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Development, Design and Construction of Offshore Windfarms
Graham Mason 15 September 2009
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Agenda
Fluor
Offshore Wind
Offshore Windfarm Project Development
Design Decisions
Construction
Cable Burial
Key Interfaces
Risks
Lessons Learned
Contract Structure
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Fluor Overview
One of the world’s leading publicly traded engineering, procurement, construction, maintenance, and project management companies
#148 in the FORTUNE 500
Over 1,000 projects annually, serving more than 600 clients in 85 different countries
More than 41,000 employees worldwide, over 1,000 employees in the UK
Offices in more than 25 countries on 6continents
Nearly 100 years of experience, 50 years in the UK
Fluor Corporate HeadquartersDallas, Texas
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2007 Fluor Financial Performance
Fluor Corporation50 Years on NYSE
Revenue: $16.7 billion
New awards: $22.6 billion
Backlog: $30.2 billion
Fluor’s debt is rated at one of the higher investment grade levels:
– Long-term Secured:- Standard and Poors “A-”- Moody’s “A3”- Fitch “A-”
– Short-term (including CP):- Standard and Poors “A-2”- Moody’s “P-2”- Fitch “F2”
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Offshore Wind
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Market Overview
19 offshore wind energy projects operational representing over 1.1 GW
Douglass Westwood offshore wind energy forecast:– 4.5 GW of new installed capacity in next 5 years– $16 billion of total capital expenditure– $5.2 billion of annual capital expenditure by 2012
EWEA offshore wind energy forecast:– 3 to 4 GW of offshore wind energy installed by 2010– 10 to 15 GW of offshore wind energy installed by 2015– 20 to 40 GW of offshore wind energy capacity operating in EU by 2020
Onshore wind nearing saturation in many European countries
Europe looking to offshore wind energy to meet future renewable energy growth targets of 20% by 2020
Large growth in USA onshore wind energy but offshore wind still in early stages of market development
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European MarketCapital Spend Forecast 2008 - 2012
Douglass Westwood; The World Offshore Wind Report
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European MarketFactors Impacting Forecast
German Alpha Ventus test site is fully commissioned in 2009 and delivers results for 5 MW wind turbine by 2011UK Round 2 projects of 500 MW or greater continue to progress and move into construction from 2009UK Round 3 launched in 2009 with sites allocated from 2010 onwardGermany resolves grid connection and power pricing issuesSweden promotes several large-scale project due to more favorable regulatory frameworkShort term supply chain bottlenecks (turbines, vessels, skilled staff) are addressed through capacity, standardization and trainingFrance, Belgium and Netherlands see projects developed and completedSpain begins its offshore development in 2012 - 2015
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UK Market
Round 1– The Crown Estate awarded a
total of 18 sites in 1999• Each site limited to 30 turbines
and approx. 100 MW– To date 14 sites have received
consent– 8 Round 1 sites operational
Round 2– The Crown Estate awarded a
total of 15 sites in 2003• Sites vary in size from 64MW to
1200MW– To date 9 sites have received
consent– 3 sites in construction
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Round 3
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Round 3 - Overview
Round 3– The Crown Estate’s procurement process for the development
of nine zones around UK coast
– The Crown Estate is targeting 25GW of capacity at an estimated TIC of GBP£80 billion by 2020
– Developer to be awarded exclusive development rights
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Round 3
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Project Development
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Project Developer
Greater Gabbard Offshore Winds Limited– A special purpose company that was owned equally by
Fluor International Limited and Airtricity Holdings Limited– Fluor sold its equity stake to Airtricity at financial close
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Project Description
Project Description– 500 MW Offshore Wind
Farm Project– Electricity output:
1.8TWh/yr– 140 x 3.6MW Siemens
wind turbines
Project Site– Outer Thames
Estuary, U.K.– 25km offshore– Site area = 147km2
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Site Layout
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Greater Gabbard Offshore Windfarm–Project Development Timeline
Oct ‘03Bids
submitted for UK
Round 2
Dec ‘03Fluor / Airtricity JV
awarded 500MW Greater Gabbard
Offshore Wind Farm Project
2004Offshore
Site Surveys
Dec ‘04Grid
Connection Offer
received
Sep 2005Met Mastinstalled
Oct ‘05Consents
application submitted
Summer 2006
Offshore geotechnical
surveys
Feb 2007•Consents received• Siemens selected
for turbines
October 2007
FEED completedEstimate prepared
May 2008
Financial Close
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The Planning Process
Consents Strategy– Section 36 for the whole project– Section 36 for the offshore elements and Section 90 TCPA for
the onshore elements
Straddling the territorial water boundary
How to create flexibility ?
Key considerations– Size– Spacing
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The Planning Process – Selected Route
TCPASection 36FEPACPA
1. Monopile Foundation2. Turbine Blade3. Nacelle
4. Interarray cables5. Offshore substation platform6. Onshore substation
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Key Elements for Success in the Planning Process
Consult
Consult some more
Listen
Bite your tongue
Listen
Consult some more
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Key Elements for Success in the Planning Process
Strategy
EIA scoping
Understand the critical path
Select the right consultants
Collaboration
Consultation
Flexibility
Sweat the small stuff
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Key Design Decisions and Issues
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Foundation Design
Design inputs– Water depth– Metocean (wind / wave regime) data– Geotechnical data– Turbine loads– Manufacturing / fabrication considerations– Installation considerations
Current Foundation types– Monopile– Gravity base– Jacket – Tripod
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Future?
Floating
Multiple turbines on a single foundation
Horizontal axis
Combined with tidal / current turbines
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Foundation Design
Monopile considerations– All the same or individually designed– Tapered– Pile top size– Pile top, above or below surface level– J-tubes, internal or external– Cathodic protection– Design / fatigue life– Pile hammer size and capacity– Pile handling
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Monopiles
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Greater Gabbard – Foundations
Monopile– Individually designed– Internal J-tubes
Transition Pieces– All the same
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Greater Gabbard– Monopile Load-out
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Greater Gabbard– Final Coating of TPs
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Electrical System Design – General
Minimising / optimising the unit cost / MWhElectrical system design studies
– Load flow– Short circuit– Network harmonic / power quality– Voltage fluctuation– Power system losses / network losses– Earthing studies– Protection co-ordination– Cathodic protection
Technology– Turbine– AC versus DC
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Electrical System Design – Layout and Topography
Windfarm layout and interarray cable topography– Maximising energy yield – balance between
• Larger spacing and therefore reduced wake losses• Larger spacing and therefore increased cable losses and cable costs
Interarray cable– Voltage and conductor size– Number of turbines on a string– Tapered systems– Looped systems– Redundancy
Offshore substation platforms– Number of platforms– Number of transformers– Size of transformers– HV switchgear configuration– Redundancy
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Greater Gabbard– Cable layout
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Electrical System Design(Continued)
Export cable– Single or multiple cables– Redundancy– Pinch points – Horizontal Directional Drill (HDD) / J-tube– Distance and terrain– Shore crossing
• HDD or open cut
Reactive power compensation– Onshore / offshore
Grid Connection
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Control and Communication System Design
Control System– Integrated or stand alone– Redundancy
Communication System– IP, VHF, Cellphone– Redundancy
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O&M Design Issues
HSE standardsOnshore vs offshore based
– Workboats– “Hotel” vessel– “Hotel” platform
Port base locationAccess method
– Boat– Helicopter
Sparing philosophyLifting plans for major components
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Key Construction Decisions and Issues
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Construction – The Basics
To date offshore wind farms are adopting (“Lego-type”) onshore construction methods
The actual offshore construction works must be kept to a minimumand as simple as possible
Extensive and early installation engineering and planning is vital
Maximise the assembly and commissioning of turbines onshore
Experience and capability of the marine subcontractors is critical– A partnering approach should be considered
Maximising the utilisation of the major construction plant is critical to driving down the cost
The ‘marine and project logistics’ is complex and a robust process must be developed
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Construction Considerations
Foundations– Type (monopile, gravity, jacket)– Soil conditions & water depths
Towers & Turbines– Pre-assembly of nacelle/blades– Pre-cabling of towers
Cables – Export & Inter-array– Easy for jack-ups to damage– Connections to foundations and offshore
transformer platform– Export cable landfall and connection to
onshore substation
Offshore Transformer Platform– Modular or custom– Size & weight
Nacelle Installation
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Construction Challenges
Installation vessels– Tight supply in Europe
Staging and O&M Ports– Substantial up-front planning required
Supply Chain Constraints– Lead times for major equipment & material
continue to increase– Commodity costs
Logistical Planning– Stock piling at staging port– Work around weather windows
Weather Impacts– Wind, wave, current limitations– Access to foundation and nacelle– Safety Transition Piece Installation
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Logistical Challenges
Logistics & Sequencing– Equipment and material deliveries– Number and types of vessels– Batch installations
Staging ports– Proximity to offshore site– Space needs - stock piles, pre-commissioning– Vessel traffic & loading areas (quay space)
Coordination with Suppliers– Design, manufacturing, delivery, installation– WTG Installation and commissioning support
Grid Connection– Electrical infrastructure completion– WTG commissioning
Disruption Contingencies– Adverse weather– Late deliveries– Vessel failures
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Installation Vessel AlternativesInstallation Vessel Alternatives
Flat bottom barges, shear leg cranes and land based cranes
Dynamically positioned vessels
Semi-submersible installation
Jack-up installation
Hybrid vessels
There are a number of different types of vessels that can be used to construct offshore wind farms
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Seaway Heavy Lifting (HLV Stanislav Yudin)
Greater GabbardMonopile size and weight (up to 700 metric tonnes and 6.5m in diameter) is much larger than previous installations
Needed to look outside the normal vessels associated with the Offshore Wind Industry to date and consider heavy lift vessels
Monopile / Transition PieceInstallation & Vessels
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Wind Turbine & TowerInstallation & Vessels
Sea Jack
Greater Gabbard140 WTG & Tower installations
Typical installation cycle time is 4 days for two WTGs & Towers (including load out and transit time to and from the staging port)
Leviathan
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Offshore Transformer PlatformInstallation & Vessels
Greater Gabbard has a “mother” OTP, which uses a jacket foundation due to large size and weight of OTP and relatively deep water
Monopiles can be used for smaller OTPs depending on weight and water depth
OTP design (modular vs. custom) will also impact foundation design and installation vessel selection
Typical Jacket Foundation
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Cable – Greater Gabbard
The 50km 132 kV export cables are approximately 4,500 tonnes each
Typical installation cycle time is 42 days for one 50 km cable (including collection from cable supplier)
The 33kV inter array cables are smaller in dimension than the export cable and allow the use of smaller installation vessels
Typical installation cycle time is 5 days for four cables (including load out and transit time to and from the staging port)
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Cable Burial and Entry
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Cable Issues
Identification of hazards to cables
Site investigation to identify seabed properties (geophysical survey, vibrocore sampling, cone penetrometer tests, boreholes)
Development of burial protection indices
Scour protection
Cable route selection
Cable transport
Vessel and equipment selection
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Underground Exposed Span
Cable Entry
Monopile
Seabed
Cable
Inside
~ 27 m ~ 3 m
Scour
Exposed Cable and Cable Entry
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Functional Requirements
Cable protection against– Environment – waves, current, storm– Dropped Objects – anchors, construction, maintenance– Scour – undermining stability– Fishing – trawling, dredging
Monopile protection against– Water ingress into MP – internal corrosion– Scour – pipe instability
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Underground Exposed Span Cable Entry
Scour
Monopile
Seabed
Cable
Inside
Rock Dump or Mattresses
Bend restrictorand Seal
J Tube~ 27 m ~ 3 m
Typical Solution – Monopile J Tube
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Key Interfaces
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WTG / Foundation Interface
The design of the foundation is an iterative process with the WTG supplier. Key issues include:
– Establishment of load cases– Identification of control cases (eg shallowest, deepest, weakest
soils)
The physical interface– WTG tower / transition piece flange design– Electrical interface– Control systems interface
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Electrical System Design
Critical electrical system design interface is between the WTG and Balance of Plant
– Completion of electrical system studies
Client’s operational and safety requirements
Grid code compliance– Modelling and testing
Electrical system studies
WTG and overall windfarm commissioning and system testing requirements
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Control Systems
Interface between WTG SCADA, BOP SCADA, Grid system operator and Owner’s systems
Energy management systems and forecasting
Regulatory requirements and standards
International and local standard requirements
Standard control systems protocols
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Other Interfaces
Communication links– VHF / radio / cell phone and or land connections
Physical connection interface between windfarm’s onshore substation and the grid
– Quality– Safety– Operations– Commercial arrangements
Submarine / land cable interface
Cable interfaces with WTG and offshore substation platform
Offshore substation platform / foundation interface
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Risks
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Risk Management – Pre-construction Risks
Securing landowner permissionsGrid availability
– Onshore reinforcement
Component lead times– Wind turbines– HV electrical equipment (cables, transformers)
Availability of suitable offshore construction vesselsReservation payments
– Wind turbines– Vessels– HV electrical equipment
Material prices– Steel– Copper
Project finance– Availability of debt / equity– Availability of insurance
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Risk Management – Construction Risks
Weather
Marine logistics / supply chain management
Ground conditions
Availability of key resources– Personnel– Marine equipment
Cable burial
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Risk Management – O&M Risks
Weather
Accessibility
Availability of key resources– Personnel– Marine equipment
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Risk Management– Interface Risk
WTG / Tower / Transition Piece / Monopile Foundation interfaces
Offshore Substation Platform / Foundation interfaces
Electrical System Design through Commissioning interfaces
Control Systems Design, Compliance and Owner/Operator interfaces
HV / MV Submarine and Onshore Cable interfaces
Communication interfaces
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Lessons Learned from UK Offshore Windfarms
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Lessons Learned – Surveys
Geotechnical surveys– Insufficient data gathered– Not in the right place
Geophysical surveys– UXO– Marine archaeology
Metocean surveys– Insufficient data gathered– Wave regime
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Lessons Learned – Engineering
Critical to have experienced design and installation engineering capability
A robust engineering plan is required
Construction and installation engineering should be completed in parallel with design engineering
Interface management
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Lessons Learned – Cables
Cables have been the major issue for offshore windfarms
Typical difficulties:– Access difficulties due to unexpectedly severe weather climate– Harder or softer ground being encountered impeding burial
machinery– Unexpected topography, eg slopes, holes– Poor definition of environmental risks leading to tight permitting
windows– Poor appreciation of the wave/tidal environment leading to tight
operational windows– Poor understanding of marine environment leading to
excessive weather delays
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Lessons Learned – Cables
Root causes:– Unrealistic permit conditions being passed onto contractors to
implement– Lack of consultation with cable manufacturers / marine
contractors regarding the practicalities of installation– Poor understanding of weather and marine environment– Lack of quality in cable route survey definition and data
interpretation for the cable route– Developers have accepted consent conditions that are
unrealistic or not practical– Poor understanding of impacts on construction
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Lessons Learned – Marine Access / Construction
Poor understanding of site metocean characteristics
Poor understanding of operational limitations of all construction / support vessels
Late identification of onshore port requirements– Sufficient space / load bearing capability– Onshore equipment– Loading/unloading capability– Vessel restrictions
Levels of redundancy in equipment, eg hammers, drilling
Management of supply chain / logistics
Late involvement of marine contractors
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Lessons Learned – Risk Allocation
Weather risk
Geotechnical risk
Interface risk
Consent risk– Noise– Archaeology– UXO– Marine mammals
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Lessons Learned – Commissioning
Too much commissioning offshore
Poor understanding of access constraints– Little focus on type of vessel to be used
Personnel transfer methods
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Contract Structures
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Offshore Windfarm Contract Structures
Multi-contract– Pros
• Potentially lower cost• Contingency held by owner
– Cons• Higher risk for owner• Multiple critical interfaces to manage (small critical subcontracts can
have significant impacts) • Requires large owner management team
Full EPC wrap contract– Pros
• Single point of contact – lower risk to client• Small owner management team
– Cons• Potentially higher cost
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Greater Gabbard – Contract Structure
Greater Gabbard Offshore Winds Limited (GGOWL) has entered into 3 main contracts:
– Siemens Wind A/S• Supply of 140 x 3.6MW offshore
wind turbines• 5 year service and warranty
agreement– Fluor Limited
• EPC LSTK for Balance of Plant including installation of turbines
– National Grid Electricity Transmission plc• Connection to the National Grid
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Fluor Scope of Work
Fluor Scope of Work– Installation of 140 offshore wind turbines (supply by Client)– Supply and installation of 140 foundations and transition pieces
(approx 120,000 tonnes steel)– Supply and installation of high-voltage (132kV) subsea export cable
(approx 180 km)– Supply and installation of medium-voltage (33kV) inter-array cable
(approx 173 km)– Supply and installation of onshore substation– Supply and installation of 2 offshore transformer platforms (approx
2,500 tonnes each)– Supply and installation of 1 met mast– Supply and installation of SCADA control system
Fluor Scope of Services– EPC LSTK
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Early Supplier Collaboration
Lead times for key equipment are long– Turbines: 2 years– High Voltage transformers: 18 months– High Voltage cable: 18 months– Installation vessels: 18 months or more
Early supplier collaboration is necessary and drives benefits– Unique expertise and product knowledge – Drives efficiencies in design– Increases innovation– Reduces engineering effort and rework – Improves quality– Optimises life cycle costs
Commitments are required
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PEpC Process and Strategy
EPCbecomesPEpC
CONSTRUCTION
PROCUREMENT
ENGINEERING
T I M EThe ability to influence the cost of a project is greatest at the beginning of a project;
bringing strategic suppliers in early is essential to success.
CO
ST IN
FLU
ENC
E
Construction Industry Institute (CII) indicates:
4-8% cost savings
10-15% savings in time
FLUORStrategic
Suppliers
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Questions
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Contacts
Graham MasonDirector, Project DevelopmentInfrastructure
Fluor Limited Fluor Centre, Watchmoor ParkRiverside Way, Camberley Surrey, United Kingdom GU15 3YL
+44 (0)1276 402335 tel+44 (0)1276 402009 fax+44 (0)7887 790462 [email protected]
www.fluor.com
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Thank You!
This document contains Fluor Enterprises, Inc.’s proprietary,business confidential and / or privileged material.
Information contained within this document is intended solely for the purposes set forth by Fluor and is not meant for company use or distribution. Recipient is not to use,
disclose, disseminate, distribute or reproduce the information contained in this document, except as set forth herein and expressly used for the evaluation or
qualification of Fluor service offerings solely by recipient.
Copyright© 2009 Fluor Corporation.ALL RIGHTS RESERVED