Case Study: Vineyard Offshore Wind Farm

Endiprev has played a pivotal role in shaping offshore wind power in the United States. Over the last decade, we’ve gathered hands-on experience on US soil, solidifying our reputation as a reliable partner for wind energy solutions. More recently, our teams supported GE Vernova in the Vineyard Offshore Wind Farm, the first large-scale offshore project in the country.

The Vineyard Offshore Wind Farm has been an exceptional project for several reasons. The first one is the fact that it is the first large-scale offshore project in the US. This represents a significant milestone in the country’s renewable energy journey. The second one is that Endiprev USA mobilized the largest number of technicians ever for a project of this magnitude. It also demanded a much more thorough preparation than any project we have ever had.

The Journey of Endiprev USA

The partnership between Endiprev USA and GE Vernova in the Vineyard Offshore Wind Farm didn’t happen overnight. Our team has been fortifying expertise from working in American wind power since 2016. At the same time, we have been sharing knowledge across every subsidiary of Endiprev Group, with technicians working in the wind power industry for more than 15 years.

Over the years, Endiprev USA has supported the development and commissioning of wind turbines, which has enriched our knowledge. In 2023 alone, we worked in almost 20 states in several onshore and offshore projects. When it comes to GE Vernova, our teams are not only prepared to work in several onshore models but also in offshore technologies.

Endiprev became a crucial partner, securing pioneering projects, such as the Block Island Wind Farm commissioning. To this day, our technicians remain on-site for maintenance operations on this landmark project, which served as the gateway for our business into the industry of offshore wind energy in the country. Therefore, our GE Offshore experience goes from models like the Haliade-150 to, more recently, the Haliade-X.

Endiprev’s preparation for Vineyard

Long before we were awarded the Vineyard Offshore Wind Farm project, we started to equip our American technicians with experience in this sector. Therefore, in March 2023, Endiprev USA started comprehensive training at GE’s factory in Saint-Nazaire, France. They immersed themselves in hands-on experience with the Haliade-X wind turbines. They started to work next to our expert European technicians, who had prior experience in offshore wind farms like the Saint-Nazaire, Merkur, and Belwind Wind Farms, among others. This was crucial to prepare our American team effectively.

Vineyard’s workforce diversification

Because of their offshore experience, our European technicians and teams played a crucial role in the preparation process. On one side, they intervene with project management and offshore technical skills and knowledge. On the other, they also guaranteed that there were health and safety forces and mindset on this project since several OHS awards were given to European technicians in offshore projects.

The Vineyard Offshore Wind Farm also tested our project management capabilities. Not only did we have to be prepared and ensure the good work of our technicians, whether American or European, but we also had to understand the challenges faced by our customers. Although our work wasn’t directly affected by the Jonas Act, we made sure we understood its implications. For example, by working with feeding barges to support our tasks, our customers can transport materials and equipment more efficiently to the wind farms, ensuring timely project completion and optimal operational efficiency. At the same time, we had to ensure that we were compliant with the visa process. Since Endiprev USA would get support from European technicians, this step was crucial. Our compliance team conducted a meticulous investigation of our compliance process to ensure that our employees were working safely and legally in the US.

On American soil, Endiprev USA had only to ensure good cooperation with the Unions: the IBEW, Iron Workers and Millwrights. Although we have been in touch with them since 2019, it took several meetings to understand how we could work together. On the one hand, Endiprev had skilled technicians and training experience. On the other, the Unions had state-of-the-art facilities and a great pool of candidates. Therefore, for this project, we assembled a team of around 100 Endiprev technicians, from the US, Portugal, and the Union workers.

Vineyard Offshore Wind Farm’s Scope

The Vineyard Offshore Wind Farm project started with work on the Marshaling harbor with the scopes of Pre-commissioning and Punch-List. In August 2023, the first rotations, of 36 technicians, of the 2 vessels were mobilized to New Bedford, with the first teams being sent offshore later that month. Union workers were mainly in charge of supporting the project on the Installation Vessel on Mechanical & Electrical completion scope.

Throughout this project, our team performed several tasks related to Mechanical and Electrical Completion and Commissioning, including:

Mechanical and Electrical Completion:

• Mechanical and electrical completion: tower and Nacelle including High Voltage activities.
• Installation & commissioning of the Hailo Lift.

Commissioning:

• Offshore setup and test of several systems.
• Cold commissioning.
• Scada commissioning.
• WTG energization.
• Supporting Hot commissioning.
• Commissioning Puch-list.

Vineyard Offshore Wind Farm Official Energy Production

Amidst the relentless dedication of our teams, the fruits of our labor began to emerge. On January 2nd, 2024, the first wind turbine started producing energy. The achievement of powering the New England Grid with the completion of the initial wind turbine string cemented Endiprev’s crucial position in this pioneering venture. This milestone underscored our pivotal role in the project’s success.

Currently, 82 Endiprev technicians are working on the wind farm. This includes 31 technicians, including the 8 Unions, in WIV (Wind Installation Vessel) and 51 technicians in SOV (Service Operations Vessel). The Vineyard Offshore Wind Farm project is situated approximately 13 nautical miles south of Martha’s Vineyard. With a capacity of 800MW, it is expected to power up to 400,000 homes annually. This is a significant milestone in the United States’ renewable energy journey as well for Endiprev.

Challenges and Lessons Learned

Being in charge of a major project like the Vineyard Offshore Wind Farm will pose several challenges for Endiprev. It marks the first installation and commissioning of the Haliade-X wind turbine on such a large scale, concurrent with similar efforts at the Dogger Bank Wind Farm. As a result, it demands cohesive teamwork and a shared focus on achieving common objectives. One of the primary challenges we face is the unpredictable nature of weather conditions, particularly during the winter months. Adverse weather can disrupt schedules, impact safety, and hinder progress, underscoring the need for contingency plans and adaptability. Moreover, integrating multiple technician entities—Endiprev Portugal, Endiprev USA, and Unions—adds another layer of complexity. Effective communication and collaboration across these diverse teams are essential to synchronize efforts, align methodologies, and mitigate potential conflicts.

The Vineyard Offshore Wind Farm project represents more than a monumental achievement for Endiprev. It symbolizes our enduring commitment to innovation, excellence, and sustainability. Being the first large-scale offshore wind farm in the US, our combined endeavors highlight Endiprev’s excellence, shaping both the nation’s maritime history and global offshore energy landscape. With each turbine generating, we propel the world towards a greener future, powered by the relentless force of wind energy.