offshore renewables: expanding vessel capability to … mcpherson.pdf · -controlled accurate...

Copyright Caley Ocean Systems Ltd 2012

Offshore Renewables: Expanding vessel capability to handle offshore renewable energy projects

Gregor McPhersonCaley Ocean Systems

Commercial in confidencewww.caley.co.uk

Overview

Caley Ocean Systems

Offshore renewables market

Offshore Renewables – Handling challenges

Offshore Vessels – Cable handling systems

Expanding vessel capability


Caley Ocean Systems- Over 40 years experience of handling systems for

Offshore, Ocean Science and Naval Defence

- Oil and Gas, and Offshore Renewables - Pipe, Hose and Cable Handling

- Handling Systems (for Ploughs, trenchers, manned submersibles, ROVs and dive bells)

- Industry leading, heavy weather, Rescue and Work Boat Davits – Sea State 6

- Dedicated manufacturing facilities - 25,000 sq ft (2,323 m2)


Caley Ocean Systems – Track Record

With over 35,000Te of carousel storage capacity since 1998,our range of power cable handling systems include

-9,000Te Cable installation system

-2,500Te Twin turntable vessel conversion

-400Te Portable carousel

-200Te Array cable handling systems


The Offshore Renewables Market

- Global offshore wind market forecast to grow by 10% a year over the next 40 years – worth £170Bn per year. UK 12% market share worth £215Bn from 2010 – 2050 (Carbon Trust)

- 235 new offshore wind turbines, in nine wind farms, worth some €2.4Bn, were fully grid connected in 2011, totalling 866 MW (EWEA).

- Demand set to outstrip supply for HV subsea cables

Average water depth 23m, distance to shore 23 – 27km (0m water depths need to be considered).Germany 40m water depth, 100km offshore


Offshore Handling System - Challenges

Types of vessel

Barges; Dredging/rock dumping; Dedicated cable laying vessel; DP type offshore construction vessel

Choice of vessel can depend on,

Cable type – small diameter telecoms to armoured umbilical/power cable

Cable storage capacity – type of cable, distance from shore

Type of Offshore wind installation

Wind farm export cables

Array/Inter-Array cabling


Cable Handling Systems

Reel v basket

Cable types – Power cables often lack the tensile strength required for reel spooling

End terminations – Large, pre-made end termination assemblies (ETAs) are less of a feature with power cables

Bend radius – Rarely above 3.5m



Basket carousels (Turntables)

-Simple construction (Open/closed lattice structure)

-Ideal for larger diameter high density power cable (>150kg/m)

-High capacity (up to 9,000Te)

-Controlled accurate loading/deployment

-Loading arm capability critical

-Below deck or barge mounted

-Modular and portable

-No back tension means better cable protection

-Higher power than equivalent reel type carousels)


Modular carousels

- Client: Blue Offshore, 2012

- 7,000Te dynamic capacity (@28m diameter)

- Self contained loading tower

- 7m hub (expandable)

- Integral HPU and controls

- Standard Caley components throughout

- Liftable or skiddable

- Containerised 10Te tensioner

- Full suite of ancillaries

- Lloyds approved M4H00023.MP4

Swan Hunter, Feb ‘12

Built in design flexibility offers the best return on investment


Below deck conversion

- Client: Global Marine Systems Ltd

- Two high capacity 2,500Te basket turntables for CS Sovereign (3,000Te static)

- Extend vessel capabilities to include non-coilable cables while retaining full telecoms capability

- Installed in existing cable tanks, with a need to retain maximum storage volume

- Loading arms / cable tracks for cables with 4.0m minimum bend radius

- Adapted to use existing HPUs tensioners and overboarding system

- Tight project timescales (Award Sept ’10, completion at yard May ‘11)

Still modular but extending an existing vessel utilisation


- FEED study, vessel survey

- Planning, HSE, Risk assessments

- Design (Integrated FE, calcs, detailing)

- Interface engineering (Client/NA/Yard/Third party)

- Cable routing (loading arm, chutes, roller tracks)

- Vessel preparation, installation planning

- Commissioning and crew training

- Sea trials and handover

Below deck conversion



High capacity reels

-More versatile than ‘Coflexip type’ reels

-High capacities (200Te plus)

-Accurate spooling and tension control

-Suited to a wide variety of cable, flexible pipe and umbilicals

-Deck mounted; liftable; road transportable

-Flexible multi-product spooling

-Ability to handle back tension

-Ideal for array cabling


Reel Systems

- Client: Global Marine Systems Ltd, 2011

- 200Te capacity reels systems (2)

- Right angled level winds (3.5m bend radius)

- Integral HPU and controls

- Flange 5.7m OD, but fully road transportable

- Multi-partitioned drum

- Containerised tensioner

- Quadrant compensator

- Ancillaries

- Lloyds approved© Severn Partnership

Array cable handling

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Expanding Vessel Capability

Modifying vessels to take advantage of the opportunities in cable laying in the offshore wind market



Bare barges – storage, transportation and installation

Telecom laying and maintenance vessels

Rockdumping vessels

Offshore construction vessels



Planning considerations (range of products, future deployments etc.)

Portability, e.g., Bearing design (Slewing ring capacities up to 1200Te)

Adaptability – Hub diameter and height;

Floor diameter and height - Partitioning;

Future proofing e.g., Blue Offshore (reel/basket interchangeability)

Mobilisation strategies – time v capital cost; lift facilities


Critical Components

- Diameter range (Can be up to 350mm)

- Product stiffness (400kNm2 and above on some export cables)

- End terminations (Tend not to be large)

Cable management and loading arm design


Other considerations

- Client preference (Experience/skill set)

- Installation (temporary/permanent/above, below deck)

- Integration with other equipment

- Size and space availability

Drives – Hydraulic v variable speed electric

Maintenance

- Inspection plans

- Lubrication (tracks, chains, rollers, bearings, etc.)


Conclusions

A fresh approach to cable installation can yield effective returns on capital investments

Project costs can be contained by imaginative use of alternative vessels

High quality engineering can reduce project risks

Your clients cables are vulnerable - they are easily damaged and expensive to replace

Let us help you to look after them

Thank you

offshore renewables: expanding vessel capability to … mcpherson.pdf · -controlled accurate...

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