Solent Composite Systems

www.solentcomposites.com

EWEC 2010 Warsaw

Huw Radley

Solent Composites Systems Ltd

AbstractSolent Composite Systems Ltd (SCS) manufacturer of ProTek™ passive fire and blast protection

systems used in the offshore Oil & Gas industry has developed an innovative passive fire and blast protection system for safeguarding transformers and critical equipment located on offshore wind substations. This composite solution delivers the required risk management whilst offering significant weight saving over steel systems coupled with low life cycle cost based on low maintenance requirement.

Structural Composite offshore substation concept

IntroductionThe advent of large scale offshore wind farms, especially those further offshore, is calling on

advanced transmission and distribution technology for grid connection. These grid networks utilise both HVAC and HVDC for longer distances (above 80-100km offshore), that ultimately will form part of the Supergrid. This will enable Europe to trade energy multilaterally and thus contribute to increased energy security across a broad network. In the interim such substations will form a crucial part of the grid connection direct to shore for wind farms being built in the North Sea and the Baltic from now until 2020.

Solent Composite Systems Ltd, Victoria Barracks, Albany Road, East Cowes, IOW, PO32 6AA, United Kingdom. Tel +44 (1983) 292602

PASSIVE FIRE PROTECTION FOR OFFSHORE SUBSTATIONS PAGE 1

Solent Composite Systems

www.solentcomposites.com

The announcement of the UK Round 3 facilitating over 25GW of new offshore wind in UK waters by 2020 will herald a new era of offshore substation technology, and simultaneously meet the need to keep wind energy transmission safe and secure.

EWEC 2010 Warsaw

Offshore EnvironmentExperience in the Offshore Oil and Gas industry affords a clear understanding of the hazardous offshore

environment - particularly in the North Sea. In addition to protecting critical equipment from fire and blast, the offshore industry has learned to design for this harsh environment - inclement weather, wide temperature range, relentless salt spray and corrosion risk, throughout the platform’s life, typically 30 years. Furthermore, today’s environmental concerns demand robust pollution protection.

Design and Risk CriteriaAs on oil and gas platforms, space management is at a premium on offshore substations. Lightweight

structural composites provide optimum packaging with no compromise to health and safety. Each area is carefully assessed for fire and explosion risk and designed accordingly. Given the size of offshore substations weight is of critical importance to reduce the need for high capacity jack up barges in the assembly and installation phase.

Though the substation risk profile is lower than the jet fire experienced on oil platforms, there remain defined risks of pool fire conditions and blast pressures of up to 1Barg - a level which can readily managed by carefully designed composite structure system. The light weight composite structure can be easily assembled onshore or offshore without hot-work.

Current designs include heli-decks and accommodation blocks for maintenance crews which will obviate a higher risk profile in specific areas of the platform.

Critical assets including the main transformers, which contain high volumes of cooling oil, can be protected for 2 hours at 65ºC even in a 1200ºC hydrocarbon fire. No additional insulation is required to meet – A60, H60 or H120 integrity. Additionally a 50mm panel provides sound attenuation of up to 38 Db complying with latest NORSOK and HSE standards.

ISO 22889 hydrocarbon fire 0.3kg /sec gas release Large scale Jet Fire test 3.00kg /sec gas release

Solent Composite Systems Ltd, Victoria Barracks, Albany Road, East Cowes, IOW, PO32 6AA, United Kingdom. Tel +44 (1983) 292602

PASSIVE FIRE PROTECTION FOR OFFSHORE SUBSTATIONS PAGE 2

Solent Composite Systems

www.solentcomposites.comSolent Composite Systems Ltd, Victoria Barracks, Albany Road, East Cowes, IOW, PO32 6AA, United Kingdom. Tel +44 (1983) 292602

PASSIVE FIRE PROTECTION FOR OFFSHORE SUBSTATIONS PAGE 3

EWEC 2010 Warsaw

The structural composite panels are mounted on corrosion resistant steel frames thus providing an extremely rigid durable but lightweight structure which can manage severe blast and wind loads, up to 1.5 Barg over pressure. Blast relief vents may be designed in to meet specific hazard requirements and accidental loads from gas cloud explosions, which tend to precede most fire incidents.

Performance OffshoreThe lightweight ProTek™ composite multi-layer structure is virtually inert, thus providing exceptional

corrosion and weather resistance over a very long life cycle - significantly longer than traditional spray-up steel systems. Design life expectancy is in excess of 30 years with zero maintenance and no pollution risk. Actual offshore experience curve now exceeds 20 years.

Composite enclosures are lightweight and easy to install without special tools. Equipment service or inspection if required is quick and easy using latched lift-off panels. Fire and blast proof doors and windows can be fitted if required.

Performance Summary

• Lightweight composite panels - 25% weight of steel• Fire Protection up to 2.5 hours Jet fire - ISO 22899• Blast Protection up to 1.5 barg over pressure plus wind and snow loads• Thermal Insulation up to 1200°C • Sound Attenuation of up to 38DB • Resistance to global offshore environment• Performance design life of 30 years • Easy access for inspection• Zero maintenance – “Fit and Forget”• Low lifecycle cost vs. steel alternatives.

Typical twin transformer protection structure Composite Blast relief vents if required

Solent Composite Systems

www.solentcomposites.comSolent Composite Systems Ltd, Victoria Barracks, Albany Road, East Cowes, IOW, PO32 6AA, United Kingdom. Tel +44 (1983) 292602

EWEC 2010 Warsaw

Additionally SCS holds DNV certification for Fire & Blast Design Methodology, based on hundreds of installation in the North Sea over a period of 20 years.

10 metres high composites fire and blast enclosure for valve and actuator on Snøhvit LNG plantHammerfest Norway

Composites Track RecordSCS has a proven track record of providing structural composite asset protection and loss prevention to

the offshore oil and gas industry for 20 years.

SCS also provides a portfolio of services in design, engineering and manufacturing technology of wind turbine blade moulds and components, including wave and tidal and micro-generation.

SCS energy industry expertise coupled with world class Quality, Health, Safety and Environmental standards enables it to execute major projects on time and on budget- mitigating risk at every stage.

SCS operates a DNV certified integrated management system incorporating. ISO 9001, ISO 14001 & OHSAS 18001. SCS is registered to Achilles JQS & FPAL as accredited supply to the

offshore industry.

All ProTek ™ structures carry third-party certification, including DNV and Lloyds and meet DNV-OS-J201 Offshore Substations for Wind Farms Oct 2009. This Joint industry Practice guideline (JIP) outlines the safety requirements for offshore transformers, converters & accommodation platforms for offshore wind farms.

PASSIVE FIRE PROTECTION FOR OFFSHORE SUBSTATIONS PAGE 4