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Developing and building an Offshore Wind Farm from scratchONP Project Experiences

5th Asia Offshore Wind Day - Tokyo


Speaker and introduction to ONP

Michael BergesArea Manager Asia-PacificBranch Manager Taiwan

[email protected]

ONP Management GmbH • Founded 2014

• TW-Branch est. 2018

• Employees: 28

• Technical advisory office focusing

on offshore wind

• Headquarter: Hamburg (Germany)

Our success stories

• Owner's Engineer for 600 MW Haixia OWF (TW)

• FEED-Study for BoE-Selection report of Haixia OWF (TW)

• Technical assessment and evaluation of Chu Feng OWF (TW)

• Project Management for 396 MW Merkur OWF (GER)

• Facilitating Financial Close (EUR 1.6b) for Merkur OWF

(GER)

• Preparing Arcadis Ost 1 OWF for 1st German auction

• Talanx Asset Management chose ONP as Lender's Technical

Advisor for two German OWFs


ONP Portfolio


Flawed design impacting the assets' lifetimeFOU-Package – Incorrect Design specifications



Impairment of the functionality and durability of the

bolted flange connection between monopile and

transition piece as well as difficulties during the

installation

Issue Type of Contract：Multi-Contracting


Impact


Repair work offshore, costly maintenance during the

operating phase and possibly reducing the durability

of the connection

Type of Contract：Multi-Contracting



Incorrect design specifications (e.g., location of the

flange connection), insufficient manufacturing

requirements (e.g. bolt specification, tolerances) and

insufficient interface management

Root Cause Type of Contract：Multi-Contracting



Choice of a robust design (e.g. flange connection to be

located under controlled environmental conditions);

clear description of the design, manufacturing and

installation requirements as well as the interfaces;

functioning interface management during all project

phases; check whether all requirements from

operation, production and installation have been

implemented in the design; check whether the design

is implemented in the fabrication and installation

methodology

Best Practice Type of Contract：Multi-Contracting


Positioning of SwitchgearTransition Piece vs. Tower


TitleInterfacemanagement – Interacting Contracts

Re-positioning of switchgear from tower base to

transition piece during detailed design of support

structure.

Issue Type of Contract：Type of Contract：BoP-EPCI, TSA-EPCI


Impact


During detailed design of the support structure (TP) a

complete new platform arrangement was required

with interactions to different work packages

(Foundation, Inner Array Cable, WTG‘s). Scope of

work and interfaces had to be re-assessed and

negotiated in a short time period to met project

schedule. Delivery schedule of switchgear had to be

aligend with TP manufacturing process.

Type of Contract：BoP-EPCI, TSA-EPCI



During the detailed design phase of the support

structure, the installation and final commissioning of

inner array cables with diameters of up to 630mm²

with planned junction boxes were questioned.

Root Cause Type of Contract：Type of Contract：BoP-EPCI, TSA-EPCI



Make sure that all project details are aligend between

the Contractors and wind farm commissioning

strategy is established prior to start of detailed

design.

Best Practice Type of Contract：Type of Contract：BoP-EPCI, TSA-EPCI

DESIGNDESIGN

Access ladders

Fabrication

Welding requirements

Installation

Steel grades

Monitoring

Primary structure

LogisticsLoad-Area

Servicec-Cane

Mounting devices

Ventilation

Cable guiding

HSE

Coating

Secondarystructure

O&M

Collision beaviour

Grouted connection

Geotechnics

Corrosion protection system

Earthing Seamarking

Sonartransponder


Delays during construction of the windfarmFOU-Package – manufacturing delays



Manufacturing process of one part of the foundation

system was massively delayed with additional quality

issues

Type of Contract：EPCIIssue



Project schedule had to be adjusted; installation

during winter season necessary; time and cost overrun

in FOU-Package of EPCI-Contractor; Project had to

invest additional money in order to secure the

continuation of manufacturing process

Type of Contract：EPCIImpact



Manufacturing surveillance incl. QA/QC not dilligent

enough; Manufacturer was not sufficiently familar

with the contractually agreed codes and standards;

only one manufacturer chosen without backup-option

Type of Contract：EPCIRoot Cause



Contractual obligation for manufacturing surveillance

is enforceable; key components are sourced from at

least two manufacturers; Employer's Requirements

need to be as functional as possible and as stringent

as necessary; "instructions" are a valid tool to ensure

progress and quality

Type of Contract：EPCIBest Practice


Leading Edge ErosionWTG-Package – Additional Maintenance Costs



Rain, hail, ice, UV and other weather conditions erode

the leading edge on the turbine blade especially at the

tip of the blade, were speeds up to 330km/h are being

achieved and raindrops or hailstones create multiple

shock wave impacts on the blade surface.

Issue Type of Contract：SMA, TSA


Impact


The WTG manufacturer applies a protection foil with

defined design lifetime of 5 years. At the current state

of the art typical market costs for leading edge erosion

campaigns are approx. 80k€ per WTG. Such campaign

need to be driven reactively several time during the

WTG design lifetime depending on the blade condition.

Such costs were not expected and are born by the

project company.

Type of Contract：SMA, TSA



The WTG SMA contract is not clearly defined in terms of

leading edge erosion, wear and tear is specifically excluded in

the SMA.

Root Cause Type of Contract：SMA, TSA



Define explicitly in the SMA, that any costs caused by

leading edge erosion are included in the SMA fee.

Better define explicitly in the TSA that the turbine

supplier is responsible for any leading edge erosion

damage during the total design lifetime of the turbine.

Best Practice Type of Contract：SMA, TSA


Commissioning of WTGs without Grid ConnectionOperation & Maintenance – Mini-Grid-Solution



"Hot" Commissioning of wind farm only possible after

(external) grid connection available

Issue Type of Contract：EPCI


Impact


Delays in commissioning process and start of

operation; revenue losses

Type of Contract：EPCI



Commissioning concept did not include measures for

establishing a wind-farm internal grid

Root Cause Type of Contract：EPCI



Make allowance for string-wise-commissioning by

applying a mini-grid-solution

Best Practice Type of Contract：EPCI


ONP Management GmbH | Member of Zech Group | Veritaskai 3 | 21079 Hamburg | Germanywww.onp-management.com

Michael Berges Area Manager Asia-PacificBranch Manager Taiwancph +49 172 513 [email protected]

TURNING VISION INTO POWER

ONP Management GmbH

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ONP Development Engineering Value Management · 2019. 2. 8. · ONP Management ONP Project Experiences 1 21.01.2019 ONP Management Development Engineering Value This is a confidential