Foreseeing an exponential growth in the offshore wind sector for the foreseeable future, the company has invested in an automated production line that is being used for serial fabrication of wind substructures

Lamprell has been delivering components for the offshore wind market around the world from the only such facility in the Arabian Gulf region.

The state-of-the-art renewables production line at the Hamriyah Free Zone in Dubai, UAE, was commissioned in 2023 and has the ability to construct transition pieces, monopiles, jackets and floating wind components for renewables projects.

Lamprell entered the offshore wind market in 2007 and has since delivered hundreds of assets for the renewables industry.

The painting and blasting shed can outfit TPs of 30 m in length

These include (at the time of publishing) 6 wind turbine installation vessels, 138 jackets, 90 suction buckets, 180 piles and 62 transition pieces (delivery still in progress).

The company had the foresight to see the exponential growth in the offshore wind sector for the foreseeable future and invested in the automated production line that is being used for serial fabrication of offshore (fixed and floating) wind substructures.

This expansion has significantly increased Lamprell’s client base and extends its reach in this addressable market beyond jacket-based foundations.

With the recent announcement from the UAE stating that its Energy Strategy 2050 aims to triple the contribution of renewable energy, Lamprell is well-placed to support the development of the UAE as a renewable energy hub.

In the past years, the region has positioned itself as a leader in the renewable energy sector, boasting numerous renewable energy projects.

According to Mordor Intelligence, the Middle East’s renewable energy market is expected to register a CAGR of around 13.43 per cent from 2024-2029.

And Lamprell is well-placed to support the energy transition

TPs sail away for Moray West project

Ian Prescott, Lamprell CEO, says: "We are thrilled with our new production line, about the global and specifically the UAE’s expansion plans in the renewables sector and the opportunities it brings to Lamprell. We are ready to continue playing our part in the energy transition. Our commitment to excellence in offshore wind manufacturing drives us, and we look forward to continuing to serve our clients with high levels of commitment, expertise and quality."

In an exclusive interview with OGN energy magazine, Prescott spoke at length about the facility and the projects pipeline.

Here are excerpts from the interview:

• What is the handling capacity of the new facility?

Based on the capacity to process, which includes cutting, rolling, welding, joining, outfitting, inspection and coating, we can output roughly 75,000 tonnes of steel per annum.

This equals an output of over 150 transition pieces (TPs), which forms a key part of offshore wind foundations.

• How long does it take to fabricate a TP at the facility?

Offshore wind jackets constructed by Lamprell

Our production line has over 40 stations for material receiving, CNC plate preparation, joining, long seam milling, rolling, flange fit-up and welding, can-to-can fit-up and welding, seam milling and welding and finally, steel outfitting.

As a guideline, a TP for a 15-17 MW turbine takes between 160 and 180 days (under 6 months) from the first steel cut to being fully commissioned and delivered to the client.

• What is the capacity of wind systems that can be built at the facility?

Lamprell can produce a variety of tubular products up to 10.5 m in diameter, sections of more than 30 m in length and up to 500 tonnes, with a material thickness of approximately 150 mm.

The sections can be joined to foundations greater than 30 m. These dimensions allow Lamprell to supply the current wind turbine foundation market, which is around 15-17 MW in size, and well into the future with turbines reaching 25 MW.

• Tell us about the blasting and painting facility?

The blast and paint facility forms a unique part of Lamprell’s renewables production line.

It houses sophisticated painting sheds that come with environmental controls, fume extraction, and optimal illumination, so our skilled applicators can meticulously apply coating following international standards such as NORSOK M 501. It has the ability to blast and paint outfitted TPs of 30 m in length.

The renewables production line also has direct access to a 1,250-m quayside, allowing for delivery straight from our yard onto transport vessels, which are then delivered to our clients’ marshalling ports worldwide.

• What are some of your projects in the pipeline?

We are currently fabricating 62 TPs for the Moray West offshore wind farm, and this project will be completed in H1 2024.

Lamprell signed a reservation agreement at 2023-end for the Norfolk Vanguard project comprising 2 x 92 wind turbine generator TPs (15 MW) for the Norfolk Vanguard West and Norfolk Vanguard East wind farms.

The Norfolk offshore wind farms are located in the southern part of the British North Sea, off the Norfolk coast, approximately 47 km from the shore.

Recently acquired by RWE from Vattenfall, the Norfolk Vanguard project, which is a 4.2-gigawatt (GW) UK offshore wind development, is expected to be commissioned this decade.

Bidding continues for further projects, and announcements will be made via our website/LinkedIn account.

By Abdulaziz Khattak