OFFSHORE MAGAZINE · JUNE 2O15
ENERGY INSIGHT Safety A key issue in offshore wind Danish Ports An overview Pre-assembly MHI Vestas cutting time and costs
“It was a bold move, but it is one we have never regretted” KP Mehlsen, key account manager on the expansion of the Port of Grenaa
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energy insight
CONTENTS 4 6 12 14 16 18
Publisher:
NEM Media
Port of Grenaa The ‘Eastern Esbjerg’ in offshore wind Danish Ports An overview Pre-assembly MHI Vestas cutting time and costs New product Brüel & Kjær developing blade damage detection product Rope access technician A job with lots of freedom Safety A key issue in offshore wind
Krondalvej 7 DK-2610 Roedovre Denmark nem@nemmedia.dk Cover photo: Danbor
Editors: Karin Jensen, Arne Jensen and Mohammed Wachah Graphics & Layout: Klaus Juul Jensen Advertisement: Mohammed Wachah, +45 23 23 80 82, mw@nemmedia.dk Magnus Lysemose, +45 42811110, ml@nemmedia.dk Print: Johnsen Graphic Solutions
by mogens tofte koch
FOREWORD Denmark has long been a maritime nation – Danish
Vikings sailed the world centuries ago, the country was among the first to become a maritime trade nation and fishing has been a natural occupation. Since the 1960s, the offshore oil & gas industry has also been playing an increasing role in the nation’s maritime activities and the industry has become a strong part of the Danish economy. In 2012, Danish North Sea oil and gas production generated more than 25 billion DKK for the Danish state. Today, Denmark’s offshore energy expertise is not limited to oil and gas. Government policy means renewables have been and will remain firmly on the agenda. Denmark is a leading country in wind power technologies and manufacturing, and Danish companies play an important part in the entire supply chain of wind farm projects across the world working on major installations in China, America and Europe. In February 2011, the Danish Government announced its “Energy Strategy 2050,” which aims to make the country fully independent of fossil fuels by 2050. This is not least due to climate considerations. The Danish government targets 50% wind power in the electricity system by 2020 and with connection of Anholt Offshore Wind Farm to the energy grid in 2013, the level of electricity coming from wind in Denmark reached 39% in 2014.
Danish offshore suppliers The supply chain included many Danish suppliers during preparation, construction and connection of Anholt Offshore Wind Farm. Many suppliers have started out with focus on the offshore oil & gas industry and by time they have applied their skills, know-how and experience to the offshore wind industry. Flexibility and innovation have been key attributes of the Danish supply industry from the start. The development
of and use of new technology is also a well-known Danish trait. With limited natural resources, Denmark has to be innovative and get the best out of what it has, driving its engineering skills and entrepreneurialism.
Knowledge sharing Denmark has a lead in developing wind energy, but has also learned lessons from the development of wind energy. This has established an expertise in time-saving and cost-saving in developing wind energy projects and now this expertise is spread to new markets such as the US where there is a huge potential in wind energy. Knowledge sharing and consulting is not an unknown phenomenon to Danish offshore suppliers as several offshore network groups exist in Denmark. “Together we are strong! is the fundamental idea behind Danish Marine & Offshore Group (DMOG) where more than 100 Danish offshore suppliers join forces and offer new innovative ways of doing business,” says Mogens Tofte Koch, Managing Director. “DMOG is a sales network and our members have realised that knowledge sharing, networking and co-operation is the way forward in the offshore industry in order to create greater cost efficiency,” continues Mogens Tofte Koch. The conditions and demands for the suppliers to offshore wind and offshore oil & gas are very often the same and this is why so many suppliers cover both industries. “We have to continue developing the skills and expertise of the Danish offshore suppliers to the ever changing industry if we will continue to take the lead in the global wind industry. This is what we hear from our members and therefore an important focus in our work,” ends Mogens Tofte Koch. ▪
Energy Insight 3
The Port of Grenaa aims to be the ‘Eastern Esbjerg’ in offshore wind by k arin jensen
4 Energy Insight
The Port of Grenaa is today a leading offshore port and the aim is to be the Eastern equivalent to the Port of Esbjerg. Anholt Offshore Wind Farm has played a key role in the transformation of the port. The Port of Grenaa on the East coast of Jutland
There are many possibilities for Grenaa within offshore wind going forward. The port is perfectly located for the upcoming Kriegers Flak and the near-coast projects.
has been undergoing a rapid transformation in recent years and is today a leading business and industry port in Denmark with a strong focus on offshore wind projects. The aim is clear as the port prepares further expansion in the coming 15 years, to be the Eastern equivalent to the Port of Esbjerg. “In 2030 we will be twice the size we are today. A port with more than four kilometres of quay and a basin water depth of 15 meters. And with regards to offshore wind, then our aim is to be the Eastern equivalent to Esbjerg,” says KP Mehlsen, key account manager at the Port of Grenaa. Esbjerg lies on the West coast of Jutland and is a European hub for wind power due to its perfect location close to the North Sea, with four-fifths of all offshore wind capacity installed in Europe originating from here. Grenaa, meanwhile, has easy access to Kattegat and thereby to the Baltic Sea and Sweden. “There are many possibilities for Grenaa going forward. We are looking at the nearcoast offshore projects and Kriegers Flak as well as the offshore project in the bay of Aarhus. If it is decided to use Danish offshore turbines for these projects then we are perfectly located,” says Mehlsen.
It began with Anholt
Anholt when the board of the Port of Grenaa decided to invest in a 300.000 square meter expansion. “It was a bold move but it is one we have never regretted,” says Mehlsen. During the expansion of the offshore port, Siemens Wind Power, the supplier of turbines for the Anholt project, played a key role in the process of defining and developing the new pre-assembly area. Located directly at the quay, the large pre-assembly area has two steel hangars instead of the typical tents while eleven light poles have been installed, making it possible to work 24 hours a day. Heavy and light transport has also been separated at the port for security reasons and Grenaa is one of four ports selected as disembarkation ports for heavy goods for the offshore wind sector with further expansion of the infrastructure in order to ensure better and smoother transportation of offshore components. Finally, the sea bed of the port has been improved and reinforced in order to receive jack-up vessels. “We removed some of the sea bed and re-established it with crushed stones so we now have a large foundation pillow on the sea bed where installation vessels can jack up. This area is today used by many installation vessels doing tests,” says KP Mehlsen. ▪
Grenaa’s expansion into a port of pre-assembly, disembarkation and services for the offshore wind industry began with the Anholt Offshore Wind Farm. In fact, it began before the Parliament had finally decided to build Energy Insight 5
offshore wind
PORTS 7 8
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The Ports of Fredericia, Nyborg and Middelfart ADP, Associated Danish Ports, operates the industrial ports of Fredericia, Nyborg and Middelfart. One of the core competencies of ADP is the cooperation with international companies for the assembly and shipping of offshore wind farms. The Port of Nyborg, for example, is favourably located for shipping wind turbines to offshore farms in the Baltic Sea and the Kattegat and in 2011 a new quay was built in Nyborg, designed for heavy project cargo, enabling the port to accommodate larger and heavier wind turbines.
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The Port of Rømø The Port of Rømø is ideally located to function as a service base for the construction and service of German wind farms in the North Sea. Water depths alongside the new quay are seven meters (mean level) and five meters in all other basins.
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The Port of Odense and Lindø Industrial Park
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The Port of Esbjerg The Port of Esbjerg is the leading port for offshore wind power in Europe. It’s ideal for the shipment of wind power due to its unique experience and location, modern facilities, flexible areas and supply chain, which includes several of the world’s leading companies specialised in handling and servicing wind installations.
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The Port of Grenaa The port of Grenaa has large areas for pre-assembly directly at the quay as well as large capacity for disembarkation and services. The port has a good distance to urbane areas, easy access to the maritime A-route in Kattegat and good infrastructure to the main land and cities.
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The Port of Thyborøn One of Denmark’s largest fishing harbours is under transformation. The port’s infrastructure is being developed and is now fully geared for the disembarkation of equipment and the servicing of the offshore industry, with main focus on offshore wind turbines near the coast.
The Port of Odense and Lindø Industrial Park offer production and warehouse facilities for large-scale infrastructure/construction projects and projects in the offshore and wind turbine industries. Lindø has a central location in relation to the North Sea and the Baltic, huge production halls, quays and dry docks and depths of up to 11 metres. It has lifting and transport capacity of up to 1.000 tonnes and can meet the requirements of projects of any size.
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The Port of Hvide Sande
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The Port of Hvide Sande offers a range of facilities especially established for offshore wind activities. The western port has water depths of seven meters, its pier is 150 m long with a load capacity of between 5-10 tonnes per m2 (47-80 tonnes’ point load).
The Port of Aarhus Denmark’s largest container port is currently undergoing a major expansion, which will see the port expand to approximately 1,800,000 m2 and with maximum water depth projected at 15.5 metres along the quays. A new Omniterminal will, among other things, be used for storage of windmill projects being prepared for shipment.
The port of Aabenraa The port of Aabenraa has water depths of between four and 11 metres and is close to the European motorway network. It is a port of shipment and disembarkation for the entire Baltic area and offers all the facilities which hallmark an efficient industrial port.
Energy Insight 7
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8 Energy Insight
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Energy Insight 9
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photo: klausEnergy juul jensen Insight 11
The introduction of a pre-assembly site in Esbjerg means less time spent at sea and reduced costs for MHI Vestas and its customers.
Pre-assembly saves time spent at sea and cut costs for MHI Vestas by k arin jensen photo: mhi vestas
The construction of an offshore wind power plant is a complicated process and requires many different components, produced at many different plants and supplied by a number of different suppliers. A process which is made even more complicated as turbines get larger and larger and moves further out at sea. The introduction of pre-assembly onshore has made the task a lot smoother, whilecosts have been reduced. MHI Vestas has assembly facilities for the nacelles and blades at both Lindø and on the Isle of Wight as well as a pre-assembly site at the Port of Esbjerg. On top of that there 12 Energy Insight
is a large supply chain with several different suppliers for the main components. At the pre-assembly site in Esbjerg, components for the V112-3.0MW are assembled. “The blades are grouped together in a formation known as a ‘blade stacker,’ which means more efficient lifting. The nacelle is made ready by installing the cooler top, the spinner on the hub and importantly by conducting pre-commissioning of the turbines systems on the site,” says Bo Bjerregaard, head of pre-assembly at MHI Vestas. Doing the pre-assembly on the site means significant savings of time at sea, which again
means reduced costs for the customers. According to Bo Bjerregaard, pre-assembly has resulted in lowering costs of offshore wind as well as it has helped increase quality and safety through a cost efficient setup with reduced logistics and by efficient implementation of improvements in a controlled environment. “Our experience over the last two years has been improved efficiency in handling of main components, the ability to handle both project delays and accelerations and a move of all pre-assembly activities towards industrialisation,” he explains.
With so much work done onshore, and preparation and planning at the pre-assembly site, very little work is left to be done at sea. “At sea we only need to do five lifts – tower, nacelle and the (three) blades – to install a wind turbine. The turbine then needs to be connected to the grid, and energized,” says Bo Bjerregaard. Reducing the amount of time spent at sea has a very positive impact on overall costs as vessel time is very costly. MHI Vestas has used pre-assembly for the commissioning of the Kårehamn, Northind and the Humber Gateway projects. “We have seen considerable savings in both time spent offshore and in loading onto the vessels, as well as an improvement in quality which results in faster increase in availability of the installed turbine,” says Bo Bjerregaard. ▪ Energy Insight 13
Brüel & Kjær developing new blade damage detection Brüel & Kjær product has just
by k arin jensen · photos: brüel & kjær
developed a prototype for an entirely new wind turbine blade damage detection product and next step will be to develop a commercial solution, which may be ready for the market in a couple of years.
After four years of work, Brüel & Kjær has just completed a EUDP project to develop a system to detect, localize and follow up damage to wind turbine blades. As part of the project, a prototype has been developed and the next step in the process will be commercialisation with the aim of producing a real product for the market. “Today, there is no remote monitoring of the blades and there is no other product in the market which can compare to this one, so it is quite unique,” says Jens J. Hansen, Global Sales Development Manager at Brüel & Kjær. The fact that blades are getting bigger all the time only adds to the number of challenges and the further from shore the turbines are 14 Energy Insight
installed, the more maintenance costs are set to rise. “It is difficult to see from 100 kilometres distance if a blade has been damaged. And if you only do visual inspections then all you see is the outside of the blade, not the structure inside,” says Jens J. Hansen. The new system is based on sophisticated algorithms using vibration measurements and provides entirely new possibilities for setting up operational maintenance systems. “You do monitoring of turbine elements today, for example gearboxes. There is nothing new in that. You do so to keep an eye on the turbines twentyfour-seven. With this new product we provide the same option for the blades,” says Jens J. Hansen. The blades are exposed to extreme weather and lighting, resulting in a number of different kinds of damages. If there is no monitoring of the blades so any damage may worsen if it is left undetected for a longer time. “A ten centimetre long crack may not by critical, but it will be if the crack is 50 centimetre, or one metre,” says Jens J. Hansen. He adds the new system also provides the possibility to better plan for the future. Instead of going out to an offshore farm and inspect all the blades, you just need to repair those that are actually damaged. And perhaps you only need one vessel instead of two. “There are obviously cost savings in this product” says Jens J. Hansen. Brüel & Kjær will now start the work of developing an actual product, but when it is available on the market depends on a number of factors such as who the company cooperates with and how much a partner is willing to invest in the product. “My estimate is that a complete product can be ready in a couple of years,” he says. ▪
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Energy Insight 15
“It’s a great job, a job with lots of freedom”
Free as a bird up on a wind turbine. The job as rope access technician offers many perks, including a second to none view. By K arin Jensen · Photo: Per Kristensen
If you suffer from acute vertigo, this may not be the job
for you. But if you like to travel and has a high degree of personal freedom, then a career as a rope access technician may be just the thing for you. “It’s a great job, a job with lots of freedom,” says Per Kristensen, who has worked as supervisor and rope access technician for various service companies for the past 15 years. A normal day starts early at the site. After having shut the turbine down, taken himself and all his tools and equipment to the nacelle on top of the turbine, he climbs onto the blades using the ropes. “Once out there in my ropes I can begin the repair work, or inspection work. Once it’s completed I restart the turbine and write my report,” says Per Kristensen. Reporting, as well as taking pictures before, during and after repair work, is an essential part of the job as rope access technician and is used, for example, to make assessments of different types of damages. “Paper work and reporting is today a large part of our work,” says Per Kristensen. Before any rope access technician is let loose on the site he or she will have to undergo a number of courses, 16 Energy Insight
including the GWO package. GWO, the Global Wind Organisation, is an association of operators and manufacturers globally, which has prepared a standard for Basic Safety Training. “These courses are necessary and there’s no way you can escape them. There’re a number of different courses, usually a couple of months of training before you can start, and then you need to renew them every now and again,” says Per Kristensen. Per Kristensen carries out maintenance and service work both offshore and onshore and travels all over the world. Over the past year, for example, he has been in Poland, Shanghai, Beijing and Macedonia. “And you have time to see some of the sights too. Rope work depends very much on the weather so if it’s too windy, raining or lighting, then you can’t go up. When offshore there’re also the wave highs to take into consideration. So yes, there’s time to go and see things,” he says. The downside, of course, is to be away for long periods of time from the family and with wife and four children this is quite a sacrifice for Per Kristensen. ▪
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the same issues applying for both sectors, according to Per Hjort Lorenzen. “For example ‘dropped object,’ that is dropping an object from a great height, providing a huge risk for people working below. There’s no doubt, that if you want people to perform this type of high-risk work then you need to show that you have full control over safety,” he says. Risk assessments are the essence of safety work, and it is vital that work is controlled centrally, that you have a full grasp of the tasks being carried out and the necessary permits are in place. “It’s all about looking at each task in a complete objective way, get a full grasp over potential risks connected to the job and based on that take the necessary precautions, both preparations before the work starts, for example putting barriers up, but also when it comes to own personal protection equipment,” says Per Hjort Lorenzen.
When working in the offshore wind sector, safety is essential. The industry is still young but many valuable lessons can be learned from the oil & gas industry.
Close cooperation with customers
By K arin Jensen
Safety is a key issue when working in the offshore wind industry and valuable lessons can be learned from oil & gas, which has been around for much longer and has spent more money on safety requirements over the years than practically any other industry. “Working on an oil rig, a production platform or an offshore wind turbine are all high-risk jobs and there‘re extreme focus on safety. And there should be,” says Per Hjort Lorenzen, HSEQ Manager at Danbor. Offshore wind is still a very young industry, but there are valuable lessons to be learned from the oil & gas industry, with many of
18 Energy Insight
A lot of money and resources are spent on safety, not least on courses and training of staff, and there is a close cooperation between customer and suppliers. “I attend quarterly meetings with customers and competitors. We might be competitors but when you talk safety, then we share the same goal. A close cooperation strengthens safety work. You will not see an electrician company, for example, with a different view on safety than a forging company working next to,” says Lorenzen. One way of ensuring that everybody works at the same high level within safety, is screening of sub-suppliers. “Long before work starts up all sub-suppliers have been screened to make sure they are all responsible and conscious sub-suppliers,” says Lorenzen, adding many large companies in the offshore sector also run their own campaigns to reduce incidents, with courses and training every two years or so. “It’s all about focus on safety and to continue to have constant focus on safety,” says Per Hjort Lorenzen. ▪
Photo: ©Niels Eisum, DHI
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