eolico-off-shore

Flanges for offshore wind foundations and towers. Rings for rotor, stator, blade extenders, break discs, pitch and yaw bearings, …

Know How

The trust placed in euskalforging from the beginning of the offshore sector has made it the world’s No. 1 manufacturer of flanges for:

  • Offshore foundations
  • Offshore towers
  • Shim flanges for offshore foundations

In a sector where delays in the construction of the wind farm, lengthy maintenance periods or failures in the equipment have a high economic impact, the supplied products must comply with the strictest technological requirements, guaranteeing the delivery time. This is why the clients continually trust in euskalforging to be able to guarantee the mechanical properties required in the most challenging environments, always meeting the agreed deadlines.

Foundations and towers

Each offshore wind farm has different features as regards temperature, depth and sea bed, all of which require a particular foundation in each case. The joint work between the client's engineering departments and euskalforging's  technical office determines the material grade (adjusting its chemical composition) and the production process, adapting them to the requirements of the flanges used in the foundation.

euskalforging has the capacity to meet the high technical demands of this sector in weldable steels and sections over 250 mm, diameters over 5,000 mm and heights over 200 mm:

  • Yield strength above 295 MPa
  • Tensile strength above 470 MPa
  • Impact value above 50 J at temperatures below or equal to –50ºC
euskalforging's ring rolling machines and machining centres have a capacity to manufacture 5,600 flanges per year with a diameter up to 10 metres.

Bearings, gearboxes and nacelle components

euskalforging’s state of the art production equipment positions the company as a market leader in the manufacturing of the critical components that determine the performance of offshore wind turbines

euskalforging’s leadership is reflected in the fact that it is the main supplier of the components listed below for turbines between 3 MW and 8 MW (currently the most powerful turbine in the commercial phase).

euskalforging manufactures the following components:

Key projects

Prototype tower 8MW Siemens Gamesa

Year: 2018
Destination: Denmark
End Client: Siemens Gamesa Renewable Energy
Grade: S355NL
Scope:
  • 2 rings ø 6000/5500 x 145 mm for the tower
  • 2 rings ø 6000/5450 x 160 mm for the tower
  • 2 rings ø 6000/5320 x 175 mm for the tower
  • 2 rings ø 6500/5800 x 185 mm for the tower
  • 1 ring ø 6900/5960 x 164 mm for the tower
Completion period: 3 months

DeBu offshore wind farm

Year: 2017
Destination: Germany
End Client: Northland Power Inc
Grade: S355NL
Scope:
  • 31 rings ø 6502/5940 x 181 mm for the monopile foundation
  • 31 rings ø 6702/5800 x 275 mm for the monopile foundation
Completion period: 4 months

Merkur offshore wind farm

Year: 2017
Destination: Germany
End Client: Consortium leaded by PG Merkur holding and InfraRed
Grade: S355NL
Scope:
  • 66 rings ø 6000/5380 x 282 mm for the monopile foundation
  • 66 rings ø 6002/5302 x 268 mm for the monopile foundation
  • 66 rings ø 6302/5382 x 289 mm for the monopile foundation
Completion period: 6 months

Galloper offshore wind farm

Year: 2016
Destination: UK
End Client: RWE
Quality: S355 G10
Scope:
  • 56 rings of ø 6000/5196 x 195 mm for the monopile foundation
  • 56 rings of ø 6300/5580 x 310 mm for the monopile foundation
  • 56 rings of ø 6500/5742 x 370 mm for the monopile foundation
 Completion period: 6 months

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Hywind offshore wind farm

Year: 2016
Destination: UK
End Client: Statoil
Grades: S355 G10
Scope:
  • 10 rings of ø 6500/5880 x 195 mm for the floating foundation
  • 10 rings of ø 6500/6040 x 186 mm for the floating foundation
  • 10 rings of ø 6500/5742 x 227 mm for the floating foundation
  • 5 rings of ø 6528/5742 x 227 mm for the floating foundation
  • 10 rings of ø 7500/6642 x 237 mm for the floating foundation
  • 10 rings of ø 7578/6642 x 241 mm for the floating foundation

Completion period: 3 months

Rampion offshore wind farm

Year: 2015
Destination: UK
End client: e.on
Grades: S355 G10
Scope:

  • 116 rings of ø 5000/4570 x 135 mm for the monopile foundation
  • 116 rings of ø 5000/4400 x 330 mm for the monopile foundation
  • 116 rings of ø 5305/4400 x 310 mm for the monopile foundation

Completion period: 6 months

Wikinger offshore wind farm

Year: 2015
Destination: Germany
End client: Iberdrola
Grades: S355 NL
Scope:

  • 41 rings of ø 6000/5432 x 200 mm for the jacket foundation
  • 29 rings of ø 6000/5432 x 195 mm for the jacket foundation

Completion period: 4 months

Dudgeon offshore wind farm

Year: 2015
Destination: UK
End client: Statoil
Grades: S355 NL
Scope:

  • 69 rings of ø 6000/5200 x 209 mm for the monopile foundation

Completion period: 3 months

Adwen AD 8-180

Year: 2015
Destination: Global
End client: Multiple
Grades: 42CrMo4
Scope:

  • Rings with an outer diameter ranging from ø 4642 mm to ø 4355 mm for the pitch bearing prototypes

Completion period: 2 months

Block Island offshore wind farm

Year: 2015
Destination: USA
End client: Deeperwater Wind; LLC
Grades: S355J2 / S355NL
Scope:

  • Rings of ø 4000/3270 x 106 mm for the brake disc
  • Rings of ø 3386/3065 x 141 mm for the blade extension
  • Rings with an outer diameter ranging from ø 6000 to ø 4000 mm for jacket foundations and tower flanges
  • Rings with an outer diameter ranging from ø 4785 mm to ø 2950 mm for the rotor and stator

Completion period: 3 months

Prototypes for an 8MW gearbox

Year: 2015
Destination: Global
End client: Multiple
Grades: Confidential
Scope:

  • Rings for the first and second stage

Completion period: 2 months

Gwynt y Môr offshore wind farm

Year: 2014
Destination: UK
End client: RWE Innogy
Grades: S355 NL
Scope:

  • 4 rings of ø 5000/4372 x “variable height” for the monopile foundation's shim flanges

Completion period: 1 month

Luchterduinen offshore wind farm

Year: 2014
Destination: Netherlands
End client: ENECO
Grades: S355 NL
Scope:

  • 43 rings of ø 4500/3820 x 225 mm for the monopile foundation

Completion period: 4 months

Siemens SWT D6.0/D7.0 • Bearings

Year: 2014
Destination: Global
End client: Multiple
Grades: 42CrMo4
Scope:

  • Regular supply of rings with an outer diameter ranging from ø 3954 mm to ø 3559 mm for the blade bearing

Completion period: 2 months

Siemens SWT D6.0/D7.0 • Rotor House

Year: Since 2012
Destination: Global
End client: Multiple
Grades: S355 NL
Scope:

  • Regular supply of rings with an outer diameter ranging from ø 6527 mm to ø 4591 mm for the rotor house

Completion period: 2 months