EXPERIENCIA Y CASOS DE EXITO - FAEN

ROBERTO PRESAOffshore Project Director

FABRICATION EXPERIENCES WINDAR

Oportunidades empresariales asociadas a la innovación en el sector eléctrico

EXPERIENCIA Y CASOS DE EXITO

WINDAR is an international company belonging to a industrial group 100% private, owned and under the control of GrupoDaniel Alonso whose headquarters are in the north-west of Spain (Asturias region).

The Group was founded by Mr. Daniel Alonso Rodríguez, who is currently the Honorary President.

Windar Renovables is founded in 2007.

Global Leader on the manufacturing of WTG towers

and offshore foundations.

Who we are?

350 miEUR revenue

1.500 employees

60 years experience


Who we are?


WINDARMEXAltamira (Tamaulipas)720 sections/year

WINDAR RENEWABLE ENERGYHalol (Gujarat)Nellore (Andhra Pradesh)1680 sections/year

TORREBRASCamaçarí (Bahía)

720 sections/year

AEMSA SANTANALinares (Andalucía)720 sections/year

APOYOS METALICOSOlazagutía (Navarra)528 sections/year

WINDAR OFFSHOREFene (Galicia)

1 Jacket/week

WINDAR WIND SERVICESGijón (Asturias)

720 sections/year

TADARSA EÓLICA TAE 2 & TAE 3Avilés (Asturias)2190 sections/year

WINDAR OFFSHORETAE 1 & TAE 4

Avilés (Asturias)2 TP/week

WINDAR RENOVABLESCentral OfficesAvilés (Asturias)

Presence

WRS TOWERSTanganrog (Rostov)

400 sections/year


WINDAR opens new

plant in INDIA

WINDAR opens new plantin BRASIL

OpensWINDAR

WIND SERVICES

Agreementfor a JV

WINDAR opensTAE3

WINDAR opensTAE4

WINDAR opens new

plant in MEXICO

WINDAR-IDESAJoint Venture

1st Offshore Project

ANHOLT Jacket for OSS

2009 2010 2012

1st Offshore TowersBORKUM RIFFGRUND (Alemania)

BORKUM RIFFGAT (Alemania)WEST OF DUDDON SANDS (UK)

BELWIND (Bélgica)+63 Towers

2013 2015

4

3

6

5

4

WINDARorganizeits plants

WINDARfoundation

2007

Windar foundation(On-shore

towers)

2016 2018

2nd Offshoreproject

WIKINGER 29 Jackets

116 piles

3th project: HYWIND5 Floating foundations

4th project:NISSUM BREDNING4 Jackets

7th project:DEBU 31 TPs

20112008 2014

7

8

5th project:MERKUR 66 TPs

6th project:EA0142 Jackets138 piles

WINDAR opens new

plant in RUSSIA

9

JV

10

8th project:WINDFLOAT1 Floatingfoundation

1st American OWFBLOCK ISLAND

5 Tower

Co

mp

any

Pro

ject

s

2017


Towers vs Foundations

EXPERIENCES TOWERS FABRICATION OFFSHORE FOUNDATIONS

ONSHORE AND OFFSHORE WIND MARKET OUTLOOK

ONSHORE Towers:

• Mature and steady/growing market in EU.

• Competitive tenders (Renewable) being developed in some countries.

• Big emerging markets (Russia, KSA, Mexico, Argentina, Morocoo,etc).

• Some countries with strict Local Content Requirements

• Lack of long term visibility as the projects are usually awarded on “fast track” (specially in Europe)

OFFSHORE Towers: same trend than for the offshore foundations.

OFFSHORE MARKET

• Growing market in EU and promising pipeline in Taiwan and USA.

• Dramatic drop of the electricity Price over the last years.

• Market extremely driven by technology: bigger WTGs; foundation design; Installation vessels; etc.

• Some countries planning to develop long term programs to support sustainability: Netherlands, Germany, UK ,Denmark…

• Relatively good visibility of the Project pipeline.



PROJECT FEATURES

Onshore tower

• Fast awarding process based on costs and capacity availability.

• Very short lead-times

• Limited implication on the design

• Scope of Works normally reduced tofabrication

• Low level of monitorization from clients

• Limited risks and liabilities

• Mature product design which allows veryreliable and tight schedules.

• Long Project negotiations

• Early involvment with designer (but limited)

• Management of sub-contractors and sub-suppliers

• High involvment from clients (certifiers, QC inspectors, manufacturing experts)

• High profile risks: warranty, LDs, liabilities

• Lot of change orders which has impact on theProject Schedule

• Project costs mainly driven by raw material prices and logistics.




STAKEHOLDERS

CLIENTS: • OEMs

COMPETITORS:• Experienced european suppliers and

growing pressure from Asian suppliersalso for the offshore towers

• Specialised fabricators with lot of yearsof experience.

SUPPLY-CHAIN:• Worldwide supplies for Steel plates and

flanges.

CLIENTS: • Utilities• EPCI contractors• Big consortiums: Pension founds, Fund

Management…

COMPETITORS:• (So far) Almost limited to european fabrication• Fabricators from other industries joining wind

market.• Only a few fabricatiors but very specialised for

each foundation type.

SUPPLY-CHAIN:• Mostly european suppliers (lead-times, anti-

dumping, service).




PRODUCT SPECIFICATION & FABRICATION

• Very mature product: structuraly very similar from designer to designer (difference on theinternals)

• Standard specifications and formats definedby the designer to fit most of the Steel mil capabilities

• Same specifications for all the tower types (foreach client)

• Perfect match between Design and Fabrication Tolerances

• Quality requirements (usually) clearly statedand well align between fabricator and client.

• Design “ad-hoc” for each Project

• Lack of standarization on some of theelements

• Fast development: difficult to incorporateleassons learnt on time before new projectsare initiated.

• Very limited and late cooperation withfabricators and/or the whole supply chain.

• Some requirements are not clearly specifiedand affecting the Project Flow.

• Fabrication tolerances too restrictive and difficult to control by standard procedures.




ROLE OF HEAVY PLATES FABRICATION & SUPPLY

• Lot of pressure from Asian market due tocheap labour and Steel prices (manyeuropean projects awarded to assianfabricators)

• Improve the delivery times and reliabilityto have a competitive advantage onrelation to the assian suppliers.

• Quality and formats “easy” to achieve bymost of the Steel mills.

• Steel Price having a big share on the total costsof any foundation type.

• Much more strict quality requirements on top of the standard norms.

• Technical support from early phases to avoidunnecesarry requirements which makes theproduct more expensive and sometimesimposible to achieve.

• Commercial support and commitments duringthe tender process to keep the risks undercontrol.

• Quality and formats, not achievable by manymills.

• Final quality of the Steel delivered, extremelycritical during fabrication (very strict foundationfabrication requirements, hihg focus from endcustomer).



11


Offshore wind floating solutions

REF. OFFSHORE COUNTRY MANUFACTURER CLIENT SUPPLY DESCRIPTION YEAR

WINDFLOAT JV WINDAR-NAVANTIA EDP 1 Floating Foundation 2018

DEUSTCHE BUTCH JV WINDAR-IDESA VAN OORD 31 MTPs Offshore foundations 2017-2018

NISSUM BREDNING JV WINDAR-NAVANTIA SIEMENS 4 X 4 Leg Jacket 2017

EAST ANGLIA ONE JV WINDAR-NAVANTIA IBERDROLA 42 x 3 Leg Jacket 2017-2018

MERKUR JV WINDAR-IDESA GEOSEA 66 MTPs Offshore foundations 2017

HYWIND JV WINDAR-NAVANTIA STATOIL 5 x Spar Floating Foundations 2016-2017

WIKINGER JV WINDAR-NAVANTIA IBERDROLA 29 x 4 Leg Jacket + 106 Piles 2015-2016

ANHOLT WINDAR PIHL-ZUBLIN 1 Transformer Substation Jacket 2012

12

76 Jackets 5 SPAR 97 TPs +200 Offshore Towers


Offshore wind experience

13

Offshore Tower

Onshore Tower

Offshore foundation



WIKINGER

HYWIND

ANHOLT

MERKUR, DEBU

NISSUM

EA01


Manufacturer WINDAR

Year 2012

Client

LocationOWF erected in the Kattegat sea between Grenå and the Island of Anholt (Denmark).

DescriptionManufacture of 4-Legs Jacket foundation for the Anholt transformer substation (Anholt Project)

Foundation

Height: 15 m

Total weight: 800 Tons

Max. Thickness: 60 m

The Gravity Based Foundation for the transformer station was a concrete caisson construction with a total weight of 4,000 tn which has been constructed in a dry dock near Copenhagen.

OW Project: ANHOLT


Manufacturer

JV WINDAR-NAVANTIA

Year 2015-2016

Client

LocationExclusive economic zone (Baltic-WestlichAdlergrund). Baltic Sea. Germany

DescriptionFoundation by the Joint Venture in Spain.Piles by WINDAR sent by barge directly to Sassnitz.

Foundation

Jackets (4-Leg). Include: 29 TPs, 116 Nodes

- Jacket height: 50 m- Jacket weight (without piles): >762 Tn- Max. diameter: 6 m- Max.Thickness: 70 mm- Quality material: S355NL+Z35

116 Piles for 29 Jackets

- Piles height: 59 m- Piles weight (Jacket+piles) >1429 Tn- Max. diameter: 2,7 m

OW Project: WIKINGER

Manufacturer

JV WINDAR-NAVANTIA

Year 2016-2017

Client

LocationFloating OWF located near Buchan Deep (Scotland), approx. 25-30 km from thecoast.

Description5 SPAR Floating Foundations Manufactured by the Joint Venture in Spain (Feneshipyard).

Foundation

Foundation lenght: 90M

Foundation weight: 2.200 TN

Max. diameter: 14,5 m

Mat. thickness: 80 mm

Material quality: NV36D

OW Project: HYWIND

17


Manufacturer

JV WINDAR-IDESA

Year 2017

Client

LocationLocated approximately 45km north of the islands of Borkum, Germany, in the North Sea.

Description66 x TP´s. Manufacturing in Avilés at thefacilicities of Windar and Idesa. Verticalization and outfitting at Aviles port.

Foundation

Weight = 290 Tm

Length = 24,5m

Wall thickness = 90mm

Diameter = 6300 mm

OW Project: MERKUR

18


Manufacturer

JV WINDAR-NAVANTIA

Year 2017

Client

LocationLocated in the North Sea close to the port of Thyborøn.

Description

Demonstration Project developed by SWP using the innovative gravity-jacketfoundation (concrete TP) concept and thenew 7MW turbine

Foundation

• Weight = 150 Tm• Wall thickness = 65mm• Height = 9m • Piles: L= 64m/ W= 89 Tm/ D=1,4m

OW Project: NISSUM BREDNING

19


Manufacturer

JV WINDAR-NAVANTIA

Year 2017-2018

Client

LocationLocated approximately 36 kilometres from the town of Lowestoft, in an area of 209 km2.

DescriptionFoundation by the Joint Venture in Spain.Piles by WINDAR sent by barge directly to destiny.

Foundation

42 jackets (3-leg) + 126 Pin –Piles

Weight = 801 Tm Wall thickness = 85mm Height = 65m Piles: L=58m/W=200Tm/ D=2,5m

OW Project: EAST ANGLIA ONE

20


Manufacturer

JV WINDAR-IDESA

Year 2018-2019

Client

LocationLocated approximately 95 kilometres west of Borkum in the German Exclusive Zone

Description31 TP´s. Manufacturing in Avilés at thefacilicities of Windar and Idesa. Verticalization and outfitting at Aviles port.

Foundation

Weight = 290 Ton

Length = 25m

Wall thickness = 90mm

Diameter = 6.700 mm

OW Project: DEUTSCHE BUCHT

21


Manufacturer

JV NAVANTIA-WINDAR

Year 2018-2019

Client

LocationLocated off the north coast of Portugal some 20 km from Viana do Castelo

DescriptionConstruction of 1 offshore floatingfoundation for a windfarm with three 3foundations cutting-edge wind turbines

Foundation

Foundation lenght: ---

Foundation weight: ---

Max. diameter: ---

Mat. thickness: ---

Material quality: ---

OW Project: WINDFLOAT

22

Photo correspond to WindFloat 1 Demo Project


THANKS FOR YOUR ATTENTION


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EXPERIENCIA Y CASOS DE EXITO - FAEN