1. Ricardo plc
Presentation to UKTI - Offshore Wind & Marine Energy Workshop
“Introduction to Ricardo Design and Innovation Capabilities”
28th February 2012
www.ricardo.com
© Ricardo plc 2012

2. Ricardo Overview
Ricardo delivers world class strategy, engineering and technology programmes to the global
automotive, transportation, defence and energy industries
Company Positioning
 Established in 1915 and independent
 £196.5 million revenue (FY 10/11), up 21%
£162.8 million revenue (FY 09/10)
 More than 1.600 employees with more than 1.300
technically qualified and engineering staff
 Global presence in 16 locations
Global Presence Ricardo supports
the full Clean
Energy systems
product lifecycle
© Ricardo plc 2012 2

3. Three dimensional Ricardo Core Business Model
Market Sectors provide domain expertise and ensure relevance, Product Groups provide deep
content technology and delivery from world class global engineering teams based around the globe
© Ricardo plc 2012 3

4. Ricardo provides technical and strategic support to project delivery
across all major Clean Energy technical sectors Wind Power references
Regional price differences can be significant mainly due to different
cost for total project development and technical solutions
BEFORE FINANCIAL
CRISIS IMPACT
Regional price differences [€/kW] Comments
2000
€/kW Project costs or add. project costs  The average total cost per kW of installed wind power
1800
Turbine system capacity differs between countries up to 100% due to
1573
significant cost differences for project development
1302
307 1289
275 1300
1262
1250
305 1217
800
1210
500
272 1121
1100
1100
1088
and application of different technologies
980
 The cost per installed wind power typically varies from
around 1000 €/kW (DEN) to 2000 €/kW (IRE) and
1300
1200
1146
1025
averages at 1300 €/kW
982
912
845
849
 Turbine system costs varies between 850 €/kW (DEN
Wind Power references
& USA) and 1300 €/kW (ITA) and averages at 1000
MEX
ITA
JPN
IRE
DEN
NED
NOR
GER
POR
CH
CAN
GRE
USA
ESP
UK
€/kW
Due to the difference in market penetration,it is important to
Source: IEA, 2006 & 2007
 Few numbers have been reported for Sweden
Turbine versus project and TCO costs manufacturers to be first movers with large projects there
Strategic
BEFORE FINANCIAL
% of turbine
 Turbine system costs generally include nacelle, tower, CRISIS IMPACT
system costs
~185% Windblades, internal electrical system, transport and
rotor
market categorisation, 2007
erection (100%)
~130% 55 O&M
 Embryonic
Project costs generally include costs for the turbine Growing Mature
Wind Energy
Project
100% 30 30 system plus land & land development, foundation & * Denmark
development
Technical wind potential
* Austria (3GW)
Installed capacity vs.
Turbine
civil works, electrical connection, control systems, EUROPE
100 100 100 W)
consultancy and finance (+ appr. 30%) (57G
system
 Total costs of ownership (TCO) include project costs * Germany
Consulting
Total cost (22GW)
Turbine Project
system costs of ownership plus operations and maintenance over the lifecycle ) * Spain
W * Portugal (15GW)
* Netherlands A
(ex. Works) (TCO) time (+ appr. 55%) (16G
Source: Ricardo estimation EAST IA RIC
AFRICA & MIDDLE AS India
* (8GW) * UK (2GW) TH AME
NOR W)
RD.08/12354.1
(0,5GW) © Ricardo plc 2008 28 (18G
* Poland * Norway
Systems
Japan
* Iran *
Egypt
* South Rest of *Greece Sweden * Italy * Belgium * USA
* * Ireland (16GW)
* Marocco Korea
* Taiwan * Europe * China *(0,7GW) * France * Canada
(2GW)
(6GW)
Time
Market  Market characterized by high  Competition is heating up for  Due to experience, the service
situation growth rates, coming from a available manufacturer capacity market is more competitive (OEM
low basis  Shortfall of supply for essential service provider, ISPs, in-house
components, technology issues service departments)
 Some mature markets already
display scarcity of good wind sites
SKAB’s Long-term these markets will Upward pressure on WTG and SKAB can profit from supplier’s
implications eventually pick up O&M service prices due to experience curve effects having
demand-supply mismatch. installed WTG in similar
Sweden is considered to be topographies
investment grade country with
double digit growth driven by
political will
Source: Ricardo Research, F&S 2007, GWEC 2008
RD.08/12354.1 © Ricardo plc 2008 22
Marine Energy Solar Energy
Engineering Systems
RICARDO
Fuel Cell
Engineering
CHP
Engineering
Energy Storage
© Ricardo plc 2012 4

5. Commercially - Ricardo’s Market strength can help clients develop
export products and overseas customer links and facilities
Ricardo can help customers by:
 Promoting overseas links to key business
contacts for export sales
 Assistance in developing links in other markets,
e.g. new European Offshore Wind markets
 Technical centre support and assistance to set-
up facilities and provide interim office space
 Supply chain development and management
 Support to gain public sector funding
 Links to testing facilities and management
 Support to obtain certification (GL, DNV, TUV)
required for bank financing / warranties
Ricardo are already doing this for major
wind turbine manufacturers
© Ricardo plc 2012 5

6. Technically - Ricardo’s strength in engineering and innovation can
help customers develop advanced products for the global market
Ricardo can help companies by:
 Helping manufacturers develop their “own
designs” rather than rely on licencing
 Design technology advantages (performance,
mass reduction and reliability) into new and
next-generation products
 Driving down the Cost of Energy through
reliability, performance and life-cycle 3.5MW 3-stage epicyclic gearbox (lower
engineering and innovation improvements mass, higher reliability)
 Analysing “through-life” performance and 10MW Variable Ratio Driveline
1:125 +/- 5% Four 2.5MW Generators
identifying improvement areas 1:20 Compound
Variable Ratio Stage
Epicyclic
“Torque Only” coupling
Ricardo are already doing this for major
wind and marine energy manufacturers
and drivetrain suppliers in many regions
als 2010
Jon Whe
Accumulators
10MW variable ratio split-path drivetrain
(lower mass, higher reliability)
© Ricardo plc 2012 6

7. Ricardo drivetrain development process and Ricardo software, can
include client participation, software licencing and training.
• Generate time
series/LDD for client
turbine design
• Verification of
client supplied time
series/LDD data
© Ricardo plc 2012 7

8. Drivetrain Design Approach
Design Optimisation Examples
Design Optimisation Process
Ricardo has extensive experience of structural design
optimisation applied across many disciplines:
Design
 Wind Turbine Gearbox Housing Space
– 33% improvement in weight for a given stiffness
Topology
– Improvement used to achieve greater stiffness - Optimisation
Housing deflection reduced by 42% with only 7%
increase in component mass Detail
– Factors of safety against extreme loading Design
maintained
– Complete turnkey task achieved including, design
analysis, models, drawings and reports in 7 weeks
 Carrier intelligent design
– Topology optimisation combined with design for
manufacture and assembly gives Ricardo more
novel solutions with significantly reduced weight
– Example of a cast iron design with an original
design weighing 2350kg. This was redesigned with
a 3% reduction in torsional stiffness and weight
reduced to 1600kg – a saving of 750kg or 32%.
© Ricardo plc 2012 8

9. Drivetrain / Power Take-Off Design Approach
Design for Manufacture, Assembly and Maintenance/Service
Ricardo can apply leading edge Design for Manufacture processes to reduce both production and
warranty cost
 Design for Manufacture and Assembly (DFMA)
– Alternative process selection
– Process complexity reduction
– Product simplification and design for serviceability
– Part count/cost reduction
– Assembly/Service complexity reduction
– Virtual build in 3D CAD to optimise design for assembly
 Design for Maintenance/Service
– Reliability prediction to identify key features for maintenance
e.g. Access to planet gears and flex pins for ease of replacement
– Consideration of nacelle handling facilities and space
– Consideration of design features and tools to support the ‘in nacelle’
environment
 Benefits of application in Design Phase:
– Reduced risk of manufacturing/assembly issues
– Improved confidence in ‘right first time’ design
– Improved serviceability/in nacelle maintenance
– Reduced warranty
© Ricardo plc 2012 9

10. Case Study
RSC procurement support of 120 wind turbines with a total invest of
mio€ ~310 for WTG + O&M saved the client more than mio€ 60
Six Step Approach to Procurement
Approach
Baseline
Definition
Supplier
Market
Analysis
Preparation
of
RFQ
Analysis of
Quotes
Negotiation
s
Implemen-
tation
 Ricardo managed the whole procurement process
 Procurement scope
– Turbines,
 Supplier market
structure analysis
 Develop procure-
ment strategy


Collect quotes
Analyse offers
 Develop negotiation
strategy (e.g. cadence
 Project implementation
management
 Ricardo Six-step Approach to Procurement applied
– strategy) – Project office
– Detailed supplier market analysis
O&M, Project Developers  Detailed analysis of – Price
development – Manufacturer demand side  1st round of – Issue manage-
– Quality ment
– Turbine size? – 1./2.-tier – Technical spec. negotiations
 Integrate offers into – etc.
– Technology? suppliers – Commercial databases
 Assessment
Interface management
– Evaluation of technology along product life cycle
 Supplier analysis: 
 Business case spec.  2nd round of neg.
 Financing (EU Strengths, weak- 
Generator
Create long list of pot.
 Generate short list
 On site excursion of
–
–
Investor
subsidies?) nesses, opportuni-ties
& threats of each
Gearbox
suppliers
 Schedule first round
of negotiations with
supplier facilities
–
Grid operator
Contractors
 Project & milestone  Decide on selection  Decision about – Authorities
supplier (SWOT) short listed
Activities

planning
Clarification of
readiness for project
 Price analysis (price
benchmark-ing for
wind farms)

criteria
Prepare request for
quotes (RFQ)
candidates

preferred supplier(s)
3rd and final
negotiation with

– etc.
Project & supplier
performance tracking
 Definition of the client requirements
implementation preferred supplier(s)
– Make or buy analysis along value-chain
 Cost analysis  Ensure compliance  Supplier management
– Permissions with legal – Price & payment  Budget/cost controlling
– breakdown on
– Location requirements – Delivery
compon.
selection  Send out RFQs schedule
– Total cost of
– Technical and commercial requirements
– Grid – Frame contract
connectivity
ownership 
Converter
Draft frame contract
– O&M
Control system – Service parts


Clear project scope
Infrastructural &
 Supplier market
transparency


Proc. Strategy
Selection criteria


Short list of suppliers
Negotiation schedule
 Preferred supplier
selected
 Successful,
in-time project
 Definition of RfQ, negotiation strategy, supplier
nomination, negotiations, factory inspections
Results commercial  Basic price- and cost  Supplier long list  Frame contract signed implementation
prerequisites clarified transparency  RFQ finalised
 Ricardo led supplier negotiations/selection
Situation and objective Results and benefits
 Utility client with ambitious plans in wind energy and  Good transparency of the supplier market with
secured finance backing from own balance sheet strengths and weaknesses by key player & market
 Determined to utilise the financial downturn for  Simple RFQ with functional specifications: 16
procurement of large number of wind turbines suppliers invited, 13 offers received from well
 Client has little experience in procurement of wind balanced mix of tenderers (low cost & high value;
turbines and the quality track records and cost levels direct drive & conventional; US, European & Asian)
for larger turbines (2-3 MW)  Four selection gates with 30%+ secured price
 Objective of the project was to procure 118 onshore reductions for WTG and O&M before 2nd gate
wind turbines rapidly at the right cost and with lowest  Duration of the total 3-phase project: ~12 months
CS: 164
operational life cycle risk  Total savings from 1st offer to final contract: mio€ 60+
© Ricardo plc 2012 10

11. Case Study – 1.5MW WT drivetrain upgrade
Ricardo role
 Ricardo undertook design review of the overall
drivetrain architecture and completed a concept
design for a new layout
 Ricardo completed detailed re-design and analysis
of the main frame, main shaft and bearing systems
 Ricardo liaised with the suppliers and teams
responsible for hub, pitch system, loads and control,
gearbox and generator to ensure a well-integrated
overall drivetrain solution
Situation and objective Results and benefits
 Long-established WT manufacturer  New drivetrain layout delivered with optimised
 Existing MW scale turbine already in production structure and weight
 Potential for uprate identified by manufacturer  Turbine uprate is being enabled within the weight
target required, to enable the uprated design to be
 Larger rotor and improved pitch control also to be
installed with the same equipment as the original
implemented as part of overall upgrade for:
design
– Improved load control
– Higher power production capability
© Ricardo plc 2012 11

12. Case Study – Concept and Detailed Design of 1MW Tidal Turbine
Ricardo role
 Detailed CFD analysis for commercial demonstrator
including flow assessment of blades and Venturi and
linked to generator model for load/speed balance
 Major loading input and boundary conditions
predicted to simulate components operating within
complete turbine system
 FE Analysis of steel and composite structure
including lifting frames for moving 1MW tidal turbine
components during manufacture
Situation and objective Results and benefits
 Device development plan required for scale-up and  Concept optimisation of blade number, blockage and
full size commercial demonstrator profile to achieve target performance
 Design support for concept layout, configuration and  Identified concerns over Venturi and improved
design of 1MW turbine design implemented for commercial demonstrator
 Detailed flow assessment of complete turbine unit  Ricardo developed concept for hybrid blade design
with individual models for blade design to optimise allowing manufacturing flexibility whilst retaining the
hydrodynamic development and durability blade structural benefits of composite materials
 Complete turbine model to assess manufacturing  Fatigue life prediction for frame using Ricardo
process (12 major lift operations planned) and sea FEARCE software – showed base structure
base structural loading and deformation performance acceptable for deployment
© Ricardo plc 2012 12

13. Case Study – 15MW Wind Turbine Drivetrain Test-rig Development
Ricardo role
 Ricardo undertook concept design of gearbox for the
testrig including application of advanced simulation
tools to ensure robust design of core rig component
 Ricardo supported definition of rig performance
envelope to maximise potential applications within
development cycle
 Ricardo defined the requirements for the installation,
commissioning and operation of the test-rig with the
prototype hardware installed
Situation and objective Results and benefits
 Design and development drivetrain testrig with  Ricardo provided support for engineering wind
partners for testing offshore WTG drivetrain under industry requirements and test and development
highly dynamic operating conditions application into the design of the testrig ensuring the
 Development of operational and test strategy for rig would be able to meet current and future
incorporation of advanced test facilities in the WTG requirements and represent value in the engineering
development cycle process
 Current status is definitive design phase of rig  Combined approach with Ricardo integrated into
completed ready to progress to detailed design and programme provided key application and operational
procurement of long lead hardware experience
© Ricardo plc 2012 13