Hart ng hel s Siemens connect the Dudgeon offshore wind far HartingCustomisedstomised Solutions (H


cre


reateanewwa windturbi es, ext


ex rapro thewo


xtra T proj heDudge roj ct ewwayof i st ge ojectmanagement flex


theproc ge


of the biggeof the biggest and most exciting energy projects currently under construction in Europe. The £1.5 billion project will harness offshore wind to generate 402MW of power for more than 410,000 UK homes. Located about 24 miles off the North Norfolk coast, the project i


geonOffshoreWind Farm is one gest andm st exciting energy


to ge generate 4


one gy


ojects currently under construction i Europe. The£1. bi on pro offsh rew or


or


The turbines and grid connections are designed, supplied and commissioned bysioned by Siemens. Each turbine generates 6MW, and stands about 150m tall with a blade diameter of 120m They also stand i


about 24m s off theNorthNorfol coast, the project is led by companies Statoil and Statkraft, and Masdar. es and gri


ed by com anies Statoi and


Statkraft, andM sdar. The tur


connecti ns are designed, suppl d and com Siemens. Each turbine gen rates 6 and


stands about 150mtal with a blade diameter of 120m. They also stand in 18-25m of water with a mean wave height of 1.1m, and the averagewind speed i 9.8m/s–chal nging construction conditions i deed.


th am anw ve h ight of 1.1m, and th average wind speed is 9.8m/s – challenging construction conditions indeed.


Design started in 2014 and the project is due to begin generating in early 2017 before bei g ful y com


Design started i 2014 and the pro ojject i


due to begin generating i early 2017 before being fully commissioned later that year. Keeping to this schedule has meant planning at every stage


sioned l ter that year.


Keepi g to thi schedule hasm ant planning at every stage to work around the dangerous sea conditions. This limits the period avai ble for construction to between l te sprng and early autum each year. ScottW


ge towork around the dangerous ge


sea con itions. T is limts the period available for construction to between late spring and early autumn each year. Scott Williams, project manager for Siemens, said: “For project efficiency the transition pieces with i tegrated switchgear are i stal ed offshore as soon as the


proj Siemens, sai ojectm nager “For proj oject efficiency the


monopole supports have been installed. This is approximately 12 months before the turbines will be installed. We therefore needed a sia simple way to connect the transition piece switchgear at the bottom of the tower with the turbine switchgear at the top at that stage, but which would also be able to withstand the elements until the following spring.” This is where Harting stepped forward. Having previously worked with Siemens on a range of other proj


transi on pieceswith integrated swi chgear are installed offshore as soon as the onopole supports have


ge ve been i stal d. Thi approxi ately 12months before the swi chge


wi be i stal d.Wethereforeneeded eway to connect the transitionpiece gear at the bottomof the tow


owerwith the turbine switchge


butwhi hwouldalsobe abl elements unti the folow Thi


ojects,


gear at the topat that stage, towithstandthe


ge owing sprng. whereHarting stepped f rward.


Having previousl workedwith Siemens on a range of other projects, introducing them as subcontractors was a safe strategy for Siemens. The taskwas to create connecti cables and a cabinet to house the swi chgear, and package themso they could be protected fromthe envi onment through thewinter. Siemens alsowanted a sol tion to reduce the tim taken to actuallym ke th


troduci g themas


subcontractorsw s a safe strategy for Siemens. The task was to create connecting cables and a cabinet to house the switchgear, and package them so they could be protected from the environment through the winter. Siemens also wanted a solution to reduce the time taken to actually make the connection.Onm st projects of thi sort, teamof two to four engin ers rigs the cables and connects each individual y, top and bottom taking 1-2 days per turbi e. Scott am sai


connection. On most projects of this sort, a team of two to four engineers rigs the cables and connects each individually, top and bottom, taking 1-2 days per turbine. Scott Williams, said: “The Harting design not only provided a suitable IP (Ingress Protection)


“TheHar provi ed a sui able I g design not onl (Ingress Protection) 18-25mofwater


rating to protect the cables from severe ath r and a corrosive salty atmosph re, eant that al connections could be t into th switchgear. Each turbine and transi on piece could then si


rating to protect the cables fromsevere weather and a corrosive salty atm sphere, but ibut it meant that all connections could be buillt into the switchgear. Each turbine and transition piece could then simply be plugged together and tested,together and tested, meaning that a team of two could do the work in as little as a day. ven the cost ofw rking offsh re, let alone the tim constraints on the proj am ssive i prov


eaning that a teamof


two could do thework i as l ttle as a day. Given the cost of working offshore, let alone the time constraints on the project, this was a massive improvement.”


oject, thisw ovement. TECHNICACAL REQUIREMENTS ECHNICAL REQUIREMEN


Each turbi e requi edHartng to connect the two pieces of switchgear


Each turbine required Hartiing to connect the two pieces of switchgear including control cabling with an Input/Output of 24 wires, a 24vDC cable, and cabl g for the 230vac supply. A total of 67 control cabinetswere requi ed eachwith one sui e of cables (1 x O; 1 X 24vdc; and 1 x 230vac).


cluding control


cablngwith an Input/Output of 24wires, 24vDC cable, and cabling for the 230vac supply. A total of 67 control cabinets were required each with one suite of cables (1 x I/O; 1 X 24vdc; and 1 x 230vac).


aluminium die-cast material ensured it met Siemens environmental requirements. These were kittedwith protectedmodules ensurng finger safe connection. Cr


TheHar ngHanMhousing r ngewas selected due to its environmental characteristics. The IP65 rating and alum


The Harting Han M housing range was selected due to i s environmental characteristics. The IP6 rating and die-castmaterial ensur d i


et


Siemens environmental requi ements. These were kitted with protected modules ensuring finger safe connection. Crimp contacts were also specified for vibration resistance. The end resul was 67 bespoke ful


p contactswer


also speci ed for vibration resistance. The end result was 67 bespoke fully assembled box builds, each with a suite of cables, createdwithi and del ver d on ti


stal rel able and finge


assem d box bui ds, eachwith a sui e of cables, created within the specified budget and delivered on time, allowing Siemens to install reliable and finger safe control


the speci ed budget al wing Siemens to ger safe control


cabinets. This sol tion will be considered on futurewndfarm as a saving for offsh re rking effort and tim


cabinets. This solutionw be consi ered on future windfarms as a saving for offshore working effort and time.


Harting Harting


www.harting.co.uk/energy T: 01604 827500


www.harting.co.uk/energy T: 01604 827500


/ ENERGYMANAGEMENT ENERGYMANAGEMENT


Harting helps Siemens create new way of installing


be plugged


switchgear for cabling and


Wind Farm


Dudgeon Offshore turbines at the offshore wind


way of installing cabling and switchgear for offshore wind turbines at the Dudgeon Offshore Wind Farm


Siemens create new Harting helps


ojjectwi harness of power


an 410,000UK hom s. Locat stal tionti eandprov


foroffshore ro


ff re ty ee tyneeded,whenwo world’smostdiff fficult seaconditions


Hartiing helps Siemens connect the Dudgeon offshore wind farm Harting


create a new way of installing the cabling and switchgear for offshore wind turbines, in the process saving installation time and providing the extra project management flexibility needed, when working in some of the w rld’s m st difficult sea conditions


ovi ngthe he Dudgeon Offshore Wnd Far


edSolutions (HCS)h s beenworking wth Siemens to stal ngthecablngandsw ocess savingi st exi


) hasbeenworkingwithSiemens to sw chgear fo


w rkingi som of


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