Lessons Learned from Overseas: Successfully developing offshore wind projects

Numerous studies have already identified the positive benefits of developing offshore wind projects in the United States, which include creating jobs, supplying domestic clean energy, capping extensive peak energy production, as well as reviving the port industry.

One need only look abroad to note many of these advantages in other offshore wind markets. According to the European Offshore Wind Energy Association (www.ewea.org), for instance, 10% of their annual wind energy installations are found offshore, and a total of five gigawatts (GW) have already been installed (as of the end of 2012).

Today, several US offshore projects have reached the planning, permitting, or development stages. Before the first kilowatt-hour (kWh) is produced, however, these projects still have several construction and installation challenges to overcome. For one, there are a limited number of installers in the country with experience in the offshore wind industry; therefore, all activities require personnel recruiting and training. Secondly, no project can be built without the suitable port infrastructure, as well as the necessary installation and service vessels. Finally, a successful, self-sustaining industry needs to have a developed local supply chain.

Workforce development
Addressing the challenges facing an offshore wind industry begins with the people behind the projects. Developing a local workforce is important to stimulate the economy and to reduce the reliance on hiring only foreign workers. The marine industry, onshore wind, and civil construction fields are the prime recruiting fields to facilitate the build-up of qualified offshore wind personnel. However, candidates must be willing to learn the specifics of this young industry. The strongest candidates will recognize that offshore wind development has specific procedures and requirements and, for example, that offshore oil and gas procedures cannot simply be “copied and pasted.” Because of the longevity of wind installations and the longer cost amortization horizon, the offshore industry requires a longer-term, more cost conscious approach.

One way to ensure a local workforce is ready to meet the rigorous demands of offshore construction is to apply a stringent qualification and training process—which relies on leveraging the knowledge and lessons learned from the European experience. Knowledge in design, construction, installation, and commissioning can be transferred, for instance, by pairing experienced European staff with newly hired US staff. European experts can provide guidance through on-the-job training and mentorship, while US team members can learn by actively performing skills and the tasks required.

Practical experience (what has worked, what did not) is a vital pillar in the learning curve. It’s important for installers, developers, and consultants to gain the skills to successfully select a given product based upon not only its concept and design, but also its long-term reliability and performance in the offshore sector.

Harbors and staging areas
Harbors and staging areas are the backbone to wind turbine installation, and are a vital component in each project. Establishing the infrastructure provides business opportunities for local assembly and supply chain providers, as well as management opportunities.

Criteria for a successful future port location include:
1.    Accessibility of next-generation jack-up vessels as used in Europe;
2.    Stable harbor sediment, which can sustain the weight of a jacked-up vessel;
3.    Sufficient quay weight bearing capacity for foundations of 1,000 tons or more;
4.    Ample storage space for blades, towers, and foundations; and, most importantly
5.    Proximity to the wind lease areas. (Proximity is crucial because it greatly influences the travel time to the sites, affecting the overall vessel lease costs of a project.)

Harbor development can take several years, making it critical for ports that want to lead in the US offshore wind sector to begin preparing for future construction projects today. Although development is capital intensive, it’s also quite promising because staging areas can revive a local port industry with near-term and long-term jobs. Esbjerg in Denmark and Bremerhaven in Germany are shining examples for port revitalization, turning areas of former high unemployment into prosperous industry centers.

Vessels
Any crew transfer vessels used for construction, as well as operation and maintenance, must comply with the Jones Act, which restricts the use of foreign flagged vessels in the US. Compared to the oil and gas industry, the wind industry uses smaller, more agile vessels. Shipyards have already reacted to this future industry, and have acquired licenses for UK/EU vessel designs. Since crew transfer vessels have shorter lead times, no constraints are expected for the US offshore wind industry.

The first US projects will likely use a mix of European and US jack-up vessels for foundation and turbine installation, however, as of today, the latter don’t yet exist. When using European vessels, local feeder barges will be used for wind turbine transfers between staging areas and project sites to be compliant with the Jones Act—creating a potential constraint. To have installation capacity available in time, it’s essential that local companies start building US flagged jack-up vessels as soon as possible. Along with fulfilling US vessel legal requirements, such construction would also benefit the shipbuilding industry.

Local supply chain
Creating long-term benefits in offshore wind requires developing and enabling the growth of a local supply chain. Relying on imports from Europe is not a lasting solution. But many suppliers aren’t prepared for the market, failing to fully understand the offshore industry’s specific quality and capacity requirements. All offshore wind projects are for-profit and, therefore, have strict supplier requirements. Local content is important, but only possible if suppliers can competitively meet industry requirements. Industry connections and networking with project developers and manufacturers—particularly those with offshore experience—can build knowledge about the industry’s specifications, along with identifying strengths and areas of concern.

By following these steps and applying some of the major lessons learned from European projects, the US offshore wind industry can avoid costly installation mistakes, accelerating its development to become a mature and vital maritime industry.


Georg Becker-Birck is a mechanical engineer and project manager, serving as a senior consultant and project manager at K2 Management, supporting US clients who are implementing their onshore and offshore wind projects.

K2 Management is an independent wind energy, design, advisory, and consulting company. K2 Management applies experience and practical knowledge to help deliver safe and efficient project solutions for clients in the global onshore and offshore wind industries.

K2 Management, Inc.
www.k2management.eu