Retooling for Wind Onshore to Offshore -- SECWC March 8-9, 2012 Patrick Fullenkamp Director, Technical Services
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1 Retooling for Wind Onshore to Offshore -- SECWC March 8-9, 2012 Patrick Fullenkamp Director, Technical Services
2 Agenda Manufacturing Workshop March 8, 1:30 3:00 1:30 Offshore/Onshore Wind Business Opportunities for Manufacturers in Southeast Region and Global Trends Driving Market Demand for Key Components Patrick Fullenkamp, GLWN 2:15 Gamesa Offshore Wind Turbine Project Dan Renshaw March 9, 8:30 10:00 8:30 Offshore/Onshore Wind Supply Chain Structure, How to get engaged Ed Weston, GLWN 9:15 Round Table Discussions: What are manufacturers needs and concerns to prepare for this new Offshore Business? Wind Turbine OEM Gamesa, Dan Renshaw Offshore Developer APEX Offshore Wind, Tim Ryan Engineering SAIC, Neil Rondorf Vessels Stevens Towing, Benjamin Smith Electrical Infrastructure ABB, Tom Weinandy at Baldor Industry Heavy Fabrication
3 Onshore History Topics to be covered Update on What s Happening Now Description of Forces and Major Players Offshore OEM and Manufacturing Drivers Offshore vs Onshore Opportunities: Ports, Foundations, Vessels, Turbines USA Offshore Project Summary SE Region Offshore Projects How to maximize US SE Regional Supply Chain
4 GLWN Call us Global Membership-based, Non-Profit International Supply Chain Advisory Group 1600 companies across 35 States + Canada Supplier Headhunters for the Wind Industry Resource for Suppliers and Service Providers Mission: -Localize New Business Opportunities -Increase the Domestic Content of North America s Wind Turbines
5 Wind Turbines: An American Invention Charles Brush Cleveland, OH 12 Kilowatts 1888 NASA Oahu, HI 3.2 Megawatts 1980
6 People Want Windpower Total Installed Global Capacity 200, , , , , ,000 80,000 60,000 40,000 20, Source: GWEC
7 US and China Lead World New Installed Capacity (2011) MW % China 18, USA 6, India 3, Germany 2, UK 1, Canada 1, Spain 1, Italy France Sweden Rest of the World 5, World Total 41, Cumulative Capacity (2011) MW % China 62, USA 46, Germany 29, Spain 21, India 16, France 6, Italy 6, UK 6, Canada 5, Portugal 4, Rest of the World 32, World Total 238, Source:GWEC
8 How much is 6.81 Gigawatts? 6,810 MW or 6,810,000 kw 1.8 million homes OE Parts for 3,680 Turbines $4,750,000,000 New Towers $ 1,287,000,000 Gears, Shafts $ 257,000,000 Fabricated Frames $ 44,000,000 Roll-threaded studs $ 37,000,000 Balance of Plant Cubic Yds Concrete 1,080,000 Pounds of Rebar 204,000,000
9 U.S. 20% Wind Scenario 305,000 MW Installed Capacity as of Dec 30, ,919 MW Source: US DOE: 20% by 2030
10 Domestic Content of America s Turbines / 2010 Domestically Mfg Components Inported Components Domestically Mfg Components Inported Components ~25% domestic components ~2,500 MW installed ~50% domestic components ~10,000 / 5,000 MW installed
11 State Renewable Energy Standards *WA: 15% by 2020 OR: 25% by 2025 (large utilities) 5% - 10% by 2025 (smaller utilities) ND: 10% by 2015 MT: 15% by 2015 MN: 25% by 2025 (Xcel: 30% by 2020) VT: RE meets load growth by 2012 WI: requirement varies by utility; 10% by 2015 goal ME: 10% by 2017 NH: 23.8% in 2025 MA: 4% by % annual increase RI: 16% by 2020 CA: 20% by 2010 *NV: 20% by 2015 AZ: 15% by 2025 CO: 20% by 2020 NM: 20% by 2020 (IOUs) 10% by 2020 (co-ops) IA: 105 MW KS: 20% by 2020 IL: 25% by 2025 MO: 15% by 2021 NC: 12.5% by 2021 (IOUs) 10% by 2018 (co-ops & munis) CT: 23% by 2020 NY: 24% by 2013 NJ: 22.5% by 2021 PA: 18%¹ by 2020 MD: 9.5% in 2022 *DE: 20% by 2019 DC: 11% by 2022 *VA: 12% by 2022 HI: 20% by 2020 TX: 5,880 MW by 2015 State RPS State Goal
12 Turbines, Towers, and Blades
13 NA Mfgs Operating Today Wind Turbine OEMs General Electric Gamesa Clipper Windpower Acciona DeWind Nordic Windpower Northern Power Vestas Nordex Aeronautica Windpower
14 What s Exciting? New Assembly Plants Siemens Kansas, 600 turbines/yr Nordex Arkansas, 300 turbines/yr Vestas Colorado, 1,400 turbines/yr Aeronautica Windpower New Hampshire
15 WTG OEMs on the Way Alstom : Amarillo, TX Mitsubishi: Ft. Smith, AR Fuhrlander (Germany) Kenersys (Germany) M. Torres (Spain) REpower (Germany) Areva (Germany) Hyundai (Korea) Sinovel (China) Goldwind (China) Mingyang (China)
16 Towers Facilities Trinity Structural Towers (Clinton IL; Tulsa, OK ) SIAG Aerisyn (Chattanooga, TN) Ventower (Monroe, MI) Thomas & Betts (Memphis, TN) Tower Tech (Manitowoc, WI, Abilene, TX) Katana Summit (Columbus, NE) DMI (West Fargo, ND; Tulsa, OK, Ft. Erie, ON) Dragon Wind (Lamar, CO) Vestas (Windsor, CO) SMI & Hydraulics (Porter, MN) Ameron (Rancho Cucamonga, CA) Ventower (Monroe, MI)
17 Blades Operations Suzlon (Pipestone, MN) LM Windpower (Grand Forks, ND; Little Rock, AR) Siemens (Fort Madison, IA) Gamesa (Ebensburg, PA) Molded Fiberglass (Gainesville, TX, Aberdeen, SD) TPI Composites (Newton, IA) Vestas (Brighton, CO) Nordex (Jonesboro, AR) Energy Composites Corp (Wisconsin Rapids, WI)
18 Gearbox OEMs Winergy Drive Systems (Elgin, IL) GE Transportation (Erie, PA) Clipper Windpower (Cedar Rapids, IA) Z-F (Gainesville, GA) Brevini (Muncie, IN) Moventas (Faribault, MN) Bosch-Rexroth (TBD)
19 Driving Forces in Wind Utilities Demand for Electricity Financing RES Grid Availability Developers Wind Turbine Mfgs Wind Resources Direct Integrators
20 Off-Shore Wind DOE Strategy DOE Offshore Wind Innovation and Demonstration (OSWind) Program: Off-shore Projected Cost: Must be cut by 50% Strategies: Technology Development: Applied Research to Reduce Inputs Reduce Wind Deployment Timeline: Thru Resource Planning, etc. Advanced Technology Demonstration: $90M Fed Funds Allocated USDOE National Offshore Wind Strategy, February 2011
21 Coastal vs. Inland State Electricity Pricing $ $0.09 /KWh USDOE National Offshore Wind Strategy, February 2011
22 Offshore Section Topics European Ports European Foundations European Vessels USA Math to 54 GW and Wind Potential USA Offshore Project Summary SE Region Wind Potential
23 Europe Offshore Wind Cumulative 2010 : 2,946 MW, 1,136 Wind Turbines Thru July 2011 added 101 Turbines 348 MW
24 Offshore Goals Europe 55 GW by 2020, 3.2 GW in 2011 Europe 150 GW by 2030 USA 10 GW by 2020, 0 GW in 2011 USA 54 GW by 2030
25 Onshore vs Offshore CAPEX Source: MAKE Consulting
26 Wind Turbine Size Courtesy - AWEA
27 Key European Ports U.K. - Harwich International Port and Ramsgate Netherlands Vlissingen Germany - Bremerhaven and Cuxhaven France - Dunkirk General rule WT Units/yr/ Port
28 Cuxhaven Germany Offshore 2010 Laydown Area
29 Cuxhaven Germany Lay Down Yard 2011 and Port Vessel Loading 200M Initial Investment 350M Future Investment 4,500 jobs in 5 yrs ~150 units/yr Towers (Dia. 6-7m, L 30-40m 150 ton / section)
30 Germany 25 GW Offshore by 2030 Footprint Example for USA Port 3 to 4 Offshore Wind Energy Ports in North Sea (service 200 sea mile radius from port) 300 Wind Turbines Annually in North Sea Projects complete units (foundation structures, towers, nacelles, hubs, and rotor blades) a year via the Offshore Terminal Bremerhaven (OTB) Bremerhaven has 200 hectares for further manufacturing and supplier production facilities OTB (Offshore Terminal Bremerhaven) Technical Data PURPOSE Handling, pre-assembly and storage of offshore wind turbines; exporting of components; logistics centre for the transportation / transshipment of large industrial components OPERATING TIME -24 hours a day, 365 days a year TARGET UP to 160 wind turbines and foundation structures of wind farms per season QUAY LENGTH 500m NAVIGABLE DEPTH 14.5m HEAVY DUTY SLAB AT THE QUAY 70m wide, 500m in Length TERMINAL DEPTH 498m AREA approx 25 hectares (2.48 acres or 1.86 football fields per hectare ) CAPACITY 160 units per season
31 OTB-Offshore Terminal Bremerhaven Primary Port for Alpha Ventus Wind Farm AREVA & REpower Turbine Assembly 100 units per year WesserWind GmbH Foundations Power Blades GmbH- Blades Plus 200 hectares for other manufacturers and suppliers
32 Offshore Foundation Types Monopile t Gravity Base 6000 t Jackets 550 t Tripods 950 t Tripiles 490 t Floaters 1000 t - Upright - Spar Mass 1X 2X 3X 4X
33 WesserWind GmbH Tripods & Jackets L/W/H up to 32/32/60 m 950 ton
34 CSC Cuxhaven Steel Construction Monopiles Tripiles
35 Offshore Gravity Test Foundation 40m x 40m legs x 8m ht 1m wall Thickness 65m tower height 6000 t with base & tower 900 wheel transport unit plant to dock loading area Side load cyclic testing on tower above Base testing in standing water right
36 Gravity Foundation Source: Strabag Images U-shaped Transport Vessel 160m long x 65m wide
37 Offshore Assembly Source: Nordex SE
38 Vessels Transport Vessels Foundations, Towers, Blades, Nacelle Installation Vessels: Jack-up or Regular ton, 2000 ton payload - 93m L, 36m W, 7m D Crew Transport Vessels 670 Vessels Worldwide, 32 crossover to Wind (ODS Pertrodata) -10 Turbine Installation (4 in O&G) -12 Foundation Install. (5 in O&G) - 10 Turbine and Foundation Installation with no cross-over
39 Offshore Assembly Size effects for scale up from 2 to 5 MW: Wind turbine dimensions 150% Foundation weights up to 400% New installation sites: Water depth increase 300% From sand to inhomogeneous, layered soil
40 Wind Farm Construction Offshore Wind Turbines Foundations Monopile, Tripile, Floating Vessels Transport, Assembly, Crew Transport Electrical Infrastructure Cable, Transformers-Substations
41 5 MW Blade Production Germany 5 MW Turbine Blade 56.5 m length 16 ton 4800 kg resin ~$25 / kg resin Lightning Protection 1 Blade per day 80 people
42 Simple Math: All 5MW Units-54 GW 10,000 MW by ,500 MW / Yr MW units / Yr 3+ WT / Port 44,000 MW by ,400 MW / Yr MW units / Yr 6 WT / Port
43 Offshore Wind Where is the Wind?
44 Off-Shore Wind Potential Mid-Atlantic States USDOE National Offshore Wind Strategy, February 2011
45 Offshore Wind Resource & Farms Virginia Chesapeake Bay Test Site, 5MW, Gamesa Hampton Roads Offshore Wind Project, 15 MW 3 T, APEX Wind Energy Seawind, 800MW 240T, Seawind Renewable Energy North Carolina APEX Offshore Wind VA, 1,500MW APEX Offshore Wind North Carolina, Phase 1: 600MW 165T Phase 2: 1,300MW 360T Outer Banks Ocean Energy Corp South Carolina Palmetto Wind Research Project, 80MW, SC Energy Office, Coastal Carolina Univ, Santee Cooper
46 Off-Shore Wind - Status Currently 45+ Active Wind Farms: Denmark, Belgium, China, Sweden, Finland, Germany, UK, the Netherlands, Norway, and Ireland US projects under development (26+ Active) partial list: Cape Wind (420MW) Mass. Nantucket Sound Garden State Offshore Energy (345MW) Atlantic City Delaware Wind Project (450 MW) Delaware Coast Block Island Wind Farm (29 MW) Rhode Island Coast APEX Offshore Wind Virginia (1500 MW) Gamesa Chesapeake Test Site (5MW) Hampton Roads Demonstration Project Virginia (15 MW) APEX Offshore Wind North Carolina (1900 MW)
47 Offshore Wind Supply Chain Opportunities for SE Region DOE Goal 54 GW by 2030 = 10,800 Units if all are 5 MW Logistic & Port Infrastructure Impact Foundations - fabrication-machining-coatings Towers fabrication-forging-machining-coatings Blades composites-processing-machining Support Bases and Hubs casting/fabrication-machiningcoatings Vessels fabrication-casting-forging-machiningelectrical-hydraulics-coatings Cable & Substation all major manufacturing sectors
48 What should states be working on together - optimizing supply chain? Goal Lowest Cost Of Energy Utilizing & Share most efficient existing resources Ports Shipyard vessel manufacture Large Tower and Monopile Manufacture Foundation Manufacture Best Laydown Areas to serve Multiple Wind Farms Manufacturing Parks for Foundations, Towers, Blades and Nacelle Assembly Port Brownfield sites
49 THANK YOU! Patrick Fullenkamp Director, Technical Services, GLWN
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