Deep Water Windfarms Seminar

Turbine Design Developments for Deep Water Projects

Ranjit MeneREpower UK

25th September 2013

2

Agenda

Introduction

Conclusions

REpower‘s Approach to Deep Water Projects

3

Agenda

Introduction

Conclusions

REpower‘s Approach to Deep Water Projects

4

Beatrice (UK)

2 x 5M126(10 MW)

Ormonde (UK)

30 x 5M126(150 MW)

Thornton Bank I

(Belgium)

6 x 5M126(30 MW)

Alpha Ventus

(Germany)

6 x 5M126(30 MW)

Thornton Bank II & III(Belgium)

48 x 6M126(295 MW)

Nordsee Ost

(Germany)

48 x 6M126(295 MW)

Innogy Nordsee I(Germany)

54 x 6M126(332 MW)

Project (Germany)

80 x 6M126(492 MW)

2006-2007 2008-2009 2009-2010 2011-2012 2012-2013 2014

Preferred supplier

2016-20172015

FID pending

Repower Offshore Project References

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Thornton Bank Wind Farm – Key Facts

Three Phases (54 REpower WTGs):Phase 1: 6 x 5M (2008)Phase 2: 30 x 6M (2012)Phase 3: 18 x 6M (2013)

Total Capacity: 325.2 MW

Location: 30 km from the Belgian coast line, 12 – 27 m water depth

Client: C-Power (Consortium comprising of RWE, EdF, Marguerite, DEME, SRIW, Socofe, and Nuhma)

Entirely project financed

First industrial-scale offshore project in the world using 6MW turbines

Gravity base foundations used in Phase 1; Jackets in Phases 2 & 3

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Cost reduction for Round 3 is imperative if we want the ambitious 2020 renewables targets to be acheived

Duddon Sands (UK)

2003 2005 2007 2009 2011 2013 2015 2017

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

5,5

Alpha Ventus (D)

THB 1 (B)

Belwind 1 (B)

Greater Gabbard (UK)

Thanet (UK)Rhyl Flats (UK)

THB 2+3 (B)

NSO (D)

Cost per MW installed (€m/MW)

COE ~ €170/MWh

Rödsand 2 (DK)Robin Rigg (UK)

Gunfleet Sands (UK)

Lynn (UK)

Burbo (UK)

Barrow (UK)

Kentish (UK)

Scroby Sands (UK)

North Hoyle (UK)Future Projects (D/UK)

Year2019

COE ~ €120/MWhor ~ £100/MWh

The last of the EPCI contracts

Rising commodity pricesSupply chain shortagesExchange rate movements

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However, we need to be clear which costs we are talking about

Cost Parameter Biggest Influence on Cost Reduction

Levelised Cost of Energy (GBP/MWh)

• Turbine Yield• Capital Costs (BoP, Turbine)

NPV (GBPm) or IRR (%) • Electricity Remuneration• Turbine Yield

Cost per Installed MW (GBP/MW)

• Capital Costs (BoP, Turbine)

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Agenda

Introduction

Conclusions

REpower‘s Approach to Deep Water Projects

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Turbines need to evolve to take advantage of deep water sites

Failure frequency

High

Low

highlow

high

LowEnergy yield

System price

1

2

3

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Increasing the yield of the well-proven 6M126 turbine requires a focus on the rotor as well as availability

Larger rotor

Blade length increases to 150m+Turbine rating remains the same

1

Lower risk

New turbine model based on the proven, bankable technology found in the 6M126~80% of components remain the sameInterface with suitable foundation types

Increased availability

Next-generation access technologies allow greater access throughout the yearAdvanced Condition Monitoring systems built inOptimal service concept

152

+ +

1 Copyright Houlder

1

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Making turbines more reliable needs experience

Design failure mode analysisHighly accelerated lifetime testing can spot potential weaknesses in design

2

End-of-line

testing

CMS

Operational

experience

DFMEA

analysis

Increased

reliability

Optimised service conceptLearning curve effects reduce the number of unplanned service eventsRobust quality procedures need to be in place

Sophisticated condition monitoring sensorsAllows remote intervention of all but the most serious issues

Quality checks at production facility outletEnsures turbine arrives at lay-down port ready to ‘plug and play’

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We are looking at six main levers for driving down capital costs

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Levers for lower capex Requirements

Industrialisation • Certainty of pipeline• Political support

Early project-specific optimisation

• Early engagement with developers

Reduced interface risks • Strong collaboration within the supply chain

Redesign of some components

• Strong engineering support• Good relationship with

suppliers

Localisation of production saves on logistics costs and good politically

• Development of local supply chain

Needs Developer

support

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Industrialisation and innovation are key to reducing the LEC

Comments

Industrialisation and innovation are key to reducing LEC in the offshore wind sectorStandardisation of large components such as foundations is criticalInnovative solutions need support from the entire supply chainIt all starts with market certainty...

Source: Carbon Trust - “Offshore Wind: Big Challenge, Big Opportunity” (2008)

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LEC

The balance of plant costs need to be optimised as well to lower the LEC of the whole project

BoP

TurbineO&M

I&C

Foundations

Electrical Systems

Cables

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Example: Methods for foundation cost reduction typically involve decreasing the fabrication and installation costs

Methods Mechanism

Reduce steel Optimise structures for depth, soils

Increase vessel utilisation

Increase weather windowLarger vessels Shuttling

Cheaper manufacturing

Mass production and standardisation

Reduce vessel hire Fewer repositionsMinimise operations at sea

Eliminate vessels Integrated installation

Focus

Reduction of

Fabrication

Costs

Reduction of

Installation

Costs

Early engagement with turbine manufacturers crucial

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Agenda

Introduction

Conclusions

REpower‘s Approach to Deep Water Projects

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Conclusion

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Greater deployment of state-of-the-art offshore turbines needs the following

The UK government needs to Provide certainty to developersEnsure that the UK becomes renewables friendlyPromote innovation in the offshore wind sector, e.g. the OWA, demonstration sites for new foundations and turbines

Developers need to Provide certainty to the Tier 1 suppliers: Turbine OEMs, Installation contractors, Foundation manufacturers, Electrical contractorsBe open to alternatives in project execution methods, technology, risk sharing etc

The Tier 1 suppliers need to contribute to the reduction in LEC by InnovatingStandardisingOptimisingLocalising

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