165 MW Nysted Offshore Wind Farm.

First year of operation - performance as planned.

P. Volund, P. H. Pedersen and P. E. Ter-Borch.
ENERGI E2, Denmark
Email: pvl@E2.dk
Abstract
Nysted Offshore Wind Farm was installed during 2003 and commissioned in December 2003. It consists of 72 wind
turbines each of 2.3 MW, corresponding to a total of 165.6 MW installed power, which presently makes it the largest
offshore wind farm of the world.
The project was implemented on schedule and on budget by ENERGI E2 as operator. Ownership is shared between
ENERGI E2, DONG and Sydkraft.
The story of the first year of operation of Nysted Offshore Wind Farm is a story of very high availability, very high
accessibility, well working boat landing, few turbine calls for manual intervention and production as predicted. It is
all documented in this paper. The reported extent of remedy of defects witnesses room for improvement without
disturbing the picture of success of the project.
This report on the first year of operation of Nysted Offshore Wind Farm is a report of performance as planned and a
proof of success for the technology.

Figure 1 Nysted 165.6 MW offshore wind farm installed 2003.

1. Introduction
Nysted Offshore Wind Farm with 165.6 MW capacity has now been in operation for a year in the western part of the
Baltic Sea south of Denmark, see
Figure 1. It is the worlds largest offshore wind farm and results from the first year of operation have been waited with
much anxiety by many involved in offshore wind activities.
The plant makes part of the Danish offshore wind demonstration programme, and it is to contribute considerably to
establishing a much needed confidence in the new technology. Environmental issues have been and are still being
investigated carefully, and few problems have been encountered. Noteworthy is that positive as well as negative
effects are experienced.
Installation was completed within budget, and final commissioning did as planned take place 1 December 2003, and
proved that large scale offshore wind farms can be implemented on schedule and on budget, which is a major success
of the project [1].
The first operation and maintenance (O&M) experiences are reported in the following.

PROJECT HISTORY

2.1 Back-ground
The project has been under way for almost 10 years, and is one of two Danish demonstration offshore wind farms
the other is the Horns Reef project. A number of environmental research projects follow the project and delivers a lot
of precious information [2].
The wind farm is situated in the western part of the Baltic Sea, south of the Danish island Lolland, see Figure 2.
A 2.3 MW stall controlled Bonus turbine is used. It is a turbine much like the 2 MW Bonus turbine of the E2
Offshore Wind Farm at Middelgrunden. The stall control is the Bonus Combistall, which pitches the full length of all
blades for control of power-output. Concrete gravity foundations from Danish contractor Aarsleff is also a wellknown technology. 33 kV pex cables excavated 1 m into the sea bed is used internally in the wind farm, and to shore
the transmission company decided to use a 132 kV pex cable.

Figure 2 Nysted Offshore Wind Farm situated south of Lolland close to Germany.
Nysted Offshore Wind Farm is owned by a consortium of three energy-companies: Danish based ENERGI E2 and
DONG as well as the Swedish Sydkraft. All are involved in wind projects elsewhere, and plan to expand their
offshore activities. E2 is the largest investor and the operator.
2.2 Planning and Installation
The project is based on the full range of E2 competences gained through sixty years of power plant implementation
and 15 years of offshore wind implementation in Denmark. Vindeby in 1991, Middelgrunden in 2000 and Samsoe in
2002 are some important offshore wind references. E2 took the contract coordination risk and know-how injection
possibility by holding separate contracts on turbines, foundations, internal cabling and SCADA using the E2 multicontract concept. The result is a project in the frontline of the technological development with few problems and full
exploitation of the lower cost of the newest technology.
Offshore works on foundations, see Figure 3, and main cabling were initiated in the year before turbine installations
to reduce risk of delayed turbine works. In June 2002 Aarsleff initiated excavation works for the foundations and by
end of the year a third of the concrete constructions were in place offshore ready for ballast and erosion protection.
In the end foundation works were finished one month early and enabled also one month early finish of turbine
installations and end of turbine commissioning. Main cable to shore was installed in October 2002. The offshore
transformer platform was the bottle-neck of the project plan, but was ready just in time by mid May 2003.
The working method of E2 includes intense design-review participation and intense installation supervision. At
project peek 50 E2 representatives were busy in the project following foundations, turbines and cables. Close
cooperation between E2 and contractors enabled prevention of many problems, and is a key element behind the
eventual success.

Figure 3 Installation of Aarsleffs ballasted concrete gravity foundation with Eide Barge 5 from June 2002 to
July 2003.
Half the foundations were commissioned by Aarsleff, when A2SEA started installing turbines for Bonus by 9th of
May. Within 79 very busy days including weather delays the 72 turbines were installed without major problems,
see Figure 4. Aarsleff finished foundation works and ABB connected cables simultaneously to enable smooth gridconnection of the turbines in packages of 4 to 9 turbines. The first turbine started running by mid July and all were
operational by mid September. Bonus worked hard and final commissioning of turbines by 1 December was one
month early compared to original schedule.

Figure 4 Turbine erection in Nysted Offshore Wind Farm May-July 2003.

2.3 Economic Result
Installation was carried out within the budget of 245 mill. Euro corresponding to 1.5 mill. Euro per MW [1].

3 O&M
3.1 General O&M setup
The small ferry harbour Gedser is used as base for the service works. A 5 year service contract was signed with
Bonus as part of the turbine contract, but a locally stationed E2-crew participates in the daily maintenance by Bonus.
Presently the E2-crew consists of 3 persons, but it will gradually be expanded and replace Bonus-staff to enable a
smooth out-phasing of Bonus after 5 years. They also cover foundation and cable service as well as boat service that
E2 delivers to Bonus and others. A small service boat of 12 persons is hired, and supposedly should be sufficient for
most needs. In practice remedy of defects and finishing of outstanding works have necessitated the use of one and at
times two more small crew boats as well as small crane vessels. E2 has taken a wait and see attitude towards the long
term need for service boats.
3.2 Remedy of Defects
As the availability results of Chapter 4 indicate few problems and outstanding works have had to be completed after
commissioning. The overall picture is satisfying with few outstanding works at final commissioning and moderate
need for remedy of defects, and in addition a pleasing O&M situation.
Two gearbox-bearings have in one working operation been replaced in all turbines. One is a high speed shaft bearing,
the other an intermediate speed shaft bearing. The condition monitoring system reported increased vibration levels
and thus forecasted problems. The gearbox-design was prepared for easy change of the two mentioned bearings, and
it was decided to replace them in all turbines before breakdowns started costing serious availability loss. During July
to mid October 2004 the change was carried out by means of the nacelle crane. The availability lost during the change
of bearings was in average 48 hours per turbine at times of limited wind. A show-case that proves how a potentially
very costly problem can be reduced to a small routine job if properly prepared for in design.
The lightening protection system has worked almost perfectly. 3 strike-receptors per blade have caught all 10
lightening strokes so far, and no damage has occurred. The tip-receptor hit by the strongest current so far is shown in
Figure 5, which looks dramatic, but where only a minor repair will be necessary primarily of the paint.

Figure 5 Photo of the tip receptor hit by the strongest of 10 lightening strikes during the first year of operation
at Nysted. Visually dramatic, but little but paint has to be repaired.
3.3 Turbine calls necessitating O&M-crew visits in turbines
A realistic estimation of how often action is needed in the turbines is difficult on a purely theoretical basis. The
general expectation is shown in Figure 6: a higher level of calls during the first 2 years followed by the planned low
level of problems and then after year 10 a rising number of problems until end of turbine lifetime. The experience so
far suggests that this will be the pattern and that the stable low level will be 2 visits per turbine per year.

N o o f V i si t s

Y ear
0

10

12

14

16

18

20

Figure 6 Expected number of turbine calls necessitating manual action.

3.4

Scheduled Service

One annual scheduled service operation per turbine is planned, and the work is presently ongoing. A crew of 3persons carries as planned the scheduled service out within one working week. During the present first annual service
operation Bonus also carries out some other changes of which the above mentioned bearing change is the most
significant. The scheduled service takes place, when access is possible, at low wind speeds.
4

AVAILABILITY

4.1 Weather caused loss of offshore working days

At severe wave conditions access to offshore turbines is impossible, and much time is spend in imagining how the
statistical situation will be in practice. We now have one year of practical experience from Nysted, which shows that
real world satisfies our expectations fairly. Boat-landing is possible at wave heights up to Hs=1.2m. The statistical
wave picture for Hs=1.0m in an average year is shown in Figure 7.
During the period November 2003 to May 2004 the number of days of reported non-accessibility has been 3-7 per
month, which corresponds well with expectations based on the data behind Figure 7. The accessibility expectations
that make part of the budgeted availability are thus in agreement with the reports from the first months of operation.

Working Days at Nysted

% of time Hs<1m

100
90
80
70
60
50
40
30
20
10
0

Month
1

10

11

12

Figure 7 Expected % of time that wave height exceeds height Hs=1m in an average year.
4.2 Boat-landing
The boat-landing system determines accessibility and is a major determinant for the availability. The system used at
Nysted is based on the need for a cone to break heavy drifting ice flakes as can be seen in Figure 8. The outer upper
periphery of the cone is continued vertically upwards to the wanted platform level 3.5 m above mean sea level. This
level is above maximum wave crest at situations of safe boat landing. At severer conditions waves wash the platform

and splashes the door. The low platform level makes access easier, quicker and safer and is according to the O&Mcrew a major advantage of the Nysted Offshore Wind Farm. Access is possible from all directions around the turbine.
The concept was also used at Middelgrunden and the present success was thus expected. An example of boat-landing
is shown in Figure 8.

Figure 8 Boatlanding at Nysted.

4.3 Turbine availability
Turbine availability is the percentage of time the turbines of the wind farm are ready to produce, if wind is reasonable
and grid is available.
Figure 9 shows the joint availability of the 72 turbines, though for July-September the availability only covers the
number of turbines already having been in operation. It should be noted that the first turbine started production 12
July, and the last turbine came in production 12 September 2003. The average turbine availability is 97% for the
period December-July, and 91.5% for the commissioning period of July-November 2003. An improvement is seen
over the commissioning period, whereas availability seems fairly constant over the period after commissioning,
ranging from 96% in March to 98.5% in April.
100

97 %

90
80
70
60
50
40
30
20
10
0
jul

aug

sep

okt

nov

dec

jan

feb

mar

april

may

june

july

Figure 9 Turbine Availability. Final commissioning took place 1 December 2003.

For comparison it can be mentioned that onshore wind farms with availability of 98-99% after commissioning are
state of the art, and that most public presentations for offshore wind farms assume availabilities of 92 to 95% for the
first year after commissioning. So availability has definitely been fine during the first year of operation.

4.4

Farm Availability

Farm Availability is the average percentage of available wind farm power, i.e. the product of turbine availability and
grid availability.
Figure 10 shows the wind farm availability during the period that turbines have been in operation. Obviously the
wind farm availability is lower than the turbine availability, as shown in Figure 9. The average farm availability is
96% for the period after commissioning, and considerably lower for the period before commissioning.
The grid-caused availability loss after commissioning is around 1%.
100
%

96 %

90

80

70

60

50

40

30

20

10

0
aug

sep

okt

nov

dec

jan

feb

mar

apr

maj

jun

jul

Figure 10 Wind Farm Availability - covering turbine availability as well as grid availability.
5

PRODUCTION

Production of the complete wind farm is shown in Figure 11. The wind resource in the period has been considerably
lower than expected for an average year, which of course can be seen on the balance sheet of the project, but proves
little about the technology. The production fits predictions based on the actual wind resource during the period.
Production (GWh)

Realised

60,0
50,0
40,0
30,0
20,0
10,0
0,0
Januar

Februar

Marts

April

Maj

Juni

Juli

August

September

Oktober

November

December

Figure 11 Monthly Wind Farm Production in 2004.

6

Multicontracting the reason why plans were realised

E2s philosophy of multi-contracting was used at Nysted. E2 signed separate contracts of turbines, foundations,
internal grid and SCADA each covering design, construction and installation. The setup enabled direct contact
between E2 and contractors.
Part of the philosophy is to enable the involvement of E2s experience and know-how in all phases. Sufficient time
for all key parts of the project process is a core element in the eventual success of multi-contracting. For Nysted much
time was spend on the preparations before tender was send out. This meant a thoroughly worked through tender
material including geotechnical investigations, wind and wave measurements and DNV-approved combined wind-

and wave-loads. It also meant that E2 was prepared to match the know-how of all contractors deep in the core of their
products.
Contracts enabled E2 to carry out design-reviews with sub-contractors as well as main contractors. Design reviews
were carried out as fruitful questioning of important and potentially risky choices. This questioning was met by
cooperative and fairly open-minded contractors, who used the questioning for rethinking and improvements of their
products. Design-reviews with sub-contractors were a positive experience, and E2 believes room for improvement is
found through wider use of this element. For E2 there is little doubt that one of the most important elements of the
Nysted success lies here.
The turbine contract included muck-up of tower-base at factory and installation of a demonstration turbine onshore
near the offshore site. Design of the demonstration turbine meant that Bonus fairly early, compared to manufacture of
the 72 offshore turbines, carried out detailed design and discovered lots of details that could be improved before
going offshore.
Intensive E2 supervision prior to and during installation meant that many minor corrections could be implemented
onshore before installation in some cases for all constructions, and in some cases for all but a few.
The E2 multi contracting philosophy of a few direct held contracts, thorough time consuming preparation by E2,
heavy involvement of E2 staff in all phases of the project, time for implementation of corrections by the contractors
and sub-contractors and very early start of foundation works is the explanation of much of the success of Nysted
Offshore Wind Farm. The use of the approach is described in more detail in [3].
7

Conclusions

E2s multi-contracting philosophy with sufficient time for thorough preparations, design reviews and implementation
of changes as well as planned separation of foundation works and turbine works is believed to be the key of the
Nysted success.
On Installation the following can be concluded:
Main cable and half of the foundations were installed the year before turbines
E2s multi contract concept and strong owner involvement in design review and installation supervision
played and important role in creating the success.
Installation was on budget of 1.5 mill. Euro/MW.
Final commissioning was one month early compared to schedule.
On first year of operation the following can be concluded:
Remedy of defects on expectable level
2 annual calls per turbine necessitating manual intervention in turbines is realistic after the first 2 years of
operation.
Boat landing working well with boat-landings at up to wave-heights of Hs=1.2 m during the first year.
Turbine availability in average 97% during the first year.
Wind farm availability 96% corresponding to loss of 1% availability for non-turbine reasons.
Production as planned, when taking the higher availability and lower wind resource in consideration.
The first year of operation has proven the planned performance.
8 Acknowledgement
Most of the results presented here was prepared by colleagues at ENERGI E2 and they deserve the honour.
9 References
1.

P. Volund, L. Woller, 165 MW Offshore Wind Farm in operation June 2003. On budget on schedule.
Proceedings of EWEC 2003, Madrid, Spain, July 2003.
2. P.H.Pedersen, C.Boesen, First conclusions from the Danish demonstration project on offshore environmental
issues, Proceedings of EWEC 2004, London, November 2004.
3. Nysted Offshore. Success down to hard work. Wind-Kraft & Natrliche Energien Journal, Ausgabe 4/2004.