Gregor McPherson - Caley Ocean Systems - Subsea UK

Offshore Renewables: Expanding vessel
capability to handle offshore renewable
energy projects
Gregor McPherson
Caley Ocean Systems
Copyright Caley Ocean Systems Ltd 2012

Overview
Caley Ocean Systems
Offshore renewables market
Offshore Renewables – Handling challenges
Offshore Vessels – Cable handling systems
Expanding vessel capability
Commercial in confidence
www.caley.co.uk

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 m 2 )
Commercial in confidence
www.caley.co.uk

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
Commercial in confidence
www.caley.co.uk

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
Commercial in confidence
www.caley.co.uk

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
Commercial in confidence
www.caley.co.uk

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
Commercial in confidence
www.caley.co.uk

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)
Commercial in confidence
www.caley.co.uk

Modular carousels
Built in design flexibility offers the best return
on investment
- 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
Swan Hunter, Feb ‘12
- Liftable or skiddable
- Containerised 10Te tensioner
- Full suite of ancillaries
- Lloyds approved
M4H00023.MP4
Commercial in confidence
www.caley.co.uk

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 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
Commercial in confidence
- Tight project timescales (Award Sept ’10,
completion at yard May ‘11)
www.caley.co.uk

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
Commercial in confidence
www.caley.co.uk

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 multi-product spooling
-Ability to handle back tension
-Ideal for array cabling
Commercial in confidence
www.caley.co.uk

Reel Systems
Array cable handling
- 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
Commercial in confidence
www.caley.co.uk

Expanding Vessel Capability
Modifying vessels to take advantage of
the opportunities in cable laying in the
offshore wind market
Commercial in confidence
www.caley.co.uk

Expanding Vessel Capability
Bare barges – storage, transportation
and installation
Telecom laying and maintenance
vessels
Rockdumping vessels
Offshore construction vessels
Commercial in confidence
www.caley.co.uk

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
Commercial in confidence
www.caley.co.uk

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)
Commercial in confidence
www.caley.co.uk

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.)
Commercial in confidence
www.caley.co.uk

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
Commercial in confidence
www.caley.co.uk