Prysmian capabilities in the Offshore Wind Farm field: developing new solutions to enable the energy transition


In the field of wind power, numerous market and technology changes are taking place, from the scaling up of offshore wind farms - that are increasingly being built further out to sea - to changing views on the role of international connections in relation to the energy transition. How is Prysmian Group primed to support and make the most of these developments – while dealing with the effects of COVID-19?

The wind power market is seeing vast growth in the level of power being generated and transported, and an overall increase in the number of offshore wind farms. According to Wind Europe study, despite the restrictions brought about by the pandemic, Europe has recently confirmed €26bn investments in new offshore wind farms for the past year. The investment amount clearly represents investors’ confidence who look out to offshore wind as a reliable, and sustainable source of energy, besides being cost-efficient. The same feeling goes for governments, with increasing countries’ expenditures. The EU Offshore Renewable Energy Strategy (ORES) outlined an expansion framework for the European offshore wind and set a goal of 300 Gigawatts by 2050, 25 times more than today (*). The energy transition is therefore becoming a reality, as demonstrated also by the electrification of cars, decarbonisation of cities, and the fact that countries are shutting down fossil fuel and nuclear facilities to accommodate sustainable energy sources.

“The transition towards renewable energy is very much linked to the capability to transmit and dispatch energy from one place to another, from those locations where clean and renewable energy is produced (offshore wind farms) to those locations where is consumed (urban centers)”

Olivier Angoulevant

BU Director Offshore Wind

“In the offshore wind market, we’re seeing expansion and change across all critical drivers, including players, expectations, volume, regions, and competition. These drivers are pointing towards consolidation and growth in this market”

Prysmian Group is committed to support the development of greener and smarter power grids, by making available innovative cable technologies to cover longer distances (eg. offshore wind parks farm from shore) and sea depths (>3000 mt water depth), ensuring higher performances, reliability and sustainability.

 

As a result of these developments, Prysmian is seeing demand for cables that offer improved electrical and mechanical performance. The level of power transmitted needs to be higher and losses need to be lower. One important driver in the submarine interconnector market is the need for cabling at ever-greater depths, which requires state-of-the-art armouring material as well as cable laying expertise. Tenders are increasingly asking for companies’ qualifications in these areas. The expected development of floating offshore wind farms should also boost the demand for dynamic cables – resulting in a highly promising new market in the horizon of 2025-2030. Prysmian is building up considerable experience and projects track record in this area from working on the Kincardine 1 and 2 floating wind power projects, and the Provence Grand Large floating offshore wind farm.

Increasingly stringent environmental requirements have also resulted in our investments in copper technology as an alternative sustainable material to replace lead. Our completely eco-friendly P-Laser technology, manufactured using thermoplastic materials and 100% recyclable, also contributes to achieving the highest levels of sustainability for our products and solutions. Several countries have formalized their commitment to producing many Gigawatts of clean energy in coming years. These clear targets offer Prysmian the possibility to plan capacity well in advance. This allows us to meet the demand for products in the areas of generation as well as distribution. In German Corridor underground energy projects, for example, we’re enabling higher levels of power generation and interconnection. The growing number of offshore wind parks in the Baltics and North Sea, for example, which need to transport vast amounts of clean power from North to South, required unprecedentedly large, safe and efficient cable interconnections to dispatch energy from where it is generated to where it is consumed. We’re investing in cable system able to increase the voltage and dimension, while ensuring lower losses.

In certain areas where offshore wind was already consolidated, investments are still increasing.  Confidence in the sector is growing as it becomes clear that this is a reliable source of cost-efficient energy. At the same time, numerous regions are starting up their first offshore wind projects, such as Far East and USA. Hence, offshore wind is no longer limited to Europe, but on the contrary it is expanding overseas (*).

We are focusing on expanding our activities in inter-array projects, floating platforms and dynamic cables.

“In the past, we’ve mainly acted as a cable supplier for inter-array projects, but now, we’re increasingly supplying cables and engineering services, as well as installation operations, terminations, and testing, effectively positioning as a solution provider.”

Riccardo Fabbri

Head of Project & Contract Management

Indeed, Prysmian has three of the most state-of-the-art cable-laying vessels in the world (plus one under construction), being able to offer extended project versatility with deep-water installation capabilities of up to 3,000m, as well as shallow-water and near-shore solutions.

In 2020, we have successfully executed many turnkey activities, and we plan to increasingly focus on turnkey projects, for which we have been awarded important project contracts. We invested extensive efforts to being able to deal with the complexity of turnkey projects, not only with regard to project management to ensure flawless execution, but also in areas such as engineering, having the right setup in production facilities, and frame agreements with dedicated critical main suppliers.

In addition, we are actively monitoring a number of topics that will also affect the wind market. These include use of hydrogen, vast generation islands, and the combination of wind plus solar.

Focus on Project Management: transforming Prysmian internal organisation

In response to the aforementioned developments, we have divided our projects into two big clusters: Interconnectors and Offshore wind parks. Our offshore wind parks activity consists of two sub-segments: export cable and inter-array cable.

“It is different not only in terms of scope of work but also with regard to critical qualities and typical clients. Less than two years ago, Prysmian created a dedicated team for Offshore Wind Farms, which has already grown to three times its original size.”

Riccardo Fabbri, Head of Project & Contract Management

A transformation plan was developed to decide what we need to be successful and to excel across diverse areas from delivery, production, quality management, engineering, jointing capabilities, and subcontractors. This has already provided a number of actionable insights.

Successfully overcoming COVID-19 challenges

This year the unexpected happened. However, thanks to a long history of dealing with issues caused by external factors, Prysmian dealt with the challenges effectively.

“We continued to produce cables, with engineers and project managers largely working from home, and kept operations going in a safe way. We also successfully continued to manage external operations”

Riccardo Fabbri, Head of Project & Contract Management.

On the land side, we had to consider social distancing and quarantines. After a while we got used to this approach – the changes were very similar to the changes previously applied to the production facilities. On the vessel, things were a little more challenging, as we could have 100 people on board for weeks at a time. We introduced a number of dedicated measures. Our vessel was sanitized and regularly underwent testing.  We have met our deadlines and made progress on operation. We now have clear processes in place with regard to COVID-19. Internally, but also with our subcontractors.

 (*) WindEurope, (8 Februrary, 2021). Press Release: Europe invests a record €26bn in offshore wind in 2020. Retrieved from Europe invests a record €26bn in offshore wind in 2020 | WindEurope