Inspection and maintenance at the Merkur offshore wind farm

Transition pieces form the interface between the foundation, the tower, and offshore access. Their condition is critical for structural integrity, occupational safety, and the reliable operation of numerous systems.

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The transition pieces of the Merkur offshore wind farm required regular and traceable inspections for structural integrity, occupational safety, and electrical functionality. Diverse inspection scopes, specialized qualifications, weather-dependent CTV transfers, and documentation for 66 locations had to be consolidated into a single campaign logic.

01 · Preparing the campaign

Method statements, risk assessments, checklists, material packages, and CTV logistics for structure, safety, electrical systems, and small repairs were coordinated prior to the offshore deployment.

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02 · Coordinating three technical workstreams

Parallel teams handled structural inspections, annual safety checks, and electrical inspection and maintenance tasks. Qualifications and measuring equipment were assigned according to specific needs.

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03 · Executing specialized inspections

Methods used included videoscopy below the airtight deck, atmospheric monitoring, visual inspections, and measurements on MP/TP flange connections, allowing for the assessment of even hard-to-reach areas.

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04 · Addressing defects directly

Minor repairs and the replacement of defective components were integrated directly into the campaign wherever technically and logistically feasible.

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05 · Documenting results

Completed checklists, inspection reports, daily logs, and digital photos created a standardized, site-specific record for all transition pieces serviced.

• 66 spatially distributed transition pieces with daily CTV logistics from Borkum.
• Structural, safety-related, and electrical services from a single coordinated source.
• Work in confined spaces with controlled atmospheres and videoscopic inspection.
• Weather-dependent offshore campaign with planned workability and integrated standby times.

The annual campaigns from 2020 to 2026 were successfully completed—each year on time and within budget. Documentation covers 17 transition pieces in the WKP program as well as safety inspections at 66 locations.

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Example 2020 campaign: Work was completed within the scheduled 42-day timeframe—nine transition pieces in the WKP program, safety inspections at 33 locations, and completion two days ahead of schedule. The project review confirmed that material availability and personnel qualifications met all requirements.