Offshore Windpark DanTysk. Cost-Effective Foundations Design to Installation

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1 Offshore Windpark DanTysk Cost-Effective Foundations Design to Installation. Kieler Branchenfokus: Kieler Winindustrie Windindustrie

2 Vattenfall s Offshore Pipeline Onshore capacity: 720 MW TOTAL Offshore capacity: 1122 MW Production: 5,213 GWh Vattenfall shared United Kingdom Onshore: 71,8 MW Offshore: 540 MW Estimated annual production: 1,847 GWh Sweden Onshore: 113 MW Offshore: 127 MW Estimated annual production: 634 GWh Denmark Onshore: 249 MW Offshore: 96 MW Estimated annual production: 903 GWh The Netherlands Onshore: 274 MW Offshore: 54 MW Estimated annual production: 449 GWh Germany Onshore: 12 MW Offshore: 304 MW Estimated annual production: 1380 GWh. 2 Kieler Branchenfokus Windindustrie

3 Vattenfalls Offshore Pipeline in Germany More than MW installation potential for offshore wind farms in the German North Sea Different development stages Next project to come: Sandbank (288 MW) 3. Kieler Branchenfokus Windindustrie

4 DanTysk Foundations: From design to installation Table of contents 1. Project overview 2. Foundation design 3. Foundation installation 4. Grouting 5. Noise mitigation 4. Kieler Branchenfokus Windindustrie

5 1) DanTysk Project overview Project Set-up and current status: Joint venture with Stadtwerke München (49%) und Vattenfall (51%) Vattenfall has the lead in construction and operation Project permit granted sites located ~70 km west of Sylt 90 km (~ 50 nm) to Esbjerg Water depth m area 71 km² grid access granted (sylwin 1) Construction start Kieler Branchenfokus Windindustrie

6 1) DanTysk Project overview: Wind Turbine Generator What: 80 x SIEMENS 3,6 SWT 120 -> 288 MW Energy yield more than 1,3 TWh/a Siemens Wind Power 6. Kieler Branchenfokus Windindustrie

7 1) DanTysk Project Overview: Instal. Vessel for WTG What: Pacific Osprey Purpose build Jack-up vessel SWIRE Blue Ocean 6 legs, load capacity of 12 complete sets of WTG SWIRE Blue Ocean 7. Kieler Branchenfokus Windindustrie

8 1) DanTysk Project Overview: Offshore Substation What: Offshore sub-station with jacketstructure 33/155 kv Strukton/Hollandia to design, manufacture and install Installation done with Seaway Heavy Lifting Oleg Strashnov August Kieler Branchenfokus Windindustrie

9 1) DanTysk Project Overview: Inter Array Cable What: 120 km cable incl laying, pull-in and burial Van Oord Dredging and Marine Contractors + Visser & Smit Marine Contracting Van Oord 3 cable dimensions, ring connection 9. Kieler Branchenfokus Windindustrie

10 1) DanTysk Offshore Accommodation Platform (OAP) What: Accommodation for 50 service technicians (DanTysk & Sandbank) Nobiskrug to design, manufacture and install Bridge connection to OSS. Kieler Branchenfokus Windindustrie None (C1) - Olaf Beeg Package Manager Civil Works DanTysk

11 1) DanTysk Project Overview: Foundations What: 80 monopiles and transition pieces installed Aarsleff/Bilfinger Berger joint venture(abjv) Installation by Seafox 5 Finalized ABJV 11. Kieler Branchenfokus Windindustrie

12 2) DanTysk Foundations: Design 2.1) Design Basis / environmental conditions Simple principle: Design drivers are always cost drivers LEC reduction by smart engineering! Main design drivers at DanTysk: Design Basis / environmental conditions: Soil, waves, wind, turbine loads etc. - Re-arrangement of park layout => Shift locations based on geophysics, electrical/cable needs, wind yield - New scour protection concept => Less rock dumping + more monitoring Load iteration turbine foundation Grouted connection Secondary steel / Equipment ABJV 12. Kieler Branchenfokus Windindustrie

13 2) DanTysk Foundations: Design 2.2) Load iteration turbine foundation M 3 clusters; dependent on water depth and reference waves 1 conservative virtual location per cluster (worst soil combined with deepest water) N 2 load iterations with Siemens => after load results: check of loads at upper bound (stiffest soil combined with lowest water depth) One interface load per cluster => detailed calculation of all locations in cluster S M Reference location cluster S 13. Kieler Branchenfokus Windindustrie M COWI/IMS

14 2) DanTysk Foundations: Design 2.3) Grouted connection Basic principle: Cylindrical Shear keys (weld beats) horizontal and vertical ZiE process based on German principles Grout volume ~ 21 m³ Grouting temperature > 5 Conservative design! => minimize risks! COWI/IMS 14. Kieler Branchenfokus Windindustrie

15 3) DanTysk Foundations Installation 3.1 ) Installation Timeline - general facts Step Planned time Real time (average) Positioning / Jack up 3 h 3,0 h Upending /placing pile 3 h 6,1 h Positioning hammer 1 h 0,8 h Drive pile 3 h 1,9 h Remove hammer 1 h 0,5 h Lifting TP + adjusting 2 h 1,6 h Grouting 5 h 5,0 h Seafastening crane 1,5 h 1,7 h 15. Kieler Branchenfokus Windindustrie

16 3) DanTysk Foundations Installation Piling timeline - all locations 02:38:24 27,00 02:24:00 29,00 2,0 h 30m 02:09:36 01:55:12 31,00 01:40:48 33,00 Netto Rammzeit [hh:mm:ss] 1,5 h 01:26:24 01:12:00 35,00 37,00 Eindringtiefe [m] Netto Rammzeit Eindringtiefe 00:57:36 39,00 00:43:12 00:28:48 41,00 00:14:24 43, Fortlaufende Monopile ID => starting MP 15 reduced piling energy 1000 kj max + 9,5 minutes average piling time 16. Kieler Branchenfokus Windindustrie

17 3) DanTysk Foundations Installation Critical steps 3.2) Basics to ease life offshore Clear definition of operational limits! Which limits are agreed? Where and how to be measured? Weather forecast Who takes which risk? Additional MWS requirements But: No compromise on HSE! 17. Kieler Branchenfokus Windindustrie

18 4) DanTysk Foundations Installation Grouting 4.1 Basics ZiE process in Germany Detailed requirements for design/calculation, material, fabrication, surveillance, testing, installation etc. Improve engineering in all phases! 18. Kieler Branchenfokus Windindustrie

19 4) DanTysk Foundations Installation Grouting 4.2 Temperature Temperature requirement: 5 C Water and air temperature < 5 C until End of April 2013 Improve engineering in all phases! Material, installation processes and additional measures! 19. Kieler Branchenfokus Windindustrie

20 4) DanTysk Foundations Installation Grouting 4.3 Grout hardening / Early age deformation Wave limits during hardening critical Initial wave limit: 1,6 m Hs => DTOW has taken action by own 3rd party calculations => 3 m Hs limit for the grout itself Remainig limiting factor: levelling tools Improve by smart engineering: Stability calculations and devices to stabilize TP temporary. 20. Kieler Branchenfokus Windindustrie

21 5) DanTysk Foundations Installation Noise mitigation 21. Kieler Branchenfokus Windindustrie

22 5) DanTysk Foundations Installation Noise mitigation BBC DBBC DBBC + linear BC DBBC + BBC TBBC + linear BC DBBC - DFI + linear BC 22. Kieler Branchenfokus Windindustrie

23 5) DanTysk Foundations Installation Noise mitigation High effort during the MP installation phase led to increased noise mitigation 23. Kieler Branchenfokus Windindustrie

24 5) DanTysk Foundations Installation Noise mitigation BBC, DBBC, TBBC, DBBC + BBC Double-end feed-in (+ extra vessel) Closing holes Nozzle tests Re-drilling holes Airflow-meters Compressor tests Reduced piling energy Manometer tests Hydrosound + C-POD measurements Reference measurements Extra hydrosound measurements 24. Kieler Branchenfokus Windindustrie Total costs 20 mio EUR

25 Thanks for your attention!. Kieler Branchenfokus Windindustrie

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