Two pioneering lifting technologies are promising significant cost savings and operational efficiencies in the offshore wind industry, particularly for smaller, older jack-up vessels. These systems—SENSEWind’s SENSE and the WindSpider WS-100—offer alternatives to traditional installation methods, reducing logistical challenges and enabling quicker, cost-effective repairs and maintenance.
SENSEWind’s SENSE technology aims to lower installation costs and offer a more efficient solution for offshore wind turbine maintenance. This innovation could eliminate the need to tow floating turbines back to port for repairs, instead using smaller, more widely available jack-up vessels. According to a report from classification society DNV, SENSEWind’s system could reduce the levelised cost of energy (LCoE) for large, fixed-bottom wind farms by 4.7%, resulting in savings of approximately £1.0 billion (US$1.3 billion) over the operational lifespan of the project.
The system’s design replaces the need for large jack-up vessels by utilizing a self-installing carriage system to transport a wind turbine’s rotor nacelle assembly to the top of the tower. This allows smaller vessels to perform the same tasks, extending the operational life of these vessels. The technology also applies to onshore and offshore projects, streamlining installation and improving maintenance efficiency. SENSEWind plans to launch a 2-MW onshore demonstrator later in 2025, with plans for a commercial 6-8 MW prototype.
“We are delighted that DNV has quantified the value of our technology to the offshore wind industry. Not only does SENSE reduce installation time and costs, but it offers an alternative approach to major component replacements, getting turbines back online quickly,” said SENSEWind CEO Patrick Geraets.
In a similar vein, WindSpider has developed the WS-100, a compact, universal lifting system that utilizes the tower of a wind turbine as part of the crane for maintenance and component exchanges. The WS-100 is designed to enable “smarter and cheaper” offshore wind repairs, particularly as turbines grow larger and more complex. With hub heights exceeding 140 meters, existing jack-up vessels often struggle to perform necessary repairs due to size and height limitations. The WS-100 addresses this gap by allowing smaller, older jack-ups to carry out operations that would typically require more expensive, purpose-built vessels.
“The WS-100 extends the relevance of existing jack-up assets, ensuring timely repairs and minimizing turbine downtime,” explained WindSpider CEO Kent Lynggaard Vinkel. “New wind turbine installation vessels are costly and often tied up with installation contracts. The WS-100 ensures that older vessels can still be used for important maintenance tasks, reducing costs and improving energy yield.”
The WS-100 is specifically designed for blade and major component exchanges on fixed-bottom wind turbines with hub heights over 140 meters. WindSpider is in discussions with wind developers, turbine manufacturers, and vessel operators to validate the potential of the WS-100 system.
In addition to these innovations, logistics company Geodis has entered into a partnership with Dolfines to develop a port-based high-capacity lifting system for floating offshore wind turbines. The Mobile XXL Offshore Heavy Maintenance Enabler (OHME) will be capable of handling components up to 1,000 tonnes, catering to the next generation of floating wind turbines, ranging from 15-20 MW. This system is expected to address the growing logistical challenges posed by large-scale floating wind turbines.
“Geodis is committed to supporting the offshore wind sector with a comprehensive suite of services. The Mobile XXL OHME will provide a scalable and sustainable solution to meet the demands of next-generation floating wind turbines,” said Nicolas Bonnier, Global Manager of Offshore Wind Solutions at Geodis.
These advancements in lifting technology not only promise to reduce costs but also improve operational efficiency across the wind energy sector, ensuring that the growing demand for renewable energy is met with innovative solutions.