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Optimizing Wind Farm Construction Logistics

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The Company (Ballast Nedam)

• Amsterdamsche Ballast Maatschappij: 1877

• Nederlandse Aannemings Maatschappij: 1899

• Merged into Ballast Nedam: 1969

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The Company (Ballast Nedam)

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Offshore Windfarm Lely - Engineering, supply and installation of 4 foundations

Offshore Windfarm Dronten / Irene Vorrink - Engineering, supply and installation of 28 foundations

Offshore Wind – The Early Years

32 foundations

1994 / 1996

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Offshore Wind Farm Egmond aan Zee

69 foundations

2006

Turn-key delivery of an Offshore Wind Farm in joint venture with Vestas. - Engineer, supply and installation of 37 foundations (1

xMeteo Mast, 36 turbine foundations. - All offshore installations (foundations, turbines and

cables) - 50% Electrical Scope

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Rhyl Flats Offshore Wind Farm

94 foundations

2008

Installation of 25 foundations at the Rhyl Flats Offshore Wind Farm in the Irish Sea. Monopiles transported floating, transition piece transported vertical on barges.

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Gunfleet Sands Offshore Wind Farm

126 foundations

2009

Installation of 32 foundations at the Gunfleet Sands Offshore Wind Farm. Installation started during the 2nd half of 2008 and was finalised during the first months of 2009. Both monopiles and transition pieces were transported on barges towards the HLV Svanen

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Belwind, Sheringham Shoal and Baltic I

228 foundations

2010

Installation of 56 monopiles at the Belwind Offshore Wind Farm. Started in 2009, finalised in Q1/2010 Installation of 24 foundations at the Sheringham Shoal Offshore Wind Farm. Design and installation of 22 foundations at the Baltic I Offshore Wind Farm in Germany. Installation with jack-up vessel

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Walney 2 and London Array Offshore Wind Farms

Logistics and installation of 51 monopiles at the Walney 2 Offshore Wind Farm. Floating transport of heaviest monopiles so far in offshore wind. Maximum weight up to 805 tons. Installation of 11 foundations at London Array ,monopile and transition piece, at shallow locations beyond the limitation of the projects existing installation vessels, Seaworker and Adventure

290 found.

2011

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Future Projects (2012/2013)

Installation of 111 monopiles at the Anholt Offshore Wind

Farm in Denmark during 2013

Engineering, supply and installation of 80 foundations at

the Butendiek Offshore Wind Farm in Germany during 2013.

481 found.

2013

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Overview designed and installed foundations - 2011

Number of foundations 290 Designed by Ballast Nedam 91 Installed by Ballast Nedam 290 Installed by HLV Svanen 235 Number of monopiles 290 Number of transition pieces 148

Type of contracts Installation contracts Engineering and installation contracts Full EPC foundation contracts Turn-key offshore wind farm project

Track record - On time - 100% availabilty - Reliable cycle times

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Project Example: Walney 2 Offshore Wind Farm (Summer 2011)

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Walney 2 Offshore Wind Farm (Logistics summary)

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Onshore Operations (Site Barrow-in-Furness UK)

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Onshore Operations (Site Barrow-in-Furness / UK)

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Onshore Operations (Logistical flow)

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Onshore Operations (Launching Monopiles)

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Onshore Operations (Launching Monopiles)

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Transport to Site (Floating Monopiles)

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Transport to Site (Floating Monopiles)

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Transport to Site (Transition Pieces on barges)

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Offshore Operations (Docking Monopile)

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Offshore Operations (Upending Monopile)

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Offshore Operations (Upending Monopile)

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Offshore Operations (Releasing Plugs & Pile Contingency Floatation Units)

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Offshore Operations (Releasing plugs & Pile Contingency Floatation Units)

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Offshore Operations (Hammering Monopile)

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Offshore Operations (Hammering Monopile)

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Offshore Operations (Transition Piece Installation)

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Weather Conditions / Working Windows

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Weather Conditions / Working Windows

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Gross cycle time :

- net cycle time

- unworkable weather

- (logistic) delays

Focus

3 weeks of delay during the project can easily results in 8

weeks delay at the end which is 1/3 of the onshore and

offshore running cost

1

24 w eeks

October November

2

3

8

April May June July August September

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Weather Conditions / Working Windows

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3

2

1

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Project Engineering Solutions (Feeding concepts)

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Project Engineering Solutions (Rigging & Temporary Works)

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Human Resources (mixing experience & ambitions)

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Human Resources (1-BN concept / in-house specialities)

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Planning & Logistics (Traditional Planning)

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,0

1,0

2,0

3,0

4,0

5,0

6,0

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10,0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

du

rati

on

(d

ays)

foundation (1 to 56)

Progress HLV Svanen + floating piles(Bligh Bank Offshore Wind Farm from 01 Sep 2009 to 05 Feb 2010)

nett duration (20% / average 12,5hrs) logistical delay (13%) repairs (1%) unworkable weather (66%)

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Planning & Logistics (Relevant Factors: nett. duration / logistical delays / repairs / weather)

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Logistical Modelling

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Logistical Modelling (Input data)

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Logistical Modelling (Input data)

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Logistical Modelling (Input data: substructure components)

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Logistical Modelling (Input data: substructure components)

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Logistical Modelling (Input data: substructure components)

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Logistical Modelling (Input data: marine spread)

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Logistical Modelling (Input data: marine spread)

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Logistical Modelling (Input data: sub-cycle times / durations)

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Logistical Modelling (Input data: sub-cycle times / durations)

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Logistical Modelling (Input data: local conditions)

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Logistical Modelling (Input data: local conditions)

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Logistical Modelling (Input data: local conditions)

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Logistical Modelling (Input data: weather)

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Logistical Modelling (Output)

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Logistical Modelling (Output: utilization rates)

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Logistical Modelling (Output: cycle time charts)

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Logistical Modelling (Output: waiting times)

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Logistical Modelling (Output: resource tracking)

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Base case Weather 2005 lock gates < 2.5h 6m MP´s only 6.5m MP´s first no buffer nett cycle 12.5hr cycle 12,5 + >

speed TT

cycle 12,5 + > speed TT + extra

6.5m plug

belwind variance on Svanen nett

cycle

1 project duration (day) 34 66 38 33 52 41 33 28 27 39

2 nett cycletime (hrs) 16 40 18 15 22 20 15 13 13 18

3 occupancy SVANEN (%) 82% 73% 73% 85% 60% 67% 68% 79% 82% 55%

4 occupancy AHT’s (%) 29% 11% 20% 32% 14% 13% 24% 36% 38% 6%

5 occupancy Transportation Tug (%) 93% 60% 95% 94% 86% 97% 95% 93% 93% 97%

6 occupancy Harbor Tug (%) 31% 10% 43% 18% 54% 80% 68% 56% 18% 11%

7a occupancies 6.0m plugs (%) 49% 43% 45% 9% 47% 47% 39% 44% 61% 47%

7b occupancies 6.3m plugs (%) 42% 19% 46% 0% 44% 49% 35% 36% 70% 47%

7c occupancies 6.5m plugs (%) 98% 98% 100% 0% 45% 99% 99% 97% 53% 100%

8 occupancy towage beams (%) 62% 80% 63% 93% 5% 69% 72% 67% 17% 68%

10 occupancy onshore equipment (60t crane) (%) 23% 12% 20% 24% 17% 19% 23% 27% 28% 19%

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Logistical Modelling (Sensitivity analysis)

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Logistical Modelling

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Walney 2

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24 hour time lapse movie available at:

www.youtube.com/watch?v=YIAovkexkYo

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A total of 1,247 offshore turbines are now installed and grid connected in European waters, bringing total installed capacity to 3,294MW, spread across 49 wind farms in nine European countries.

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Developments Offshore Wind

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Future Locations

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Logistical Challenges

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Questions & Discussion