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On the move
From design to maintenance: an all-in approach Heavy lift vessel Svanen: the jewel in the crown Drilled concrete monopiles With contributions by Gran Loman and Gijs van Kuik
Preface
The offshore wind energy market is exciting and highly dynamic. Financial developments, technological possibilities and the political climate together play a significant role in the construction of wind turbine farms. Over the next few years, the northern European wind energy market will witness the completion of many new projects. Ballast Nedam, a Dutch company of international acclaim has been a civil and marine contractor for more than a century, while Ballast Nedam Offshore has been operating in the European market for well over ten years. At the time, the establishment of Ballast Nedam Offshore was the direct result of initiatives taken by Ballast Nedam to promote sustainability through practical and feasible applications and solutions. Its investments in offshore wind energy form part of a wide range of activities focusing on sustainable energy concepts for the benefit of civil engineering projects, mobility and real estate. Ballast Nedam Offshore offers its clients the convenience of a one-stop shop, culminating in the turn-key provision of a foundation. We also offer assistance with project development, including financing and permits, design, construction and ongoing maintenance. To be able to offer this comprehensive package, Ballast Nedam Offshore closely cooperates with other Ballast Nedam companies, such as Ballast Nedam Engineering, Ballast Nedam Funderingstechnieken (Foundation Technologies), Ballast Nedam Beheer (Operations and Maintenance) and Ballast Nedam Concessies (Concessions). Since 2008 we have offered our clients one clear point of contact for the construction of offshore wind farms: Ballast Nedam Offshore. We welcome clients at any point in the chain. We can help them arrange the necessary funding, we can carry out maintenance work (also with respect to wind farms built by other firms) and we rent out our heavy lift vessel (HLV) Svanen. In short: we do it all. As yet, Ballast Nedam Offshore is the one and only European contractor to combine all the activities necessary for the construction of offshore foundations. In this magazine we describe Ballast Nedam Offshores current position and expertise, and present our goals for the future. In a European energy market where offshore wind energy is expected to be a significant force by 2020, we are more than ready to apply our broad experience in this area and create new successes; for ourselves, but chiefly for our partners and clients, long-standing and new. Marcel van Bergen Director Ballast Nedam Offshore 1,000 1,500 6,000 MW 10 million tonnes per annum 1,000 km2 25 per cent of all Dutch households
2009
Offshore wind farms: Total number of wind turbines: Combined capacity: CO2 reduction: North Sea surface area: Enough power for: Offshore Windpark Egmond aan Zee, Princess Amalia Wind Farm 96, each with a capacity of 2-3 megawatts (MW) 228 MW 316,000 tonnes per annum 44 km2 225,000 households
2020
Total number of wind turbines: Combined capacity: CO2 reduction: North Sea surface area: Enough power for:
Table of Contents
Interview with Director Marcel van Bergen and Commercial Manager Edwin van de Brug 4 Gran Loman, Project Manager at Vattenfall: Kriegers Flak Foundation Study 7 Heavy lift vessel Svanen: ready to handle the next generation of monopiles 8 Innovation: the prefabricated drilled concrete monopile & one-lift concept 10 Ideas simply present themselves, usually on a lazy Sunday afternoon 12 Collaboration: complete and integrated solutions for offshore wind farms 14 Director Marcel van Bergen: Quality through cooperation in the chain 16 The road to a certified design 18 Low-maintenance offshore wind farms 22 History focus 24 Gijs van Kuik (EAWE): The Netherlands has got exactly what it takes 26
Director marcel van bergen and commercial manager edwin van de brug AT ballast nedam offshore
A dynamic market
Van Bergen and Van de Brug are highly enthusiastic about HLV Svanen, Ballast Nedam Offshore and the offshore wind energy market. Van de Brug: We entered this market at a very early stage. The first wind farm had been constructed in Sweden in the early 1990s, and as early as 1994 Ballast Nedam laid the foundations for the Lely Wind Farm, which was followed by the Offshore Windfarm Dronten. For the first time, we used monopiles as a basis for the turbines for both farms, and this has since become the standard in offshore wind. Surely no mean feat, and a fact we are very proud of! Van Bergen continues: Now, more than 10 years later, the market has matured. It has become an interesting and exciting market with a great deal of activity, where a lot is happening at the moment. The political climate, financial developments and technological possibilities all play a part in whether or not projects are carried out. We know that in the northern-European market around 4-5 projects will be realised each year over the coming period. But the question is: which ones will they be? This depends on many factors. For instance, currency exchange rate fluctuations in non-euro countries such as the UK may well threaten the feasibility of proposed projects, as this may lead to certain market vulnerabilities. On the other hand, Germany is currently catching up, which opens up new opportunities.
Anything is possible
Ballast Nedam Offshore focuses on the European market. And this is no problem whatsoever, thanks to the companys extensive experience and thanks to its specialist sister companies. Ballast Nedam Offshore offers clients a complete package, culminating in the turn-key provision of a foundation. The company can also take care of project development, including financing and permits, design, construction as well as ongoing maintenance. With its 36 turbines, the Egmond aan Zee wind farm is one example. Van Bergen: We can jump on board at any point. Sometimes our clients just want us to provide consulting services during the development stages. Given our extensive experience in the market, we can often provide the exact data they need in order to finalise a projects financing and get it off the ground. Clients may also call us in for our equipment. In short, we do it all. And since we operate across the entire chain, our clients always do business with people who can see the complete picture, even though we are only brought in for part of the entire project. A huge advantage.
Foundation evaluation
Gran Loman Project Manager at Vattenfall
Constructability
Ballast Nedam combines strengths
As part of the project development effort, Vattenfall has carried out an extensive evaluation of various types of foundations. Consultants and manufacturers participated in a design and evaluation project specifically tailored to an area like Kriegers Flak. The work was based on an actual site assessment for the region (geology, wind, waves, currents, ice). The main purpose of the study was to evaluate the different kinds of offshore foundations suitable for 3-5 MW turbines and for water depths of 20-40 metres. The study was also meant to develop possible improvements (in terms of cost, manufacturing, installation and maintenance) of existing foundation concepts as well as possible new ones.
Ballast Nedam Offshore combines all the activities required for the construction of offshore foundations, and performs the necessary calculations. Thanks to the close collaboration between our companys designers and structural engineers, we can always guarantee clients that we are genuinely able to build what we design. Thats what we call constructability, says Van Bergen. When designing, Ballast Nedam Offshore also bears in mind a parks expected service life of 20-30 years, and its maintenance needs. Sometimes this means higher initial design or construction costs, but nevertheless results in a smaller overall price tag in the long run.
Foundation concepts
The following concepts were studied: a gravity based concrete structure, a conventional steel monopile, a drilled concrete monopile, a steel jacket and a concrete tripod. The gravity based concrete structure has been used in many offshore projects, such as Vattenfalls wind farm Lillgrund in resund. The technique has been tried and tested and found to be competitive in deep waters such as Kriegers Flak. The project included the development of a floating structure that could be towed to the site, where it was submerged. The steel monopile studied is another concept that has already been used in many projects (for instance for Vattenfalls wind farm at Horns Rev). This concept, too, can be considered tried and tested. The drilled concrete monopile presented a new concept, developed by Ballast Nedam, and was found to be very compatible indeed. As a result of high investment costs, the cost per megawatt highly depends on the total number of foundations in the wind farm, but in a large farm such as Kriegers Flak the drilled concrete monopile remains a very interesting and promising concept. Since this application is relatively new, it may need some more development and evaluations before it can be regarded as proven. In the foundation study, major improvements were made to the steel jacket, for instance by reducing the nodes and thus the amount of welding needed. For this type of steel foundation, a concrete transmission piece was developed: one example of measures that can reduce the estimated costs. The concrete tripod was another new concept. Because this structure is very large (adapted for water depths of 35-40 metres), special attention was paid to manufacturing and transport.
Next moves
At present, various licences are being obtained for the Swedish section of Kriegers Flak, and information about the site assessment is being gathered. This part of the process is expected to be concluded during 2009, after which the detailed design for the procurement is scheduled. Allowing a year for procurement and several years for delivering the first foundations, turbines and grid system, installation works could start in 2012 or 2013, although Vattenfalls profitability requirements may cause some delays here.
Heavy Lift Vessel Svanen: ready to handle the next generation of monopiles
As a part of its offshore working method producing prefabricated elements on land and installing them at sea Ballast Nedam requires specific heavy lift equipment. One of Ballast Nedam Offshores great strengths is the special equipment it can deploy in support of its projects. And the jewel in their crown is the Heavy Lift Vessel Svanen.
When the Zeeland Bridge was constructed, existing floating sheerlegs were used, but for the King Fahd Causeway in Saudi Arabia the Ibis lifting ship had to be specially developed. This was done by Ballast Nedam. The vessel lifts from its centre of gravity, which significantly reduces the movement of the hoisting load. On the basis of this principle, the self-propelled heavy lift vessel Svanen was designed and built for the Storebaelt Bridge in Denmark. To meet the heavier demands for the Confederation Bridge, HLV Svanen was then enlarged and its lifting capacity further increased to an impressive 8,700 tonnes.
Monopile installation
innovation
Ballast Nedam invented, engineered and installed the very first monopile foundations for offshore wind turbines. These monopiles were installed at the Lely near-shore wind farm in 1994 and the Dronten near-shore wind farm in 1996. Both wind farms are situated in the IJsselmeer lake in the Netherlands. Although their dimensions are relatively small by todays standards (with diameters of up to 3.70 metres and a maximum weight of 89 tonnes) their design and installation principles differed little from the approach used today. The Svanens almost unlimited lifting capacity means that it can handle the installation of monopiles for generations of wind turbines to come. Ballast Nedam has developed an ideal installation method to suit the actual situation of a particular offshore wind farm, its foundation design and related base harbours.
Innovation
The prefabricated drilled concrete monopile
For Vattenfalls research project entitled Foundation Concepts Kriegers Flak Wind Farm, Ballast Nedam Offshore and MT-Piling (a 50% Ballast Nedam subsidiary) have developed a new foundation concept: the Drilled Concrete Monopile.
The drilled concrete monopile concept is highly innovative. It consists of the installation of concrete monopiles with the help of a drilling method based on the horizontal tunnel-drilling methods Ballast Nedam uses onshore.
Drilling equipment
The drilling machine, including the cutter head is designed to drill through the various soil layers. The diameter of the cutter head is extendable. This enables the machine to drill inside and under the monopile. It excavates in two directions and is able to crush boulders in front of the cutter head.
Cost
A cost estimate for a continuous fabrication and installation process for 128 foundations resulted in the following costs per MW: 3.6 MW 500,000 Euro 5.0 MW 400,000 Euro
Conclusions
The concrete monopile for offshore wind turbine foundation is technically feasible. The vertical drill method using the Svanen is technically feasible. From an economic perspective, the concept is highly competitive.
One-lift concept
Ballast Nedam has developed a sound and solid installation method based on the deployment of the reliable HLV Svanen.
The need for suitable and efficient equipment for installing increasingly large and powerful turbines demands the development of new concepts that will enable the offshore wind energy sector to contribute to European renewable energy targets. The HLV Svanens large turbine installation method enables the pre-assembly and initial commissioning of the complete turbine in sheltered conditions prior to its actual installation. Once the turbine is ready for installation, it is collected by the HLV Svanen, which then transports the turbine to the offshore installation site. At the site, the Svanen facilitates a safe and rapid operation to complete the installation cycle of the large wind turbine.
Background
The drilled concrete monopile concept was developed for a number of reasons. First, concrete monopiles are inexpensive compared to steel monopiles: concrete is less vulnerable to price fluctuations. Second, the concrete market has unlimited manufacturing capacity and a wide range of suppliers. Third, underwater noise can be prevented, reducing the environmental impact of installation. And finally, the method can be used for various soil types, even where boulders are present on the seabed.
Design
At Kriegers Flak concrete monopiles are designed for 3.6 and 5 MW WTGs in water with a depth of 30 metres. The top of the monopile is +3.5m MSL, including a concrete ice cone. Dimensions Outer diameter (mm) Wall thickness (mm) Pile length (m) Weight (tonnes) 3.6 MW 5.0 MW 6,500 6,900 500 700 61 64 1,450 2,200
Fabrication
The monopiles are made of pre-cast reinforced concrete ring elements and are fitted with a steel cutting shoe to cut through the soil, creating an overcut. This overcut is filled with self-hardening drill fluid. The monopiles are transported by floating them to the offshore site.
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For example, we have built a hydraulic mini-robot that can automatically screw on bolts underwater, which means that we dont need a diving team when there is no time to bring one in. Still, most innovations arent developed during the installation process at that time were too busy managing the work and the people doing it. It is mostly the effort you make during preparations that is decisive in the success of a project, not the effort during the work itself or afterwards.
Non-standard work
Blokland: We are a group of people who think outside the box and put our backs into our work. We do everything, and this is what makes Ballast Nedam truly unique. Were not afraid to leave the beaten track and break new ground, and we are used to being confronted with critical and sometimes even unexpected questions. As a company and as a team, you need the guts to take responsible risks. For us, its practically standard that our work is never standard.
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High commitment
Ballast Nedam Concessions is utterly committed to its projects. Alma: We want to invest in wind farms ourselves, and therefore benefit directly from good-quality, long-term results. We could decide to sell our share in a wind farm after a few years, but thats not our grounding philosophy. In principle, we remain bound to a wind farm for the duration of the entire contract period, just as with concessions for other types of projects.
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Sometimes a supplier is also a sister company this is one way in which Ballast Nedam Offshore builds on its own foundations. Van Bergen: But we cant supply everything ourselves. The production of steel monopiles, for example, is a field all of its own. Although we regularly collaborate closely with the same partners, we always remain alert and look out for new parties in the external market. We want to keep abreast of the newest developments and we always strive to find the best solution for our customers.
In order to promote variety in solutions, we also participate in various R&D programmes and input our knowledge at the base. We are also regularly involved in start-up companies that wish to enter the market. Thanks to our experience with the process of wind farm realisation from start to finish, we can play a helpful role for companies that develop new products for offshore wind turbines, says Van Bergen. In this manner, Ballast Nedam Offshore also looks at quality aspects from the outset and increases clients options.
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Various types of foundation constructions are available, depending on the location, water depth and the type of turbine. Van Os: In the preliminary stages we produce a rough design and perform an approximate check of the functionality and dimensions, keeping in mind the sea bed conditions, the type of turbine and the loads involved. Thus, we can obtain a rough idea of what the design will ultimately look like. Sometimes it turns out that the standard design is not suitable and that we need to come up with a new construction.
Concrete construction
Ballast Nedam is encountering increasing competition as far as the existing steel monopile construction is concerned. For Ballast Nedam the choice for a drilled concrete monopile is a logical one. Van der Veen: The market motivation is the price of steel concrete foundations should be cheaper. Environmental concerns also play a role here. Pile-driving at sea is viewed as problematic for underwater wildlife, but a drilled pile eliminates vibrations. Concrete piles create far less noise in comparison to driven steel piles. Van Os adds: We are experts in the vertical drilling of piles into the seabed. Furthermore, thanks to the Svanen we are currently the only contractor able to lift the concrete monopiles.
The drilled monopile creates far less noise in comparison to a steel monopile
Ballast Nedam has carried out a concept study of the concrete monopile as proposed for the wind farm to be built by Swedish energy provider Vattenfall off the coast of Sweden and Denmark. Van der Veen: Vattenfall has announced that our draft design of the drilled concrete monopile is the most realistic of all submitted designs, and also the one that best satisfies their sustainability requirements in terms of price. Van Os: Vattenfall is interested, but has not yet given us an actual commission to start building. Van der Veen continues: We also need to generate more support for this new concept. We need people to believe that we are truly equal to the task, and that the risks are manageable. We are currently working on getting our design certified, and an independent certification agency is performing the evaluation. In due course we plan to enter the market with a certified design for a drilled concrete monopile.
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Securing a strong position: the complete construction of the first Dutch wind farm
Projects involving both design and construction offer the greatest possible scope, says Van der Veen. This means that we can offer clients a complete package we take care of design, installation and management. Still, we also welcome clients for installation work only, or to rent the Svanen, for example. Starting in 2001, we completely built the Netherlands first wind farm off the coast of Egmond aan Zee, which at that time constituted a very special project. I must admit that initially we were still rather wet behind the ears back then and really had to rack our brains, but in Egmond we were able to build on our experience, which has allowed us to secure a strong position in the offshore wind energy market.
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Vincent Leenders, Project Manager at Ballast Nedam Beheer (Operations and Maintenance)
We maintain long-term relationships with our partners, says Leenders. They are important to us, because they possess valuable knowledge and experience in their specific fields of business. Together we investigate how we can make our work more effective, efficient and safe. We want our partners to feel that they are a part of the wind farm. We can achieve great things by applying the knowledge that they have, knowledge that has to be nurtured, shared and developed, so that together we can continue to create innovative solutions. Ballast Nedam Beheer (Operations and Maintenance) works exclusively with independent specialists certified for offshore activities. These are people who regularly take training courses on rescue techniques and the dangers of working offshore. Moreover, everybody has passed a medical examination qualifying them for offshore work and all employees know the rules laid down for a wind farm environment.
Effective coating
Last year, Ballast Nedam Beheer (Operations and Maintenance) studied possible improvements in the maintenance of the coating work on wind turbines. We work with professionals, but there is always room for improvement. The maintenance of the coating must be carried out as effectively as possible. Together with the team leader, we investigated where improvements could be made without neglecting safety aspects. The working method has now been modified; next year we will start reaping the benefits. The coating manufacturer may also become involved. If durability and workability can be increased, it will mean fewer visits to the wind farm, allowing us to work more effectively, Leenders explains.
Points for improvement and innovative ideas are always shared among Ballast Nedams departments and sister companies. Operations and Maintenance maintains close contact with Ballast Nedam Engineering, Ballast Nedam Offshore and Ballast Nedam Concessions. Leenders: Within the group, we know where to find each other. Knowledge gained during the operations and maintenance stage is passed on to the designers and ultimately reflected in our product, allowing us to raise its level higher and higher. We have a sharp eye for detail and strive for a maintenance-free wind farm. This makes Ballast Nedam truly unique. At other companies, knowledge is often lost to a certain extent, simply because there are various different parties working on one and the same wind farm.
Companies that leave their management to us can rest assured. Its what we call onestop shopping
The organisation consists of managers with a technical background. Leenders: We always listen to our customers carefully. The primary role of Ballast Nedam Operations and Maintenance is to put our clients minds at ease. We hold a strong position in our network and have positioned ourselves well within the offshore wind energy sector. Our partners are loyal and highly dedicated to our common cause. We complement each other well: they engage in the professional hands-on work on the shop floor, while we concentrate on operating as a management organisation. In the end the synergy is reflected in our product.
Our safety policy is strict, says Leenders. We only deploy people with the necessary knowledge and experience to carry out maintenance work at a wind farm. For example, all the rope access companies we do business with have an IRATA certification, which stems from a certain level of safety. Everybody needs to be well aware of the risks run on open sea, and those risks are carefully evaluated. Together with our clients, we are doing all that we can to keep improving procedures and operations.
Ballast Nedam Operations and Maintenance is a management organisation it employs no welders or painters.
Leenders: In the future, large-scale maintenance (such as the replacement of a damaged boat landing) will involve interaction between Ballast Nedam Engineering, Offshore and Operations and Maintenance. I will gladly pass on relevant tasks to Ballast Nedam Offshore. Our organisations are complementary and can adapt quickly and expertly. After all, we are the only company in the Netherlands to possess all the required knowledge and experience ourselves. Companies that leave their management to us can rest assured. Its what we call one-stop shopping.
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History focus
1962 - 1965
In the past, Ballast Nedam built a number of highly notable bridges. The most impressive of these (in terms of scope and complexity) were built offshore, of which the Zeeland Bridge is a fine example. Over five kilometres long, this concrete bridge was the longest bridge in Europe. The entire construction consists of pre-fab concrete elements that were attached to each other from the water up. To carry out the construction work, a floating sheerlegs crane was used with a 600-tonne lifting capacity.
1989 - 1992
Ballast Nedam designed the Svanen especially for the construction of the Storebaelt Bridge, which links the Danish islands Fyn and Sjaelland. The bridges pre-fab elements were so large and heavy that a floating crane was needed, the Svanen, to lift the 6,200-tonne components nearly four times the capacity of the Ibis, Svanens predecessor.
1982 - 1986
The King Fahd Causeway is a dam bridge, 25 kilometres in length, connecting Saudi-Arabia to Bahrain. In technical terms it is constructed in the same manner as the Zeeland Bridge, but its scope is much larger. Ballast Nedam created the Ibis - a crane ship with a capacity of 1700 tonnes - especially for the transportation and installation of the Causeways pre-fab elements and foundations.
1993 - 1997
Just like the Zeeland Bridge, the King Fahd Causeway and the Storebaelt Bridge, the Confederation Bridge belongs to the category of mega-structures. The construction of the Confederation Bridge required the use of elements that were larger and heavier still, and so the Svanen was modified accordingly. Following its transformation, the heavy lift vessel now has a capacity of over 8,700 tonnes and is exact to within a few millimetres. The Svanen is now over 100 metres high. The Svanen was designed to transport and install pre-fab elements and foundations, and its capabilities are also put to full use in the construction of new wind farms. The floating crane drives giant-size monopiles into the sea bed, on top of which the wind turbine towers are then attached.
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Favourable conditions
Gijs van Kuik, President of the EAWE
The Netherlands has particularly good conditions for raising wind energy to new levels. The future, says Van Kuik, lies mainly in the offshore generation of energy with the help of wind turbines. The North Sea is shallow, making it extremely suitable as a location for wind farms. The Netherlands has a formidable electricity infrastructure, and we have relatively large amounts of wind. In addition, the government has compiled a number of plans for the development of offshore wind energy. Still, it takes an incredibly long time before existing plans are carried out. In this respect, bureaucracy is working against us.
Realistic objectives
In Germany, its a very different story. The German government pursues highly stimulating policies where sustainable energy (such as wind energy) is concerned, which means that supply goes up and prices come down. According to Van Kuik, wind energy funding in the Netherlands leaves a lot to be desired. Nevertheless, he says, there are still considerable opportunities open to the government. And it must be admitted that their objectives are sound and realistic: the plan is that by 2020, wind energy will supply one quarter of our energy needs.Van Kuik: We are not lacking in knowledge or expertise, and we have everything it takes to develop wind energy to the point where it can supply one quarter of our energy needs. The Netherlands currently has a share in nearly all offshore wind farms being built in Europe. The Dutch concrete drilled monopile has shown promising results, and we are making quite a contribution to the installation and maintenance of offshore wind farms.
Studies have shown that by 2050, the Netherlands should be able to supply 40-50 percent of its energy needs using wind power, which Van Kuik says would be a marvellous achievement. First and foremost, I remain concentrated on 2020 and the objectives formulated by the Dutch government. Permanent activity is needed in the North Sea to realise these objectives. At present, the construction of offshore wind farms regularly comes to a standstill, and this is something we simply cannot afford. We are a prime location for the generation of offshore wind energy, and we need to make full use of our potential if we want to reach our goals.
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Ballast Nedam Offshore Ringwade 71 3439 LM Nieuwegein PO Box 1451 3430 BL Nieuwegein The Netherlands Telephone: Fax: Internet: E-mail: +31(0)30 285 37 27 +31(0)30 285 48 41 www.bn-offshore.com info@bn-offshore.com
Ballast Nedam on the move This is a publication of Ballast Nedam Offshore. Copy and editing: EPP public relations. Translation: Metamorfose Vertalingen, Taalcentrum-VU. Photography: Marc Heeman (portraits), Ballast Nedam image database. Printing: Vandenberg drukwerken.