PO.

44

Key learnings from the prototype of 6MW Direct Drive

Daniel Castell, Offshore Wind Platform Director, Alstom
December 2011

Abstract summary
Large scale deployment of offshore wind requires the development of a new
generation of wind turbines that reach new edges in performance, reliability,
adaptation to the environment and maintainability of product. Todays offshore wind
turbines cannot cope with these requirements. OEMs are struggling to develop their
offer as soon as possible to build a track record with the new products. Time to
market is key but having the right product specifications is even more important.
This poster discusses the key aspects that should be considered in order to have the
right product at the right time.

Objective
Give guidance on best practices to develop specific Offshore Wind power generation
equipment.

In order to warrant the right quality in the development of the new product, a
thorough methodology has to be applied. The Product Development Quality (PDQ)
process, used within Alstom, defines the different steps to be followed during the
development of a new product, including the right deliverables that are
progressively revised in the PDQ gate pass committee, attended and approved by
the top management.
Planning of activities and resources is key to achieving the targets on time. A first
work breakdown structure allows to have a clear picture of the dimensions of the
project and a first rough idea of the required resources. Identifying key profiles with
the right know-how and experience is of special importance when going offshore.
A very detailed scheduling of the necessary activities has to be derived from that
initial work breakdown structure.
Work Breakdown Structure

Approach
First relevant aspect is to have the best approach for the turbine specification. In
case of offshore wind the turbine cost itself is representing less than 50% of the total
investments required to set up a wind farm, being 80% for onshore. Consequently,
the approach to the specification of the turbine has to take into account not only the
turbine components but a number of other aspects like substructure, foundation,
electrical infrastructure, installation process and vessels, and O&M.
WTG cost model based on
external data and internal
calculations

Wind

Turbine

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Resource data from internal

wind engineering team

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Foundation model developed

internally (Monopiles/Jackets
Tripods/Gravity Base)

Power curve
Foundation
Availability

Revised electric infrastructure

model, including adjustments
to account for realistic costs
Installation costs based on
real offshore experience and
state-off-the art methods

Electrical
infrastructure

Internally generated power

curves, adjusted to industry
standards
Availability model based on
expected reliability and
accessibility data

Energy Yield
Tariff

Installation

Take into account

market specifics case
by case

Cash in
CAPEX

O&M cost calculation based

on actual market data and
internal forecasts

OPEX



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Results
The result of this project has been the creation of a new generation offshore
turbine: Alstoms Haliade 150-6MW. This is a product that has been developed in
half of the time dedicated to the previous new turbine development in the same
organisation. This is a proof of the great advantage of having a project-driven
organisation involved in such a project.

IRR / LCOE

Applying an integrated approach

This approach will let the designer evaluate the different specification options from
the point of view of the added value for the final customer, leading to the most
competitive solutions in terms of final cost of the energy produced by the specified
wind farm characteristics. This is how Alstom defined its new product for offshore
wind, the Haliade 150 - 6MW offshore turbine.
In order to reduce the time to market it is essential to set up a simultaneous
engineering development process within the organisation designing and developing
the turbine, that guarantees all necessary functions in the organisation are aligned
and sharing the correct information from the start. These teams have to work in
parallel in every aspect of the development such as product design but also supply
chain development, manufacturing process, installation process, serviceability and
HSE. This leads to streamlining the engineering process in a way that final product
and operational processes are prepared in advance to cover all aspects, and costs
are controlled at the right time.

Offshore Project Management



Conclusions

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WT Subsystem Module 1
SET* Leader

WT Subsystem Module 2
SET* Leader

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WT Subsystem Module
SET* Leader

*Structure of project team composed by

SET (Simultaneous Engineering
Teams)

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Market constraints require a significant reduction in the time-to-market for any

new turbine development.
Robust project management procedures have to be applied to achieve the
targets on time.
The Project quality system has to be thoroughly applied to warrant the expected
results.
Wind farm modeling (Systems approach) and planning definition and follow-up
are key to the success of the project.