Overview Selected Findings Contents Page The Authors  

Take a look at this report's contents page

1   Foreword
2   Executive Summary
3   Report Methodology
4   Introduction 
4.1   Offshore Project Forecasts: general growth prospects in Europe, Asia and North America
4.2   Turbine Technology
4.3   OEM Assembly Strategies – Current supply chain strategies and issues
4.4   How component suppliers can best work within OEM strategies
5   Project Forecast 
5.1.   General Trends
5.2   UK
5.3   Europe
5.4   Asia
5.5   North America
6   Turbine Technology and future trends
6.1.   Blades
6.1.1.   Material
6.1.2.   Aerodynamic Design
6.1.3.   Structural Design
6.2.   Tower
6.2.1.   Tubular Steel
6.2.2.   Precast Concrete
6.2.1.   Hybrid
6.3.   Structural Foundations
6.3.1.   Monopile
6.3.1.   Tripod / Tripile
6.3.2.   Jacket
6.3.1.   Gravity-Based Foundation
6.3.2.   Floating
6.4.   Bearings
6.4.1.   Rotor Shaft Main Bearing
6.4.2.   Slewing Ring Bearing
6.4.3.   Gearbox Bearings
6.5.   Electromechanical Drives
6.5.1.   Nacelle Yaw Actuators
6.5.2.   Blade Pitch Actuators
6.6.   Hydraulic Systems
6.6.1.   Hydraulic Power Unit
6.6.2.   Yaw Drive Brake
6.6.3.   Main Shaft Brake
6.6.4.   Rotor Lock Piston
6.7.   Electrical Systems
6.7.1.   Slip Rings
6.7.2.   Switch Gear
6.7.3.   Converter
6.7.4.   Back-to-Back IGBT
6.7.5.   Step-Up Transformer
6.8.   Drive train
6.8.1.   Gearbox
6.8.2.   Direct Drive
7   Original Equipment Manufacturer Assembly Strategies
7.1.   In-house, Strategic Partnerships or Outsourcing
7.2.   Manufacturing – Global or Local
7.3.   Supplier Selection Criteria
7.4.   Best Ways To Present Innovation to OEMs
7.5   Europe Case Studies
7.5.1   Siemens 
7.5.2   Acciona
7.6   Asia Case Studies
7.6.1   Goldwind  
7.6.2   Mitsubishi
7.7   North American Case Study
7.7.1   General Electric
8   Coping with OEM Strategies 
8.1.   Risk Mitigation
8.2.   Asia and Eastern European Manufacturers
8.3.   Financial Instruments
8.4   Case Studies 
8.4.1   LM Wind Power
8.4.2   Hansen Transmissions
9   Conclusions
10   About the Authors
11   References

List of Figures

Figure 1   Technical Outlook (EWEA – Design of Very Large Scale Turbines)
Figure 2   Wind Speed and Capacity (Durham University)
Figure 3   UK Round 3 Projects (Vattenfall)
Figure 4   First Wind Turbine at Greater Gabbard Offshore Wind Farm 2010 (RWE Npower Renewables)
Figure 5   European Offshore Installation (BVG Associates)
Figure 6   Scaling Trend (UpWind 2011)
Figure 7   acelle and Rotor Mass as a Function of Rotor Diameter (UpWind 2011)
Figure 8   Multiaxial Weaved Glass Fiber Fabric (SAERTEX 2011)
Figure 9   GE Aero-Elastic Blade (Bussières 2011)
Figure 10   Blade Pre-bend (LM Wind Power 2011)
Figure 11   GE Blade featuring Truncated Airfoils (Bussières 2011)
Figure 12   Various Winglet Configurations (Johansen & Sorensen 2006)
Figure 13   BARD Offshore Winglet (REpower 2011)
Figure 14   Leading Edge Tubercles (WhalePower 2011)
Figure 15   Vortex Generators (LM Wind Power)
Figure 16   Shear Web and Spar Cap Concept (Bottasso 2010)
Figure 17   Spar Box Concept (Bottasso 2010)
Figure 18   Gamesa Tubular Tower Technology (Gamesa 2007)
Figure 19   Offshore Wind Turbine Technological Foundation Landscape (Wybren 2011)
Figure 20   Manufacturing Stages of a Tripod Foundation (UpWind Final Report WP4.2)
Figure 21   Floating Foundation and Water Ballast Schematic (Statoil 2011)
Figure 22   HyWind Offshore Project (Wind Systems 2011)
Figure 23   SKF's Nautilus Bearing in a Direct Drive Configuration (SKF Group n.d.)
Figure 24   SKF's Nautilus Bearing in a Gearbox Configuration (SKF Group n.d.)
Figure 25   SKF Hybrid Steel Bearing with Silicon Nitride Rolling Elements and Ceramic Insulation (SKF Group n.d.)
Figure 26   Slewing Ring Bearing (Rollix 2011)
Figure 27   SKF High Capacity Cylindrical Roller Bearing (SKF Group n.d.)
Figure 28   SKF Sealing Protection for Harsh Environment (SKF Group n.d.)
Figure 29   Bonfiglioli Yaw Drive on the Alpha Ventus Offshore Wind Farm (Bonfiglioli 2011)
Figure 30   Bonglioli Pitch Drive on the Alpha Ventus Offshore Wind Farm (Bonfiglioli 2011)
Figure 31   Rexroth Hydraulic Pitch Drive Unit
Figure 32   Wind Turbine Hydraulic Power Unit (Fritz Schur Energy 2011)
Figure 33   Yaw Drive Parking Brakes (Rexroth Bosch Group 2011)
Figure 34   BSFI 3000 Hydraulic Brake (Svendborg Brakes 2011)
Figure 35   Rotor Lock Hydraulic and Electromechanical Drives (Roemheld Hilma 2011)
Figure 36   Compact Slip Ring Unit for Onshore and Offshore Wind Power Application (Schleifring 2011)
Figure 37   Siemens NXPLUS C Switch Gear Cabinet (Siemens 2011a)
Figure 38   ABB ZX 1.2 Medium-Voltage Switch Gear for Offshore Application (ABB 2011)
Figure 39   Back-to-Back IGBT Converter (Lipo et al. 2006)
Figure 40   Alstom Eco-Efficient Power Transformer (Alstom 2011)
Figure 41   Down-Tower Electrical Module Arrangement (Knight 2010)
Figure 42   Rexroth Bosch REDULUS GPV-D Differential Gearbox for Multi-Megawatt (>2MW) Wind Turbines (Rexroth Bosch Group 2011)
Figure 43   GE Two-Stage Planetary with One-Stage Parallel Shaft (General Electric Company 2010)
Figure 44   Doubly-Fed Induction Generator Schematic (Matlab 2011a n.d.)
Figure 45   Directly Rotor-Driven Variable-Speed Synchronous Generator with Inverter (Hau 2005)
Figure 46   Which wind turbine components are proving difficult to source? (WEU Survey 2011) 
Figure 47   What is your contract preferences for Offshore projects? (WEU Survey 2011)
Figure 48   A2SEA’s new Sea Installer vessel (A2SEA)
Figure 49   What is the typical length of a long-term contract? (WEU Survey 2011)
Figure 50   What sourcing methods do you use for the major components of a wind turbine? (WEU Survey 2011)
Figure 51   Where are the majority of your new suppliers based? (WEU Survey 2011)
Figure 52   In five years time where do you expect the majority of your suppliers to be based? (WEU Survey 2011)
Figure 53   Do the cost savings of manufacturing in China and Eastern Europe outweigh the additional logistics costs? (WEU Survey 2011)
Figure 54   Truck Transport Cost Differential Between US Sourcing of Towers compared to Asia (TML Global Logistics)
Figure 55   Labour Costs (Global Production)
Figure 56   Hourly Compensation Costs (Bureau of Labour Statistics)
Figure 57   In which areas can component manufacturers best help you reduce supply chain costs? (WEU Survey 2011)
Figure 58   Turbine Component Reliability (Faulstich et al 2008)
Figure 59   How many new suppliers do you take on each year? (WEU Survey 2011)
Figure 60   The proposed offshore development at Alexandria Dock, Hull (Siemens)
Figure 61   How are you improving your economies of scale? (WEU Survey 2011)
Figure 62   What is the average lead time from order to delivery for offshore projects? (WEU Survey 2011)
Figure 63   Cost Breakdown of a 5MW Onshore Project (Renewable Energy Focus)
Figure 64   Component Capital Costs of a typical £6million 5MW turbine (BTM Consult)
Figure 65   Have you utilized subsidies for offshore wind energy in (WEU Survey 2011)
Figure 66   Was this the deciding factor for you to manufacture in this region? (WEU Survey 2011)
Figure 67   LM’s 73.5P wind turbine blades on Alstom’s 6MW (Alstom)
Figure 68   LM Wind Power’s chief executive Roland Sunden meets Chinese staff (LM Windpower)
 
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Offshore wind Turbine Supply Report
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Release Date: September
2011