Offshore Renewables: Expanding vessel capability to handle offshore renewable energy projects. Gregor McPherson Caley Ocean Systems
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1 Offshore Renewables: Expanding vessel capability to handle offshore renewable energy projects Gregor McPherson Caley Ocean Systems Copyright Caley Ocean Systems Ltd 2012
2 Overview Caley Ocean Systems Offshore renewables market Offshore Renewables Handling challenges Offshore Vessels Cable handling systems Expanding vessel capability
3 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)
4 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
5 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 (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
6 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/InterArray cabling
7 Cable Handling Systems Reel v basket Cable types Power cables often lack the tensile strength required for reel spooling End terminations Large, premade end termination assemblies (ETAs) are less of a feature with power cables Bend radius Rarely above 3.5m
8 Cable Handling Systems 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)
9 Modular carousels Built in design flexibility offers the best return on investment Client: Blue Offshore, ,000Te dynamic capacity 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
10 Below deck conversion Still modular but extending an existing vessel utilisation Client: Global Marine Systems Ltd Two high capacity 2,500Te basket turntables for CS Sovereign (3,000Te static) Extend vessel capabilities to include noncoilable 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)
11 Below deck conversion 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
12 Cable Handling Systems 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 multiproduct spooling Ability to handle back tension Ideal for array cabling
13 Reel Systems Array cable handling Client: Global Marine Systems Ltd, Te capacity reels systems (2) Right angled level winds (3.5m bend radius) Integral HPU and controls Flange 5.7m OD, but fully road transportable Multipartitioned drum Containerised tensioner Quadrant compensator Ancillaries Lloyds approved Severn Partnership
14 Expanding Vessel Capability Modifying vessels to take advantage of the opportunities in cable laying in the offshore wind market
15 Expanding Vessel Capability Bare barges storage, transportation and installation Telecom laying and maintenance vessels Rockdumping vessels Offshore construction vessels
16 Expanding Vessel Capability 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
17 Critical Components Cable management and loading arm design Diameter range (Can be up to 350mm) Product stiffness (400kNm2 and above on some export cables) End terminations (Tend not to be large)
18 Other considerations Drives Hydraulic v variable speed electric Client preference (Experience/skill set) Installation (temporary/permanent/above, below deck) Integration with other equipment Size and space availability Maintenance Inspection plans Lubrication (tracks, chains, rollers, bearings, etc.)
19 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
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