Offshore Wind
Offshore Wind
28 November 2007 1/ November 2007
Offshore Wind … GW Scale Renewable • US East Coast, Great Lakes, UK, Germany, China, … • Proximity to Population & Load Centers • 10-20 Km Offshore • Water Depths to 10-40 M
Huge renewable asset within 50 km of US coast, 40m depths
Challenges • Hurricane Exposure, Waves, Sea Bed Stability • Deep Water Foundations > 40 m Can Open Vast Resource • Tough Service Environment, Need Autonomous Operation Great Lakes close to large load centers in US & Canada
100’s GW Potential off NE Coast, Capacity Factors to 50%
2/ November 2007
The Offshore Projects
160 MW Vestas Offshore Farm – Horns Rev, North Sea
40 MW Bonus Middlegrunden Farm in Copenhagen Harbor 10 MW GE Wind at Utgrunden, Sweden
5 MW Bonus Vindeby Wind Farm – Offshore Denmark 10 MW NEG Micon Yttre Stengrund Offshore Sweden 90MW Vestas Barrow, UK 176 MW Siemens/Bonus Nysted, DK
3/ November 2007
UK Round 1 & 2 Projects
4/ November 2007
Offshore Machines Nacelle Power Rotor Weight Manufacturer Model Generator (MW) (m) + Rotor (kg) Enercon E112 4.5 112 440 WF Sync Enercon E120 6 120 440 WF Sync Vestas V90 3 90 108 DFIG Vestas NM110 4.2 110 214 DFIG Vestas V120 4.5 120 214 DFIG GE 3.6s 3.6 104 280 DFIG GE 3.6sl 3.6 111 265 DFIG Siemens/Bonus 3.6 3.6 107 200 Induction Repower 5M 5 126 400 DFIG Prokon Nord Multibrid 5 116 280 PM Sync
Cf (%) 44.0 41.6 43.5 44.6 46.5 45.3 47.9 46.4 46.3 43.4 * planned upgrades
GE 3.6 MW 104/111m
Vestas NM110/V120m 4.2/4.5 MW
Enercon E-112/120m, 4.5/6MW
Vestas V90 3MW, 90m
Siemens Bonus 3.6 3.6MW, 107m
Prokon Nord 5MW, 116m
Repower 5M 5MW, 126m 5/ November 2007
Economics of 500 MW UK Offshore Wind Park Windfarm Price vs. Turbine Size 2.60
1280
2.55
1260
UK Market Price
2.50
1240 2.45 1220 2.40
1200 1180
2.35
1160
2.30 4
5
6
• Next-gen turbines: 4, 5, 6, or 7 MW • Swept Area: 2.6 m2/kW • Specific Weight: 55 kg/kW • Tip clearance to water: 25m • GunFleet Sands - 12 m water depth, 20 km to shore • 90 m/s tip speed
Capital Cost per MW ($/MW)
7
Electrical BOP Costs vs Turbine Rating
Turbine Rating (MW) BOP Cost
500MW Wind Farm Breakdown $1.2B Total w/ 5MW Turbines
$190M $180M
Installation Costs vs Turbine Rating (MW)
$170M $160M
$220
$150M 3
4
5
6
7
8
Turbine MW
35%
16%
$ MM
12% Turbines
Foundation Costs vs Turbine Rating
Foundations & Towers CSA
1000
200
950
180
900
Construction & Installation
160
850 140
BOP Electrics Project Other
15%
Cost (K $)
800 750
120
700
100
650
80
600
10%
12%
60
$200 $180 $160 $140 $120
Fab Cost (K$ / MW)
Windfarm Capital Cost ($)
Assumptions 1300
$100 3
4
5
6
7
550 40
500
20
450 400
0
GE 4 MW unit
GE 5 MW unit
GE 6 MW unit
GE 7 MW unit
6/ November 2007
8
Foundation Technologies 0 – 20m : Monopile & gravity foundations; Resonance constraints from rotor operation leads to increasing tonnage & manufacturing limits.
Jacket weight increases with depth even at constant MW rating Depth dependence on weight can be reduced substantially with a floating foundation system
Monopile
Gravity Foundation
20 – 40m: Multi-legged jacket/tripod/braced pile structures from O&G industry experience. Joint Fatigue & O&M issues are main design drivers.
40m – beyond : Floating Platforms: Mini-TLP / Spar buoy based platforms under investigation; Primary motivation is to de-couple WTG weight dependence from water depth. 7/ November 2007
Gravity Foundations - Nysted Rødsand
72 foundations: 1300 tons + 500 tons ballast at depths of 7-12 m • 37,000 m3 of reinforced concrete • 33,100 m3 of ballast material (olivine, rock and sand) • 22,500 m3 of Scour Protection • 53,000 m3 of Dredging • 6,800 m3 of crushed stone ( 100 m/s Gearless direct drive Space frame structure Multivariable damping controls 40 m water depth foundation Hurricane ride-thru capability
Can we build it? Do the economics make sense? 13 / November 2007
Backup
14 / November 2007
Foundation Fabrication Cost Model Foundation Fabrication Cost Model 1000
200
950
180
900
160
850
120
700
100
650
80
600
Unit Foundation Fabrication costs decrease from $180K/MW (4MW) to $130K/MW (7MW )
60
550 40
500
20
450 400
Weight of Turbine & Foundation Components
0 GE 4 MW unit
GE 5 MW unit
GE 6 MW unit
GE 7 MW unit 1400
1200
Assumptions
1000
• Nacelle + Rotor Mass ~ 55 tons/MW • Tip clearance 25m • Soil Profile from GunFleet Sands • 12 m Water Depth • 2000 USD/ton for monopile & 3000 USD/ton for TP
Weight (tons)
Cost (K $)
750
Fab Cost (K$ / MW)
140
800
Rotor Nacelle Tower Transition Piece Monopile
800
600
400
200
288 Tons
379 Tons
0
GE 4 MW unit
GE 5 MW unit
Source: GRC physics based model - foundation/tower mass as f(tower top mass)
GE 6 MW unit
GE 7 MW unit
15 / November 2007
Installation Costs – Turbine & Foundation Turbine Installation – Considerations • Arklow & Bid Planning experience each component lift = 4 hours/lift (Based on MV Resolution) • Larger turbines = More Lifts/Turbine BUT Fewer turbines = Fewer Lifts/Farm • Arklow lesson – Weather down time and site specific wave dynamic risks must be understood on project basis.
4
5
6
7
125
100
83
71
5
6
6
7
Dredging/Scour Protection
$18.1
$14.6
$12.2
$10.3
proportional to # turbines
Foundation & TPs
$41.0
$38.4
$35.8
$33.1
proportional to # turbines
$230
WTG Installation
$41.1
$42.5
$37.8
$39.7
proportional to # lifts/turbine
$210
Construction Partner Scope
$101.3
$81.0
$67.3
$57.5
proportional to # turbines
WTG Installation & Commissioning & Transport
$25.4
$20.3
$16.9
$14.2
proportional to # turbines
$226.9
$196.8
$170
Number of Turbines Number of Lifts Req’d
Total for Windfarm
1.5MW Star lift - Utgrunden Comment
$154.8 (million $)
Est. Windfarm Installation Costs vs, Turbine Rating (MW) for 500MW Farm
$ MM
Size
$190 $170 $150 $130 $110 3
Source: GE Wind UK Offshore Team – Lynn & Inner Dowsing/Gunfleet
4
5
6
7
8
16 / November 2007
BOP Cost Estimates Cape Wind BOP Estimate Equipment 468 MW ESP (electrical equipment) 468 MW ESP (platform) 33 kV Cable (84 miles) 33 kV Cable installation and burial (84 miles) 115 kV Cable (8 miles submarine, 6 miles land) 115 kV Cable - Install submarine
Cost Total $12,925,000 $32,075,000 $45,000,000 $25,000,000 $33,000,000 $64,000,000 $21,000,000 $143,000,000 Total $188,000,000
Cape Wind
System Layout for 500MW UK Farm
•
70-76 77-84
Collector ESP (500MW block)
CBs x x x x x x
Shore Connection (500MW block) CB x x
33kV 132kV
x x
x x Transformer Disconnect/ Earthing Switch
Proposed 468 MW Farm – close to UK R2 130 x 3.6 MW turbines Eleven turbines per feeder at 33 kV One Electrical Service Platform (ESP) with 115 kV transmission cable to shore. • 8 miles between ESP and shore.
132kV
400kV
500MW Reference Plant $190M Transmission Connection
x x TransformerDisconnect/ Earthing Switch
BOP Cost
Collector Circuits 1-7 8-14 15-21 •• 22-28
• • • •
$180M $170M $160M $150M 3
High Power Density Reduces Collector Cabling Costs Source: Capewind EMI/Lynn & Inner Dowsing
4
5
6
7
Turbine MW
17 / November 2007
8
Blades Blade Weight versus Blade Length 140
Weight (Ton)
120
Yesterday
100
Carbon Spar Cap
Today
80
Tomorow
60
Blade Root
40 20 0 20
40
60
80
100
Wind Turbine Blade Le ngth (m)
Blade Scaling Shoreline Manufacturing RT/LT Cure Resins Eliminate Curing Ovens & Paint Booths Simplified Molds
Automated tape placement Swept Spar Cap
70 m Aeroelastic Tailored Blade • Selective Carbon Fiber & High Lift Airfoils to Reduce Blade Weight (~25%) • In Plane Sweep & Bend-Twist Coupling to Reduce Loads • Automated carbon layup – quality control for key load elements 70m aeroelastic blade
18 / November 2007
Structures Key Benefits • Weight reductions – nacelles tower & foundation • Optimized tubular space frame/GBS architecture • Eliminate large castings – mfg bottleneck • Cost effective foundations to 40m • Passive tower damping key technology • Manufacturing, QC, shoreline locale
Space Frame Structures - Sheathed for on-shore - Manufacturing, transport - NREL: potential 35-50% material savings
Monocoque Load Bearing Nacelle - Bonus currently used load bearing steel nacelle
Space frame & concrete gravity foundation -Preassembled boltless design -Wave loading
19 / November 2007
28 November 2007 1/ November 2007
Offshore Wind … GW Scale Renewable • US East Coast, Great Lakes, UK, Germany, China, … • Proximity to Population & Load Centers • 10-20 Km Offshore • Water Depths to 10-40 M
Huge renewable asset within 50 km of US coast, 40m depths
Challenges • Hurricane Exposure, Waves, Sea Bed Stability • Deep Water Foundations > 40 m Can Open Vast Resource • Tough Service Environment, Need Autonomous Operation Great Lakes close to large load centers in US & Canada
100’s GW Potential off NE Coast, Capacity Factors to 50%
2/ November 2007
The Offshore Projects
160 MW Vestas Offshore Farm – Horns Rev, North Sea
40 MW Bonus Middlegrunden Farm in Copenhagen Harbor 10 MW GE Wind at Utgrunden, Sweden
5 MW Bonus Vindeby Wind Farm – Offshore Denmark 10 MW NEG Micon Yttre Stengrund Offshore Sweden 90MW Vestas Barrow, UK 176 MW Siemens/Bonus Nysted, DK
3/ November 2007
UK Round 1 & 2 Projects
4/ November 2007
Offshore Machines Nacelle Power Rotor Weight Manufacturer Model Generator (MW) (m) + Rotor (kg) Enercon E112 4.5 112 440 WF Sync Enercon E120 6 120 440 WF Sync Vestas V90 3 90 108 DFIG Vestas NM110 4.2 110 214 DFIG Vestas V120 4.5 120 214 DFIG GE 3.6s 3.6 104 280 DFIG GE 3.6sl 3.6 111 265 DFIG Siemens/Bonus 3.6 3.6 107 200 Induction Repower 5M 5 126 400 DFIG Prokon Nord Multibrid 5 116 280 PM Sync
Cf (%) 44.0 41.6 43.5 44.6 46.5 45.3 47.9 46.4 46.3 43.4 * planned upgrades
GE 3.6 MW 104/111m
Vestas NM110/V120m 4.2/4.5 MW
Enercon E-112/120m, 4.5/6MW
Vestas V90 3MW, 90m
Siemens Bonus 3.6 3.6MW, 107m
Prokon Nord 5MW, 116m
Repower 5M 5MW, 126m 5/ November 2007
Economics of 500 MW UK Offshore Wind Park Windfarm Price vs. Turbine Size 2.60
1280
2.55
1260
UK Market Price
2.50
1240 2.45 1220 2.40
1200 1180
2.35
1160
2.30 4
5
6
• Next-gen turbines: 4, 5, 6, or 7 MW • Swept Area: 2.6 m2/kW • Specific Weight: 55 kg/kW • Tip clearance to water: 25m • GunFleet Sands - 12 m water depth, 20 km to shore • 90 m/s tip speed
Capital Cost per MW ($/MW)
7
Electrical BOP Costs vs Turbine Rating
Turbine Rating (MW) BOP Cost
500MW Wind Farm Breakdown $1.2B Total w/ 5MW Turbines
$190M $180M
Installation Costs vs Turbine Rating (MW)
$170M $160M
$220
$150M 3
4
5
6
7
8
Turbine MW
35%
16%
$ MM
12% Turbines
Foundation Costs vs Turbine Rating
Foundations & Towers CSA
1000
200
950
180
900
Construction & Installation
160
850 140
BOP Electrics Project Other
15%
Cost (K $)
800 750
120
700
100
650
80
600
10%
12%
60
$200 $180 $160 $140 $120
Fab Cost (K$ / MW)
Windfarm Capital Cost ($)
Assumptions 1300
$100 3
4
5
6
7
550 40
500
20
450 400
0
GE 4 MW unit
GE 5 MW unit
GE 6 MW unit
GE 7 MW unit
6/ November 2007
8
Foundation Technologies 0 – 20m : Monopile & gravity foundations; Resonance constraints from rotor operation leads to increasing tonnage & manufacturing limits.
Jacket weight increases with depth even at constant MW rating Depth dependence on weight can be reduced substantially with a floating foundation system
Monopile
Gravity Foundation
20 – 40m: Multi-legged jacket/tripod/braced pile structures from O&G industry experience. Joint Fatigue & O&M issues are main design drivers.
40m – beyond : Floating Platforms: Mini-TLP / Spar buoy based platforms under investigation; Primary motivation is to de-couple WTG weight dependence from water depth. 7/ November 2007
Gravity Foundations - Nysted Rødsand
72 foundations: 1300 tons + 500 tons ballast at depths of 7-12 m • 37,000 m3 of reinforced concrete • 33,100 m3 of ballast material (olivine, rock and sand) • 22,500 m3 of Scour Protection • 53,000 m3 of Dredging • 6,800 m3 of crushed stone ( 100 m/s Gearless direct drive Space frame structure Multivariable damping controls 40 m water depth foundation Hurricane ride-thru capability
Can we build it? Do the economics make sense? 13 / November 2007
Backup
14 / November 2007
Foundation Fabrication Cost Model Foundation Fabrication Cost Model 1000
200
950
180
900
160
850
120
700
100
650
80
600
Unit Foundation Fabrication costs decrease from $180K/MW (4MW) to $130K/MW (7MW )
60
550 40
500
20
450 400
Weight of Turbine & Foundation Components
0 GE 4 MW unit
GE 5 MW unit
GE 6 MW unit
GE 7 MW unit 1400
1200
Assumptions
1000
• Nacelle + Rotor Mass ~ 55 tons/MW • Tip clearance 25m • Soil Profile from GunFleet Sands • 12 m Water Depth • 2000 USD/ton for monopile & 3000 USD/ton for TP
Weight (tons)
Cost (K $)
750
Fab Cost (K$ / MW)
140
800
Rotor Nacelle Tower Transition Piece Monopile
800
600
400
200
288 Tons
379 Tons
0
GE 4 MW unit
GE 5 MW unit
Source: GRC physics based model - foundation/tower mass as f(tower top mass)
GE 6 MW unit
GE 7 MW unit
15 / November 2007
Installation Costs – Turbine & Foundation Turbine Installation – Considerations • Arklow & Bid Planning experience each component lift = 4 hours/lift (Based on MV Resolution) • Larger turbines = More Lifts/Turbine BUT Fewer turbines = Fewer Lifts/Farm • Arklow lesson – Weather down time and site specific wave dynamic risks must be understood on project basis.
4
5
6
7
125
100
83
71
5
6
6
7
Dredging/Scour Protection
$18.1
$14.6
$12.2
$10.3
proportional to # turbines
Foundation & TPs
$41.0
$38.4
$35.8
$33.1
proportional to # turbines
$230
WTG Installation
$41.1
$42.5
$37.8
$39.7
proportional to # lifts/turbine
$210
Construction Partner Scope
$101.3
$81.0
$67.3
$57.5
proportional to # turbines
WTG Installation & Commissioning & Transport
$25.4
$20.3
$16.9
$14.2
proportional to # turbines
$226.9
$196.8
$170
Number of Turbines Number of Lifts Req’d
Total for Windfarm
1.5MW Star lift - Utgrunden Comment
$154.8 (million $)
Est. Windfarm Installation Costs vs, Turbine Rating (MW) for 500MW Farm
$ MM
Size
$190 $170 $150 $130 $110 3
Source: GE Wind UK Offshore Team – Lynn & Inner Dowsing/Gunfleet
4
5
6
7
8
16 / November 2007
BOP Cost Estimates Cape Wind BOP Estimate Equipment 468 MW ESP (electrical equipment) 468 MW ESP (platform) 33 kV Cable (84 miles) 33 kV Cable installation and burial (84 miles) 115 kV Cable (8 miles submarine, 6 miles land) 115 kV Cable - Install submarine
Cost Total $12,925,000 $32,075,000 $45,000,000 $25,000,000 $33,000,000 $64,000,000 $21,000,000 $143,000,000 Total $188,000,000
Cape Wind
System Layout for 500MW UK Farm
•
70-76 77-84
Collector ESP (500MW block)
CBs x x x x x x
Shore Connection (500MW block) CB x x
33kV 132kV
x x
x x Transformer Disconnect/ Earthing Switch
Proposed 468 MW Farm – close to UK R2 130 x 3.6 MW turbines Eleven turbines per feeder at 33 kV One Electrical Service Platform (ESP) with 115 kV transmission cable to shore. • 8 miles between ESP and shore.
132kV
400kV
500MW Reference Plant $190M Transmission Connection
x x TransformerDisconnect/ Earthing Switch
BOP Cost
Collector Circuits 1-7 8-14 15-21 •• 22-28
• • • •
$180M $170M $160M $150M 3
High Power Density Reduces Collector Cabling Costs Source: Capewind EMI/Lynn & Inner Dowsing
4
5
6
7
Turbine MW
17 / November 2007
8
Blades Blade Weight versus Blade Length 140
Weight (Ton)
120
Yesterday
100
Carbon Spar Cap
Today
80
Tomorow
60
Blade Root
40 20 0 20
40
60
80
100
Wind Turbine Blade Le ngth (m)
Blade Scaling Shoreline Manufacturing RT/LT Cure Resins Eliminate Curing Ovens & Paint Booths Simplified Molds
Automated tape placement Swept Spar Cap
70 m Aeroelastic Tailored Blade • Selective Carbon Fiber & High Lift Airfoils to Reduce Blade Weight (~25%) • In Plane Sweep & Bend-Twist Coupling to Reduce Loads • Automated carbon layup – quality control for key load elements 70m aeroelastic blade
18 / November 2007
Structures Key Benefits • Weight reductions – nacelles tower & foundation • Optimized tubular space frame/GBS architecture • Eliminate large castings – mfg bottleneck • Cost effective foundations to 40m • Passive tower damping key technology • Manufacturing, QC, shoreline locale
Space Frame Structures - Sheathed for on-shore - Manufacturing, transport - NREL: potential 35-50% material savings
Monocoque Load Bearing Nacelle - Bonus currently used load bearing steel nacelle
Space frame & concrete gravity foundation -Preassembled boltless design -Wave loading
19 / November 2007
