how to reduce maintenance costs by means of …how to reduce maintenance costs by means of...
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Project supported within the Ocean of Tomorrow call of the
European Commission Seventh Framework Programme
How to reduce maintenance costs by means of innovative lifting solutions? 1st Stakeholders Showcase Event 08/09/2016
Nicolas Degand OWA
Ole Jacob W. Nielsen HighWind
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Service and Maintenance in the Offshore & Wind Industry
A GeoSea company & Member of the DEME Group
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Company Profile
SITE INVESTIGATION RENEWABLES OIL & GAS CIVILS
O W A: Offshore&Wind
Assistance Operation & Maintenace
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Company Profile
Customer
Survey & Inspection Services
Monitoring & Maintenance Management
Maintenance & Repairs
Transportation & Logistics
Major Repairs, Retrofits &
Decommissioning
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Meet the fleet GeoSea
Creating land for the future 5 All rights reserved – © D.E.M.E. NV
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OWA, partner in the LEANWIND project
• Construction, Deployment & Decommissioning
• Novel Vessels & Equipment
• Operation & Maintenance
• Integrated Logistics
• System Integration
• Testing and validation of tools & technologies
• Economic & Market Assessment
• Dissemination and Exploitation
WP1
WP2
WP3
WP4
WP5
WP6
WP7
WP8
WP9
WP10
OWA involved in work packages 2 to 9
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Offshore Wind Challenges & Trends
Size and weight impact
Bigger vessels
Adapted lifting gear
Port infra-structure upgrade
More lifting
capacity + reach
On land transport
limitations Increased waterdepth
impact
Upgraded Installation
Fleet
Improved lifting
equipment
... Transit and
Transfer system
implications
Environ-mental
conditions further
offshore
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O&M Challenges & Trends
• OWF farther from shore: • Focus on remote monitoring • Reduced more efficient site visits
• Larger projects: • Economies of scale • Reduced risk adversity
• Larger turbines: • Higher downtime costs • Heavier components • More capable O&M vessels
• Higher availability: • Technology Innovation • Expected increased reliability
• Deeper waters • Floating solutions being developed • Need for larger jack-ups
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O&M Cost breakdown and cost levers
OWA’s fleet and marine experience well positioned to optimize Logistics
Jackups and innovative technologies to
optimize major correctives
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Novel Lifting Equipment some examples
Liftra Blade Dragon
IHC Boom Based Blade Manipulator
Siemens B75 Lifting Yoke
Ravestein Maintenance tower
HighWind Boom Lock
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Boom Lock System Al
l rig
hts
rese
rved
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Hig
h W
ind
NV
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Turbine installation, a seasonal activity?
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Turbines have grown fast
Giant leaps are being made in turbine & blade development
Blade size has grown from 45 to 90 meter – Single blade installation is standard A solution is needed to uphold current workability limits
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Lifting operations: analysis
Load is free to move
Wind is variable in direction and magnitude
Object orientation cannot be changed in all directions while installing
Installation requires careful communication, continuous iteration & correction & a lot of experience
Increasing controllability results in: DECREASED DOWNTIME DECREASED RISK OF DAMAGE INCREASED SAFETY
Wind Sensitivity vs. Controllability
Z X Y
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Downtime due to lifting: is it worth anything?
Souce: BVG Associates
Improvements in jack-up vessels have pushed weather down-time back to the lifting operation
80-90% of Weather Downtime now relates to lifting operations
As much as 23,7% time can be saved during Summer installation
As much as 32,3% time can be saved during Winter installation
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The weakest link: lifting operations
• Weather downtime and installation risk is under pressure • Installation tools and methods remain sensitive to wind and crane motions • A NEW FUTURE PROOF SOLUTION IS REQUIRED
Less transport time per vessel
Optimised vessel lay-out
Weather forecasting Optimised supply chain Adapted harbour infrastructure
Wave-resistant vessels
Waiting on weather due to high wind speeds
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Finding a solution: The High Wind ‘Robot’
6 Degree of freedom control is required
Needs to work with all components
Low impact on vessel capabilities
Make use of experience built up
Low threshold for implementation and operation
CONCEPT???
Target
Safer
More control
Less Downtime
How to ‘robotize’ WTG installation?
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• Improved stability & control
• All turbine components and parts
• Works with any lifting tool
• Easy to operate
• Short installation time
• No hinder to non-WTG operations
“Boom Lock” concept
The Boom Lock is a tool that allows an offshore crane to install WTG components in high wind speeds
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• Large heavy objects with large inertia make will not stop moving.
• Actions of the crane cause unwanted and potentially dangerous motion of crane and load
BOOM LOCK SYSTEM BRINGS MAJOR BENEFITS FOR ALL TURBINE COMPONENTS
The “Boom Lock” All turbine components and parts, all turbines
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• 15 x 3.3 MW V112 turbines
• 45 x blades + 15 nacelles
• Vattenfall, MHI Vestas and GeoSea joined hands in supporting this new technology
• High Wind provided training, support and data logging
Installation of turbines at Kentish Flats
First project finalized
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• The Boom Lock lived up to its expectations (however limited to <12 m/s due to the blade yoke design)
• Proven to be technically reliable
• Increased safety for installation
• New technology was adopted fast
NEXT STEPS
Simulations of larger blades sizes in higher wind speeds
Offshore trails with new blade yoke designs
Successful first project finalized
Kentish Flats: conclusions
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Thank you very much for your attention
QUESTIONS?