by Jerome a Paris
Thu Mar 12th, 2009 at 11:49:58 AM EST

Princes Amalia (Q7) wind farm - Vestas V80 2MW turbines
June 2008, photo by author
When one sees pictures of offshore wind farms such as the one above, it is hard to conceive how incredibly big and heavy these things are. I have now visited the factories or construction site of all the major manufacturers of offshore wind turbines, and would like to give you a small glimpse of what it means to build these things... Follow me below the fold.
Part of the Wind Power series
First, some more pictures of the various turbines that are being used, or contemplated for, offshore wind today:


Thornton Bank (C-Power) wind farm - Repower 5M turbines
August 2008, photo by author

Hooksiel nearshore test site - BARD 5MW turbine
March 2009, photo by author

Bremerhaven test area - Multibrid 5MW turbine
(monopile foundation design in the background; tripod foundation design in the foreground)
March 2008, photo by author
The above are the 3 turbine models currently available in the 5MW range. The German market, where permits are given for wind farms with a given number of turbines, has focused on putting, naturally, the largest turbines in order to have the largest possible output for a given permit (and for a given transformer + development costs, as these items benefit from effects of scale). These 5MW turbines are still in their early days, with only a small number operational, but massive buildup plans. The other commercially available turbines for offshore are the Vestas V90 (3MW) and the Siemens 3.6MW machines - which have been selling (and are already installed) in larger numbers in markets like the UK and the Netherlands as of today.
As the last picture suggests, these machines are rather big. But let me show you how big, by taking a look at their foundations:

Hooksiel nearshore test site - BARD 5MW turbine
March 2009, photo by author

BARD 5MW turbine tripile foundation outside factory gates - Cuxhaven Steel Construction
March 2009, photo by author
The above is the specially designed tripile foundation for the Bard turbine, in the water, and outside the factory. That foundation has the advantage of being identical for all turbines, and can thus be mass manufactured: it rests on 3 steel piles which are adjusted to each site's conditions, and are smaller than a (bigger) monopile.

BARD 5MW turbine tripile foundation in construction - Cuxhaven Steel Construction
March 2009, photo by author
The above is one of the these foundations as it is being assembled inside the factory. As you can see, it gives a whole new meaning to "heavy industry."

C-Power turbine foundations in construction - Ostende
April 2008, photo by author
The C-Power project uses a "gravity-based" foundation design, ie a heavy concrete cylinder, later filled with sand, which simply rests on the sea floor. The above shows the foundations for the first 6 turbines as they were being built onshore, before being transported to site and filled there. They weigh about 3,500 tones empty, and double that full (for 25m water depths).

C-Power nacelle prior to erection - Ostende
August 2008, photo by author
The above is one of the Repower nacelles - that apparently small box on top of the tower is in fact a 300 ton (not counting the rotor) steel box bigger than a home. As can easily be understood, one of the most important issues for offshore manufacturing and construction is the availability of cranes to carry these things and ring them to their rightful position 80m above the sea level - and of the vessels that can handle that manoeuver in the middle of the sea.

Multibrid nacelle in factory - Bremerhaven
April 2008, photo by author
You've seen the foundation above; the nacelle assembly halls can be similarly impressive. Above is the Multibrid nacelle (prior to a redesign that will allow for a helicopter platform), which is actually the most compact of the three 5MW turbine designs.
So this is heavy industry - in fact, the main consideration to site the factories for the 5MW turbines and other elements (foundations, tower, blades is the logistics, as it is rather complicated to transport turbine parts, let alone turbines, and you need specially built ground floors and pontoon to withstand the weights that are carried around. So, quite logically, the factories are built near the sea, or near rivers. Cities with shipyards are ideal in that respect, with existing infrastructure, metal-bashing companies - and a rather strong desire to see the jobs lost in the previous decades reappear in this new industry.
Each of these manufacturers is creating jobs by the hundreds right now, and providing solid demand to a lot of subcontractors (gearbox manufacturers, electrical equipment, crane and lifting equipment manufacturers, transport companies) that also provide jobs. And the vast majority of these jobs will never be offshorised, because of the logistical constraints that apply on the industry.
Oh - and this will provide us with climate-friendly electricity that requires no imports of oil or gas and whose price will not move for the next 25 years.