Experience with the design, manufacture, test and commercialisation of the REpower 6M turbine UK Offshore Wind Danish Embassy in London 4th of December 2012 Norbert Giese, REpower Systems SE
REpower founded in 2001 as a merger of several companies Denker & Wulf HSW Jacobs bwu 2
From a small company to a global challenger 3.000 2.500 Installed MW Turnover (EUR m) Employees (number) 2,958 2.000 2,097 1.500 1,675 1,304 1.000 1,073 863 500 132 127 142 0 2001 2009/10 2011/12 Denker & Wulf, Jacobs HSW, BWU, pro + pro REpower Systems SE 3
Around 7.2 GW installed across the world...which accounts for ~3% of global installations REpower Global Installations, MW Germany Poland Europe German y 2,248 France 1,365 N. America Canada 66 USA 813 Total 879 Canada USA Belgium & Netherland UK Czech Republic France Portugal & Spain Italy, Austria, Hungary & Switzerland Greece UK 805 Italy 660 Others 712 Total 5,790 China Japan India Australia Asia China 234 Total 149 REpower Source: REpower As of July 2012; Includes all installed and SCADA connected systems; 2. REpower installation from 1987 onwards Japan 118 India 23 Total 375 Australia 4
Offshore? What kind of offshore? Offshore I Offshore II II Offshore III 1. Near to shore, < 20 km, mainly 5-15 km from the nearest harbour 2. Shallow water, < 20 m, mainly 5-15 m water depth 3. Mainly onshore turbines used with 2-3 MW 4. Strong wind regimes 1. Far from shore, more than 20 km, up to 150 km from the nearest harbour 2. Deep water, up to 60 m water depth 3. Real offshore turbines needed 4. Strong or very strong wind regimes 1. Far from shore 2. Very deep water 3. For the time being floating foundations needed 4. Strong or very strong wind regimes
Main data as of 1999 Nominal Nominal rated rated power power 5 5 MW MW Rotordiameter Rotordiameter > > 110 110 m Hub Hub height height > > 85 85 m
DEWI OCC Test Site Cuxhaven 2 x REpower 5M, 117 m hub height - Customer turbine 1: EWE AG - Customer turbine 2: EWC (joint venture of e.on Renewables and Essent) Installed: Nov. 2006 Commissioned: Dec. 2006
Jacket Test Project Bremerhaven 1 x 5M, 120 m hub height Installed: Q1 2008 Jacket 57 m, mass: 340 tonnes Tower 60 m, mass: 200 tonnes
Transport of the Nacelle (Cux) Length: 19 m Width: 6 m Total Height: 6.8 m (incl. Helihoist: 8.5 m) Total Mass: 316 to. Road transport possible in modules of 120 to. and 3.8 m total height maximum
REpower 6M The most efficient Offshore Wind Turbine Rated Power: 6,150 kw Same outer dimensions as the 5M Rotor ø: 126 m Swept Area: 12,469 m² Hub Heights Onshore: Offshore (site specific): Design Onshore: Offshore: 100 m / 117 m 85-95 m IEC IIA (8.5 m/s / 18% turbulence) IEC Ib (10 m/s / 16% turbulence)
REpower Offshore Strategy with Super Turbines Beatrice 2 x 5M (10 MW) Thornton Bank Phase II 6 x 5M (30 MW) alpha ventus 6 x 5M (30 MW) Ormonde 30 x 5M (150 MW) Thornton Bank Phase II II & III III 48 x 6M (295 MW) Nordsee Ost 48 x 6M (295 MW) 2006-2007 2008-2009 2009-2010 2011 2012-2013 2013 11
Track Record and Order Book (as of 14th of September 2012) Turbines installed onshore 9 7 offshore 44 30 Order Book: Firm orders: - 120 Frame work / non binding: - 119
REpower Offshore Production Facilities, Bremerhaven
Thornton Bank - Foundations (fabrication)
alpha ventus Project Shipping of Jackets
Beatrice Project Turbine Installation on Jacket For the first time in the world a fully pre-assembled wind turbine installed offshore - Total lift of 655 tonnes
Ormonde: Installation method with existing jack up barge for 2 sets of 5 MW turbines Jack up barge Seajack built in in 2002, wellrehearsed crew Manitowoc crane M1200, leg length 50 m Well established installation method One nacelle on an outrigger construction 4 tower sections in in upright position with preassembled lifting device
Thornton Bank Wind Farm Key Facts Three Phases: Phase 1: 6 x 5M (2008) Phase 2: 30 x 6M (2012) Phase 3: 18 x 6M (2013) Total Capacity: 325,2 MW Annual production: ~1000 GWh, enough to provide power to 600.000 inhabitants Location 30 km from the Belgian coast line, 12 27 m deep sea Client C-Power
Thornton Bank: Two Jack-Up Barges Transport & Installation Jack-Up: DP2 Jack-Up Platform Neptune Crane: boom length 85m, capacity 600t @ 26m Accomodation Jack-Up: Vagant Neptune transports WTG components from Oostende to Project Site Installation and Mechanical Completion teams stay on Vagant Mechanical Completion continued when Neptune leaves site to pick up next WTG Commissioning from Oostende with CTVs
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