design shall be suitable to allow for de-risked and cost efficient installation (including all aspects of the installation process)

Learned: 1. Post piling is slow and

requires expensive installation spread. Use pre-piling instead

2. Apply established techniques, also from oil & gas to avoid cost & time overrun



Lessons Learned FOD – storage capacity

Lesson: Storage capacity insufficient to cope with project delays due to „just in time“ production from supplier

Learned: 1. Avoid „just in time“

production, but allow for significant buffer and sufficient storage capacity with the supplier

2. Prepare for intermediate storage facility well in advance

3. Consider alternative means of moving heavy components instead of cranes



Lessons Learned FOD – insufficient storage capacity

Bremerhaven – CT1

Manufacturer’s yard



Lessons Learned FOD – grout seals working fine

Lesson: Sound design of grout seals Only 1 out of 196 seals failed!

Learned: 1. Solid grout seal design and

material is important (guiding plates, one seal )

2. Ensure counterpart (= pile) is prepared accordingly !!



Foundation (FOD) Impressions



Foundation (FOD) Big Bubble Curtain (BBC)

2 main configurations Post-laid system Pre-laid system



Environmental Monitoring Noise Mitigation: Configuration and Vessels

Normand Draupne

Søløven

VM Victoria Mathias

ND

SOE

WDS Buoy Hydrophone & CPOD

WDS Buoy Hydrophone & CPOD

SOE

VM

WDS Buoy

WDS Buoy

WDS Buoy

WDS Buoy

WDS Buoy

WDS Buoy

WDS Buoy

BBC

ND



Environmental Monitoring Noise Mitigation: Summary Achieved BSH target of 160 dB or less at 750m

Close interface with offshore installation team:

- Continuous improvements BBC layout and BBC system (hose, compressors)

- Change in BBC installation procedure during construction process (changes in BBC vessels, BBC post-laid to prelaid method)

- Reducing hammer energy from 1200 kJ to 850 kJ 2-3 dB reduction

- HSE risks, weather limits, vessel coordination

WDS allowed for effective mitigation measures to be applied instantaneously during piling if necessary (additional deterrence, delay in start of piling)



Inter-array Cables

Total ~ 63 km (33kV/AC)

~ 31 km 240 mm²

~ 19 km 630 mm²

~ 13 km 800 mm²

Strings in open loop layout

Offshore Substation

(33 kV / 155 kV - AC)

Export Cable to TenneT

~ 4 km ( 155 kV/AC)

HVDC Station (AC HVDC)

90 km sea cable / 45 km land cable (HVDC)

Inter Array Cable (IAC) Layout

600

m

914 m

Nordsee Ost Offshore-Substation

TenneT Converter Station

Metmast NSO

N

630 mm²

630 mm²

240 mm²

240 mm²

Open loop

240 mm²

240 mm²

630 mm²

240 mm²

240 mm²

630 mm²

630 mm² 630 mm²

630 mm²

Open loop

240 mm²

240 mm²

240 mm²

240 mm²

240 mm²

240 mm²

630 mm²

630 mm²

240 mm²

240 mm²

240 mm²

Open loop

240 mm² 240mm²

240 mm²

630 mm²

630 mm² 630 mm²

630 mm²

240 mm²

240 mm²

240 mm² Open loop

240 mm²

630 mm² 630 mm²

240 mm²

240 mm²



Inter Array Cable (IAC) Installation

Installation Concept: Post-Lay-Burial

Cable laying and pull-in

Cable trenching

Installation Sequence:

Cable laying and pull-in

Temporary cable hang-off

Cable trenching via jetting

Permanent cable hang-off

Cable testing

Installation Durations:

18 h for cable laying and pull-in of one cable section

24 h for cable trenching of one cable section



Inter Array Cable (IAC) Impression

Stemat Spirit – cable installation off back

Cable hang-offs and storage of cable

Cable protection system and cable chute

Hang-off Team Temporary hang-off of cable



Lessons Learned IAC – Installation

Lesson:

1. Contract strategy

2. Weather down time

3. Installation cables and trench separately

4. Inter array cables

5. Use contractors learning curve

Learned: 1. Strategy for contract structure

early in project timeline 2. Weather down time

negotiated into contract 3. Flexibility of two campaigns

beneficial 4. Choice of cable not just cost

based, consider all factors 5. Vessel / crew came directly

from similar North Sea job



Offshore Substation (OSS) Topside

Transforms from 33kV to 155kV AC

35m x 22m x 15 (L x W X H)

Operational weight: appr. 2000 tons

Unmanned

2x boat landing access

Helicopter winching plattform



Lessons Learned OSS

Lesson:

1. Many interfaces require time to properly implement and ensure workability

2. Do not underestimate the requirements due to marine environment

Learned:

1. Allow sufficient time buffer before delivery + turnkey solution from a highly experienced supplier;

2. Select supplier familiar with marine challanges who can provide sustainable and cost effective solutions



Logistics (LGS) Harbours

Bremerhaven Containerterminal I

Base Harbour NSO Installation

Cuxhaven Alternative Harbour UXO, CTVs, OSVs

Heligoland Service Harbour

Nordsee Ost



Since April 2014 up to 14 vessels in daily use 39 vessels planned from April 2014 until end of project 4‘186 vessel days planned from April 2014 until end of

project 2 main installation vessels:

„Victoria Matthias“ and „Friedrich Ernestine“

Logistics (LGS) Vessels



Logistics (LGS) Vessels

Big Vessel

Service Heavy Lift

Small Vessel

Das Bild kann zurzeit nicht angezeigt werden.

Das Bild kann zurzeit nicht angezeigt werden.



Sikorsky S-76 in operation

7 PAX per flight

1 crew change – 5 flights over 2 days

Flight time 30 min per flight

Flights from Nordholz (Sea-Airport Cuxhaven) or

Sande/Marieensiel (homebase Wiking)

Logistics (LGS) Crew Transfer – Personnel Transport



Lessons Learned LGS

Lesson: 1. Storage costs of components

2. Port access restrictions

3. Tool breakdowns

4. Vessel „child disease“

5. Same vessel for FOD and

WTG installation, delay risk!

Learned: 1. Alternative loading solutions

more flexibility 2. Nautical experts to evaluate

harbour and and conditions 3. No new build tools, contract

experienced companies 4. No new build vessels, no new

crew 5. Vessels reserved with

financial close, contracts include delivery milestones



Operation & Maintenance (O&M) Operation Base on Heligoland – Base Port

Operation and maintenance regardless of wind and weather conditions

Servicestation with Storage Hall (ca. 622 m²), Workshop, Control room, offices and Social Space for approximately 40 persons (over 2.5 floors, total floor space 1200m²)

External Storage Space

Helipad facility

Mooring places for 2 to 3 crew transfer vessels (30 x 8 m)

18 Apartments for Service personnel:

25 m² with bed, seating area with TV, kitchen, bathroom, as well as a central lounge with kitchen and barbecue for common use



Operation & Maintenance (O&M) Operation Base on Heligoland – Base Port

Berths Helipad facility

Berths

Storage area

Service Station

Helipad Facility

Apartments



Outlook Current timeline after grid connection delay incl. necessary adjustements to reduce cost impact of delay

Current information for “grid connection ready”

WTG

Foundation

Offshore Substation Inter Array Cable

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec2014

Park fully operational 1st half 2015



Lessons Learned Overall Project

1. Employ senior, well experienced staff, at least one per work package

2. Educate young engineers / team members in project culture / understanding of projects and project management

3. Encourage prompt decision making 4. Avoid over-engineering 5. Use synergies with neighbouring parks(i.e. share of guard

vessels, emergency helicopter, environmental monitoring. etc.) 6. Always have a plan B in place, ready to be deployed 7. and …



3.937 step overs during foundation installation campaign



The Project – Facts and Figures Press Activities “Vom Winde gedreht”

A camera team is following the construction of the biggest German offshore wind farm to provide insights in the daily work and the people behind the scenes See more at:

www.rwenordseeost.com

http://www.google.de/imgres?imgurl=http://www.cmstatic1.com/105886/c/hollywood-movie-camera-and-film-home-movie-theater--UDU2Ny0xMDU4ODYuMzg0MDY5.jpg&imgrefurl=http://www.custommade.com/hollywood-movie-camera-and-film-home-movie-theater/by/sayitallonthewall/&h=375&w=500&tbnid=KlBh8ZD11ToPbM:&zoom=1&docid=7bR6K76o44jLvM&ei=-TFrU9fOH8rTPLyAgYAP&tbm=isch&iact=rc&uact=3&dur=407&page=12&start=360&ndsp=35&ved=0CIsCEK0DMFc4rAI

RWE Innogy 6/16/2014 PAGE 46



Last, but not least …

Thank you for YOUR

attention !

Questions ?

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