Wind Power Systems - Project Rödsand 2

Transcription

1 Wind Power Systems - Project Rödsand 2 Nysted & Rödsand 2 Jörgen Svensson Industrial Electrical Engineering and Automation

2 Outline - Rödsand 2 Background The task Project phases Design inputs Project management Construction phase

3 Background

4 Offshore Wind Power development in Denmark > 4000 MW > 40 % wind power Goal: 50 % in 2020 Tendering system Every two years Lowest offer wins Fixed price for years Managed by DEA ( Danish Energy Agency (DEA)

5 Rødsand 2 - History Nysted Offshore Wind Farm 165 MW in operation since wind turbines, 2.3 MW each 570 GWh/year DONG 80%, EON 20% Winner bid DKR/kWh ( EUR/kWh, 63 EUR/MWh ) Important learnings from Nysted - wind conditions - environmental program and reports - operation & maintenance - suppliers - project management - bidding process and strategy

6 Rødsand 2 - History First auction won in April 2006, consortium E2 / Dong / E.ON. The consortium performed site investigations and prepared an environmental impact analysis fall 2006 to spring In May 2007 Dong Energy (E2 + Dong) decided to withdraw due to cost increases, E.ON decided to continue, got approval from Danish authorities. E.ON performed extensive geotechnical investigations and contract negotiations during the fall Permits ready October Global market prices on raw materials even higher. In December 2007 E.ON decided to withdraw due to capital constraints. The Danish Energy Agency announced a rapid re-auction of the project in February 2008, E.ON was announced as winner 25 th of April DKK/MWh Örsted former DONG - > More than 2 years process

7 The task according to agreement with DEA

8 Agreement with Danish Energy Agency Contract signed 6th of May 2008 Permit for development and establishment Delivery of 435 MDKK performance guarantee Fixed price, 629 DKK/MWh (first 10 TWh) Max 215 MW, Max 35 km2, Max 150 m Requirements on Environmental program Requirements on Technical solutions In operation latest mid 2011 Permit to operate for 25 years

9 Project phases

10 Wind Power Project Phases SCREENING COMMENCES/ APPLICATIONS ARE SUBSEQUENTLY MADE ALL APPROVALS IN PLACE/ STRUCTURING OF PROJECT COMMENCES INVESTMENT DECISION MADE/ CONSTRUCTION OF WIND FARM COMMENCES CONSTRUCTION OF WIND FARM COMPLETED/ OPERATION COMMENCES Onshore: months Offshore: months Onshore: 3-6 months Offshore: 6-12 months Onshore: 3-12 months Offshore: months Phase 1 Pre Development Phase 2 Development Phase 3 Construction Phase 4 Operation Site identification and securing Initial feasibility study Land-lease rights secured Initial surveys made (grid connection, wind assessment, economics) Legal procedures and lobbying Environmental impact studies Communication with local authorities Applications to local authorities Technical planning and Sign all contracts engineering Supervising Detailed farm engineering construction of wind Wind measurements farm Grid connection study Installation of finalised foundations Final negotiation with suppliers (LOI) Installation of substation Economic valuation and finance Installation of cables Production calculation Installation of wind Financial valuation and turbines structuring PPA, Power Purchase Agreement (acc. to bid) Commissioning Delivery to O&M Supervision and control Maintenance and repair Daily wind forecasts Power sales Optimizing facilities, consumptions and spare parts Safety Continuous work with increasing efficiency and decreasing costs Onshore: 1 ½ - 3 years; Offshore: 3-6 years Expected lifetime approx years

11 Wind Power Project Phases SCREENING COMMENCES/ APPLICATIONS ARE SUBSEQUENTLY MADE ALL APPROVALS IN PLACE/ STRUCTURING OF PROJECT COMMENCES INVESTMENT DECISION MADE/ CONSTRUCTION OF WIND FARM COMMENCES CONSTRUCTION OF WIND FARM COMPLETED/ OPERATION COMMENCES Onshore: months Offshore: months Onshore: 3-6 months Offshore: 6-12 months Onshore: 3-12 months Offshore: months Construction Phase 1 Pre Development Phase 2 Development Phase 3 Construction Phase 4 Operation Site identification and securing Initial feasibility study Land-lease rights secured Initial surveys made (grid connection, wind assessment, economics) Legal procedures and lobbying Environmental impact studies Communication with local authorities Applications to local authorities Technical planning and Sign all contracts engineering Supervising Detailed farm engineering construction of wind Wind measurements farm Grid connection study Installation of finalised foundations Final negotiation with suppliers (LOI) Installation of substation Economic valuation and finance Installation of cables Production calculation Installation of wind Financial evaluation turbines and structuring PPA, Power Purchase Agreement (acc. to bid) Commissioning Delivery to O&M Supervision and control Maintenance and repair Daily wind forecasts Power sales Optimizing facilities, consumptions and spare parts Safety Continuous work with increasing efficiency and decreasing costs Onshore: 1 ½ - 3 years; Offshore: 3-6 years Expected lifetime approx years

12 Inputs from: Pre-development phase and Development phase

13 Pre-Development phase: Results - localisation - wind assessment (Nysted) Nysted Havmöllepark From EIA approved (VVM) - specific area for construction - plan for environmental issues Environmental Impact Assessment (EIA)

14 Development phase: Results Approved building permit (all technical and environmental details in place) - micrositing Approved turbine layout (turbine/foundation layout)

15 Development phase: Results - micrositing - grid connection Approved cable layout Power Purchase Agreement (PPA) with Energinet.dk DKK/MWh (first 10 TWh)

16 Development phase: Scope & Goal Plant 90 wind turbines 207 MW 800 GWh/year, 2%, households 34 km 2 5,5-12 depht Time schedule Procurement 2008 Construction 2009/2010 Operation 2011 Mars Budget Approx. 450 MEUR I01-18 Distance 1,7 km to onshore 3,1 km to Nysted Wind Farm J01-18 K01-18 L01-18 M01-18

17 Development phase: Time Schedule Time Schedule for Offshore Installations at Rödsand 2: Test of seabed Schedule goals: Enough flexibility Not too many parallel activities (Nysted)

18 Project management

19 First important tasks for project management Established project team ( 4 -> ) Safety, Risk management, Environment Negotiate/Purchase and sign all major contracts Establish site office in Rödbyhamn, Nyborg and Malmö Building permit (all technical and environmental detail in place) Approved Certification for Site assessment and Design Basis Test trenching and digging Start foundation and cable manufacturing

20 Rödsand 2 Project Organisation Steering Committee Project Coordinator Deputy PC persons Project Admin & Documentation Scheduling & Economy Procurement & Legal Risk Manager Technical Manager PM- Foundation PM- Cable PM- WT PM- Site (Health & Safety) Environment & Permits Project Manager (PM)

21 Project Team - Critical Success Factors Project Mission Clearly defined goals & direction Management Support Organization, authority, plans & instructions Schedule Plans Details for individuals & team actions Client Consultation Active listening to those affected by the project. Personnel Resource management, people selection and training Technical Tasks Availability of technology & expertise, quality Monitoring and Feedback Providing relevant & timely information Communication Keeping people up-to-date Troubleshooting Handling unexpected crises or deviations from plan. Manage conflicts effectively - Effective cooperation - All functions important

22 Risk management (updated 7/24) Risk Matrix (example) Areas of consequence Time Delayed activity/activities that results in a delay in the project s time schedule Cost Increase in cost threatening to exceed the project s budget Work Environment Injury to a physical person who is engaged in the project Environment Damage to the eco system Property Damage to any parties property engaged in the project Third party, personal injury Injury to a physical person who is not engaged in the project Third party, property Damage to anyone's property not engaged in the project Media Bad publicity for the project Most likely % Likely % Possible % Most unlikely 0 3% Probability Acceptable Moderate Substantial Unacceptable Consequence Costs (MSEK) Delay (weeks) Unacceptable risk critical for goals. Significant risk need to be monitored. Acceptable risk no risk response 3 different types of risk responses: Preventive measures Insurance solutions Preparedness plans (alt. B,C )

23 Safety and Traning Temporary fence on foumdation Test with survival suit - 20 min in less then 8 degrees Lift instructions Safe climbing Turning a life raft

24 Construction Phase

25 Rødsand 2 - Multi-Contract Approach Multi-contract approach implemented including the following contracts: Wind Turbine Supply: Siemens Wind Power Wind Turbine Installation: A2Sea Foundations: Aarsleff-Bilfinger JV Cable Trenching: Peter Madsen Cable Supply and Inst.: NSW (General Electric) Switch gear: Port of Rödby: Port of Nyborg: Offshore vessels: Grid supplier: Areva Scandlines ADP ÖBS Energinet.dk (Danish TSO) Joint Venture (JV)

26 207 MW Rødsand 2 Offshore Wind Farm Brande Malmö Nyborg Rødby Havn Rødsand 2 Offshore Wind Farm Nordenhamn Swinoujscie

27 Rødsand 2 The construction area Ferie Line Rödby Hamn Transport area 35 km2, 4-12 m depth Extra area

28 Interface Management

29 Interface Management Energinet.dk E.ON (subsuppliers) WTG erection (A2SEA/SWP) 2. Foundation / tower (bolt-in section) 6 33 kv 132 kv 3. Connection of cables to WTG / earthing busbar connections / optical fibers connection 4. J-tube entry / cable pulling / cable trenching (3 suppliers) 5. Cable laying cable trenching 6. J-tube entry / cable pulling 7. Switch gear delivery / cable connections / SCADA connections /Park regulator 8. SCADA servers placed in grid station on-shore 7 8

30 Foundations

31 Foundation supplier: ABJV (Per Aarsleff / Billfinger Berger Joint Venture) Gravitations foundations: 8-edged in concrete with erosion protection 1900 ton (1400) 9.5 m 17 m

32 Foundations Site in Poland Supplier: Aarsleff Bilfinger JV Manufacture in Poland Swinoujscie Concrete casting on flat top barges Concrete 1300 ton Iron 100 ton (reinforcement) 6 structures per barge (3 barges) Barge 1 barge to Denmark every 2 weeks (24h)

33 Foundations Transport Poland to Denmark

34 Foundations Meantime - Sea Bed Preparation Excavating all postions for the fundations

35 Screeding frame to prepare seabed Rödbyhamn Test of new techology (at Nysted divers smoothed the seabeed with a rake) High risk for delays Forced to double set of equipment

36 Gravel Nysted Bed Photo 2003

37 Foundations Installation at Site

38 Foundations 500 tons extra heavy stones from Norway 9.5 m 3.5 m Ballast Ready Total 1900 tons Foundation + installation -> 0.4 MEuro/MW Half the cost of monopiles in U.K.

39

40 Cables

41 Rødsand 2 Cable overview Cable layout 11 sections 80 km internal cables 120 & 240 mm2 8-9 km (external) export cable to shore 1000 mm2, 73 kg/metre

42 Cable Dredging: Peter Madsen Cable Trenches Did not dig straight Major disputes investigation Errors in GPS equipment -> New digging

43 Cables - Supplier: NSW (Subsidiary of General Electric) New cable vessel 90m x 27m - Manufacture of Cables - Installation of Cables - Connection to WTG s - Cable vessel not ready at start of construction phase!!

44 Cables pulling through foundation Total internal cable cost: 32 MEUR (cables+installation)

45 Offshore Substation Interface to Energinet.dk Crane vessel Rambiz Substation: Energinet.dk (not part of E.ON's project) EON s project on sub-station: 36kV switch gear 36kV cable connections SCADA connections Park regulator (SCADA servers placed in grid station on-shore) Good cooperation Ready before schedule 900 tons 4 floors

46 Wind Turbines

47 Wind Turbines (WTs) Nacelle: 82 tons Tower: 100 tons Foundation: 1900 tons Rotor: 60 tons Supplier: Siemens Wind Power 2.3 MW generator 68.5 m hub height 93 m rotor diameter System voltage level: 33 kv The WT is one of the most referenced in offshore wind: Samsoe, Nysted, Lillgrund, Horns Rev 2 70 m? 4 met masts at Nysted Total: 2142 tons

48 Wind Turbine Assembly Site

49 Wind Turbine Assembly site: Nyborg Transport and temporary storage 7 major parts per wind turbine * 90 = 630 parts in total -> more than 700 transports with trucks

50 Wind Turbine Assembly site: Nyborg Rotor assembling

51 Wind Turbine Assembly site: Nyborg Loading

52 Offshore Wind Turbine Installation

53 Wind Turbine Offshore Installation Supplier: A2SEA The most experienced installation company in Offshore Wind Vessel picks up WT s in Nyborg 3 WT s per trip (12h) At Nysted: 72 WT s installed in 80 days Rødsand 2: 90 WT s installed in 110 days

54 Wind Turbine Offshore Installation Supplier: A2SEA Crane Installation of turbine in 4 pieces: Lower half tower section Upper half tower section Nacelle Rotor WTs+installation -> 1.4 MEuro/MW

55 Nysted Offshore Wind Farm 165 MW in operation since 2003 Rødsand 2 Offshore Wind Farm 207 MW in operation since > Nysted Movie

56 Summary Planning and preparation of WPPs are very important The infrastructure is a large part of a WPP The construction phase is much about project management and coordination More than 1500 persons were involved Close to working hours; about 2500 hours only on diving About 100 ships involved during the period Rödsand 2 was built on budget and ahead of time schedule