Veja Mate Offshore Project Installs One Third of its monopiles

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Veja Mate Offshore Project is pleased to announce the installation of one-third of its 1300T monopiles. The construction phase began in April 2016 and Veja Mate contractor Offshore Wind Force (OWF) has managed to successfully install 24 monopiles, in the German North Sea using the world’s largest Jack-up vessel, Scylla.

Veja Mate's Foundation Package Manager said “It´s quite an achievement to maintain installation speed of the world’s heaviest monopile with a newly-built mega jack-up vessel and balance the requirements from the authorities. After an initial learning curve, speed picked-up and on the 28th of May OWF was able to complete installation of two monopiles in a single day.”

To date the Project remains on schedule thanks to the great efforts and dedication from suppliers, their sub-suppliers, the authorities and the Veja Mate project team.

The next step in construction of the Veja Mate wind park will be installation of transition pieces which will commence next week and will be completed independently from the monopiles.

Veja Mate is a 402 MW, 1,9 bn EUR offshore wind project owned by the Highland Group Holdings Ltd, Siemens Financial Services and CI II managed by Copenhagen Infrastructure Partners. Bank financing was completed on the 1st of July 2015. Construction started on the 4th of April 2016 and the project is expected to be fully operational by the end of 2017. It will produce over 1,6 TWh of green, renewable electricity annually, equivalent to the annual consumption of 400.000 German households.

Project Background and Significance

The Veja Mate offshore wind farm is located in the German Exclusive Economic Zone of the North Sea, approximately 95 kilometers northwest of the island of Borkum. With a planned capacity of 402 megawatts, it ranks among the largest offshore wind projects under construction in Germany. The project is a key component of the country's Energiewende, the transition towards renewable energy sources and away from fossil fuels and nuclear power. Once fully operational, Veja Mate will generate over 1.6 terawatt-hours of green electricity annually, enough to power approximately 400,000 German households and offset hundreds of thousands of tonnes of CO2 emissions each year.

The project is owned by a consortium comprising Highland Group Holdings Ltd, Siemens Financial Services, and Copenhagen Infrastructure II, a fund managed by Copenhagen Infrastructure Partners. Financial close was achieved on 1 July 2015, securing the necessary capital for construction. The total investment amounts to 1.9 billion euros, reflecting the scale and complexity of modern offshore wind developments. The project's successful progress is a testament to the collaboration between the owners, contractors, suppliers, and regulatory authorities.

Monopile Foundations: Design and Installation

Monopiles are the most common foundation type for offshore wind turbines in water depths up to around 35 meters. For Veja Mate, each monopile weighs approximately 1,300 tonnes and has a diameter of up to 7.8 meters at the base, making them among the heaviest ever installed. The monopiles are manufactured from thick steel plates rolled and welded into large cylindrical sections, then transported to the offshore site by heavy-lift vessels. The installation process involves driving the monopile into the seabed using a hydraulic hammer, a technique that requires precise positioning and careful monitoring to ensure verticality and penetration depth.

The installation of the monopiles is being carried out by Offshore Wind Force (OWF), a joint venture between Boskalis and VolkerWessels. OWF is utilizing the Scylla, the world's largest jack-up vessel, specifically designed for offshore wind installation. The Scylla has a lifting capacity of 1,500 tonnes and can operate in water depths of up to 65 meters. Its four legs, each 105 meters long, allow it to elevate above the sea surface, providing a stable platform for lifting and driving the massive monopiles. The vessel's advanced dynamic positioning and crane systems enable high precision, even in challenging North Sea conditions.

Despite the initial learning curve associated with operating a newly built vessel and handling the heaviest monopiles in the industry, the installation team quickly optimized their procedures. By late May 2016, they achieved a remarkable milestone: installing two monopiles in a single day. This rate of progress is essential to keeping the project on schedule for completion by the end of 2017.

Transition Pieces and Next Construction Phases

With one-third of the monopiles installed, the project is now moving into the next phase: installation of transition pieces. Transition pieces are steel structures that connect the monopile foundation to the wind turbine tower. They provide a level platform for the tower and house critical electrical and mechanical equipment, including the yaw system, access ladders, and cable connections. The transition pieces for Veja Mate are being installed independently from the monopiles, allowing for parallel work streams and optimized use of installation vessels.

The transition pieces are typically installed using a grouted connection, where high-strength grout is pumped into the annulus between the monopile and the transition piece. This creates a rigid bond that can withstand the enormous bending moments and fatigue loads experienced by offshore wind turbines. The installation of transition pieces is expected to commence shortly and will continue throughout the summer and autumn of 2016. Following this, the project will proceed with the installation of the wind turbine generators, inter-array cables, and the offshore substation.

For more details on the project's milestones, see our previous press release on the installation of the offshore substation and the groundwork launch.

Grid Connection and Power Export

Veja Mate will be connected to the German high-voltage grid via the BorWin2 offshore grid connection system, operated by TenneT. The BorWin2 converter platform, located approximately 40 kilometers from the wind farm, will collect the electricity generated by the 67 Siemens SWT-6.0-154 wind turbines and convert it from alternating current (AC) to high-voltage direct current (HVDC) for transmission to shore. This HVDC technology minimizes transmission losses over the long distance to the mainland, ensuring efficient delivery of renewable energy to consumers.

The grid connection agreement with TenneT is a critical enabler for the project. The timely completion of the BorWin2 platform and associated cables is essential for Veja Mate to achieve full commercial operation by the end of 2017. For more information on the grid connection, see our press release TenneT connects offshore wind farm Veja Mate to grid connection BorWin2.

Environmental and Community Benefits

Offshore wind energy is a cornerstone of Germany's renewable energy strategy, offering significant environmental benefits compared to conventional power generation. Veja Mate will contribute to reducing greenhouse gas emissions and improving air quality, while also enhancing energy security. The project has undergone rigorous environmental impact assessments to minimize its footprint on marine ecosystems. Measures include careful routing of cables, use of noise mitigation during pile driving, and scheduling of construction activities to avoid sensitive periods for marine life.

In addition to environmental benefits, the project brings economic opportunities to the region. The construction and operation of Veja Mate create jobs in manufacturing, maritime services, and maintenance. The project also supports the development of a robust offshore wind supply chain in Germany and Europe. As the industry matures, costs are expected to decline, making offshore wind increasingly competitive with other forms of energy.

Looking Ahead: Full Commissioning and Operation

With construction progressing on schedule, Veja Mate is on track to be fully operational by the end of 2017. The remaining monopiles will be installed over the coming months, followed by transition pieces, turbines, and cables. Commissioning of the wind farm will involve extensive testing of each turbine and the overall electrical system to ensure safe and reliable operation. Once operational, the wind farm will be managed from an onshore control center, with maintenance activities carried out by service vessels and technicians.

The success of the Veja Mate project demonstrates the viability of large-scale offshore wind as a major contributor to Europe's clean energy future. The lessons learned and innovations developed during construction will benefit future projects, driving down costs and improving efficiency. We look forward to sharing further updates as the project advances. For all press inquiries, please visit our Media page or see our Press Releases archive.