ONPManagement ONP Project Experiences 1 21.01.2019
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Developing and building an Offshore Wind Farm from scratchONP Project Experiences
5th Asia Offshore Wind Day - Tokyo
ONPManagement ONP Project Experiences 2 21.01.2019
Speaker and introduction to ONP
Michael BergesArea Manager Asia-PacificBranch Manager Taiwan
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
ONPManagement ONP Project Experiences 3 21.01.2019
ONP Portfolio
ONPManagement ONP Project Experiences 4 21.01.2019
Flawed design impacting the assets' lifetimeFOU-Package – Incorrect Design specifications
ONPManagement ONP Project Experiences 5 21.01.2019
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
ONPManagement ONP Project Experiences 6 21.01.2019
Impact
Flawed design impacting the assets' lifetimeFOU-Package – Incorrect Design specifications
Repair work offshore, costly maintenance during the
operating phase and possibly reducing the durability
of the connection
Type of Contract:Multi-Contracting
ONPManagement ONP Project Experiences 7 21.01.2019
Flawed design impacting the assets' lifetimeFOU-Package – Incorrect Design specifications
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
ONPManagement ONP Project Experiences 8 21.01.2019
Flawed design impacting the assets' lifetimeFOU-Package – Incorrect Design specifications
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
ONPManagement ONP Project Experiences 9 21.01.2019
Positioning of SwitchgearTransition Piece vs. Tower
ONPManagement ONP Project Experiences 10 21.01.2019
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
ONPManagement ONP Project Experiences 11 21.01.2019
Impact
TitleInterfacemanagement – Interacting Contracts
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
ONPManagement ONP Project Experiences 12 21.01.2019
TitleInterfacemanagement – Interacting Contracts
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
ONPManagement ONP Project Experiences 13 21.01.2019
TitleInterfacemanagement – Interacting Contracts
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
ONPManagement ONP Project Experiences 14 21.01.2019
Delays during construction of the windfarmFOU-Package – manufacturing delays
ONPManagement ONP Project Experiences 15 21.01.2019
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
ONPManagement ONP Project Experiences 16 21.01.2019
Delays during construction of the windfarmFOU-Package – manufacturing delays
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
ONPManagement ONP Project Experiences 17 21.01.2019
Delays during construction of the windfarmFOU-Package – manufacturing delays
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
ONPManagement ONP Project Experiences 18 21.01.2019
Delays during construction of the windfarmFOU-Package – manufacturing delays
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
ONPManagement ONP Project Experiences 19 21.01.2019
Leading Edge ErosionWTG-Package – Additional Maintenance Costs
ONPManagement ONP Project Experiences 20 21.01.2019
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
ONPManagement ONP Project Experiences 21 21.01.2019
Impact
Leading Edge ErosionWTG-Package – Additional Maintenance Costs
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
ONPManagement ONP Project Experiences 22 21.01.2019
Leading Edge ErosionWTG-Package – Additional Maintenance Costs
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
ONPManagement ONP Project Experiences 23 21.01.2019
Leading Edge ErosionWTG-Package – Additional Maintenance Costs
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
ONPManagement ONP Project Experiences 24 21.01.2019
Commissioning of WTGs without Grid ConnectionOperation & Maintenance – Mini-Grid-Solution
ONPManagement ONP Project Experiences 25 21.01.2019
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
ONPManagement ONP Project Experiences 26 21.01.2019
Impact
Commissioning of WTGs without Grid ConnectionOperation & Maintenance – Mini-Grid-Solution
Delays in commissioning process and start of
operation; revenue losses
Type of Contract:EPCI
ONPManagement ONP Project Experiences 27 21.01.2019
Commissioning of WTGs without Grid ConnectionOperation & Maintenance – Mini-Grid-Solution
Commissioning concept did not include measures for
establishing a wind-farm internal grid
Root Cause Type of Contract:EPCI
ONPManagement ONP Project Experiences 28 21.01.2019
Commissioning of WTGs without Grid ConnectionOperation & Maintenance – Mini-Grid-Solution
Make allowance for string-wise-commissioning by
applying a mini-grid-solution
Best Practice Type of Contract:EPCI
ONPManagement ONP Project Experiences 29 21.01.2019
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