offshore: groter, sneller, efficiënter

1

Offshore: groter, sneller,

efficiënter

10 november 2011

‘s-Hertogenbosch

Offshore W

ind Installation

Experienced, Safe, Reliable

Avans H

ogeschool 10 N

ovem

ber 2011 –

“Offshore

: gro

ter, s

nelle

r, e

ffic

iënte

r””

Jan-P

ete

r B

reedeveld

Index

1)

Introduction S

HL

2)

Com

parison O

il &

Gas

3)

Case s

tudy

�G

reate

r G

abbard

�S

heringham

Shoal

4)

Jacket in

sta

llation

5)

Turb

ine insta

llation

6)

Substa

tion insta

llation

7)

To c

onclu

de

3

4

SHL Installation

Experienced, Safe, Reliable

�20 y

ears

of in

sta

llation e

xperience in O

il &

Gas a

nd O

ffshore

Win

d m

ark

et

�O

ver 140 p

latform

s a

nd o

ver 200 foundations insta

lled (80%

North

Sea)

�O

wn a

nd o

pera

tes m

onohull

cra

ne v

essels

Sta

nis

lav Y

udin

(2,5

00 m

T) and

Ole

g S

trashnov (5,0

00 m

T) and k

ey

insta

llation e

quip

ment, s

uch a

s p

iling

ham

mers

�E

xtensiv

e in-h

ouse e

ngin

eering e

xpertis

e a

nd e

xperienced o

ffshore

cre

w

�O

ffering lum

p-s

um

, fixe

d p

rice c

ontracts

(fu

ll w

eath

er risk taken b

y S

HL)

�D

eliv

er a s

afe

, sound, re

liable

and e

conom

ic o

ffshore

insta

llation s

olu

tion

based o

n a

n a

s-insta

lled c

ost basis

5

SHL Premises

Cyp

rus O

ffic

e L

imassol

Neth

erlands O

ffic

e Z

oete

rmeer

SHL installation equipment; perfect for

foundation and substation installation

�2,5

00 m

T revolv

ing c

apacity

�Length

183 m

/ B

readth

36 m

/ 1

40 p

ob

�2,5

00 m

2deck s

pace

�5.5

m m

inim

um

dra

ught

�A

nchors

�5,0

00 m

T revolv

ing c

apacity

�Length

183 m

/ B

readth

47 m

/ 2

20 p

ob

�4,0

00 m

2deck s

pace

�8.5

m m

inim

um

dra

ught

�A

nchors

and D

P 3

Stanislav Yudin

Oleg Strashnov

6

SHL owns all key installation equipment

�H

ydra

ulic

piling h

am

mers

�IH

C S

-500

�IH

C S

-600

�IH

C S

-900

�IH

C S

-1200

�IH

C S

-1800

�P

ile top d

rill

rig

�400 m

T levelling tools

�In

tern

al pile

lifting tools

(up to 8

4”)

�S

lings a

nd (hydra

ulic

) shackle

s

7

8

An impressive client portfolio

EGPC

9

SHL Footprint on the Globe

Solid offshore wind track record

Project

Scope

Gre

ate

r G

abbard

Foundations, S

ubsta

tions a

nd M

et M

ast

Sheringham

Shoal

Foundations a

nd S

ubsta

tions

Bork

um

West II

Tripods a

nd S

ubsta

tion

Riffg

at

Foundations a

nd S

ubsta

tion

Thanet

Substa

tion

Dan T

ysk

Substa

tion

Meerw

ind

Substa

tion

Nord

see O

st

Substa

tion

Gw

ynt y

Môr

Substa

tions

Anholt

Substa

tion

10

SHL provides safe and fast solutions for

monopile and jacket installation

Note

: “d

ura

tions”are

inclu

din

g a

.o. w

eath

er, tra

nsport, le

velli

ng, gro

uting a

nd b

reakdow

n

11

Wind Energy Potential

12

Wind Energy Potential

13

SHL to strengthen their position in the

offshore wind m

arket in cooperation

�M

arine c

ontracto

r fo

r th

e w

hole

offshore

tra

nsport a

nd insta

llation s

cope!

�O

ffer lu

mp-s

um

insta

llation c

ontracts

in the o

ffshore

win

d m

ark

et

�Fix

ed p

rice p

er in

sta

llation

�D

rives innovation a

nd im

pro

vem

ent (industria

lise / low

er costs

)

�E

nte

r in

to a

Long T

erm

Fra

mew

ork

Contract w

ith U

tilit

ies / D

evelo

pers

�Join

tly

develo

p m

ost effic

ient in

sta

llation c

oncept (e

arly

involv

em

ent)

�In

vest in

(purp

ose b

uild

) in

sta

llation e

quip

ment if required

�M

anagem

ent of oth

er vessels

/ s

erv

ices

14

Index

1)

Introduction S

HL

2)Comparison Oil & Gas

3)

Case s

tudy

�G

reate

r G

abbard

�S

heringham

Shoal

4)

Jacket in

sta

llation

5)

Turb

ine insta

llation

6)

Substa

tion insta

llation

7)

To c

onclu

de

15

We all started the same…

Offshore locations

Offshore

oil

and g

as

Offshore

win

d

16

�N

ear shore

�M

inim

um

wate

r depth

�S

heltere

d a

reas

We all started the same….

Installation equipment

Offshore

oil

and g

as O

ffshore

win

d

1973

~1950

2010

2008

Sheerleg

Jack-u

p

17

Developments

�Further offshore

in d

eeper w

ate

rs

�H

eavie

r and larg

er structu

res

�H

igher volu

me in repetitive insta

llation

Requirements

�S

afe

, sound, re

liable

and industria

lised (in

sta

llation) solu

tion

�E

xperienced o

ffshore

(construction) cre

w

�E

quip

ment able

to w

ork

in h

ars

h o

ffshore

conditio

ns

�S

ubsta

ntial cra

ne c

apacity

(outreach a

nd lift capacity)

�E

quip

ment able

to s

tay

offshore

and take c

arg

o b

arg

e a

longsid

e (fe

eder sys

tem

)

�D

edic

ate

d (handlin

g) equip

ment (h

am

mer, lifting tools

, upendin

g tools

, …

)

…and then we m

ove further offshore

Installation requirements

North S

ea o

ffshore

conditio

ns

18

Some m

ishaps Oil & Gas

Topsid

e insta

llation w

ith S

heerleg

1966

Jack-u

p p

unch thro

ugh (exam

ple

)

19

2010

Some m

ishaps Offshore W

ind

�Various projects

�M

in. 6 m

onth

s d

ela

y due to p

oor w

ork

ability

of in

sta

llation e

quip

ment

�G

rout fa

ilure

(poor desig

n)

�Larg

e v

ariation in p

ile d

rivin

g resis

tance

�Logis

tic p

roble

ms (supply

of m

ate

rial, load o

ut, e

tc)

�…

……

.

20

From near-shore to off-shore (in Oil & Gas)

Equipment selection is key

0

20

40

60

80

100

120

140

1950

1960

1970

1980

1990

2000

2011

020

40

60

80

100

120

140

Technology

Let’s c

ontinue in

Offshore

Win

d,

usin

g O

il &

Gas

experience

Distance to shore

21

From day-rate to lump-sum contracting in

Oil & Gas

�O

il and g

as s

tarted w

ith d

ay-

rate

contracts

=> m

ore

days

, m

ore

$

�V

essels

chartere

d for series o

f pla

tform

s

�The b

ill w

as p

aid

at th

e e

nd o

f th

e c

ontract by

the O

il C

om

pany

�O

il C

om

panie

s s

oon s

tarted to d

em

and for perform

ance d

riven / lum

p-s

um

contracts

�C

ontracto

rs h

ad to b

e m

ore

innovative to d

eliv

er and e

arn

their m

oney

�U

se w

eath

er sta

tistics for unders

tandin

g e

xposure

�D

evelo

p im

pro

ved insta

llation m

eth

ods a

nd (handlin

g) equip

ment

�D

evelo

p h

ydra

ulic

piling h

am

mers

vers

us s

team

ham

mers

�U

se o

f back-u

p e

quip

ment

22

From day-rate to lump-sum contracting in

Offshore wind

�P

roje

cts

will m

eet in

sta

llation s

chedule

/ d

eadlin

es

�R

isks a

re p

ut to

the p

arty

who is a

ble

to m

anage it

�In

sta

llation c

osts

are

know

n u

pfront

�no c

ost overr

uns, no p

re-investm

ents

, no loss o

f pro

ject in

com

e

�In

sta

llation in c

om

plia

nce w

ith H

SE

and M

arine W

arr

anty

Surv

eyo

r

requirem

ents

�C

ontinues innovation / im

pro

vem

ent on insta

llation

�W

ith p

roven c

oncepts

as a

sta

rtin

g p

oin

t

23

Safe

ty &

Schedule

Relia

bili

ty &

Fix

ed

Cost

Gro

ter, S

nelle

r, E

ffic

iente

r

Index

1)

Introduction S

HL

2)

Com

parison O

il &

Gas

3)Case study

�Greater Gabbard

�Sheringham Shoal

4)

Jacket in

sta

llation

5)

Turb

ine insta

llation

6)

Substa

tion insta

llation

7)

To c

onclu

de

24

Project comparison

25

Projects

Greater Gabbard

Sheringham Shoal

Wate

r depth

m L

AT

22 - 3

214 - 2

4

MP's

by

SHL / T

ota

l#

140 / 1

40

66 / 9

0

TP's

by

SH

L / T

ota

l#

0 / 1

40

71 / 9

0

MP T

op D

iam

ete

rm

5.1

4.7

MP F

oot D

iam

ete

rm

5.5

- 6

.35.2

- 5

.7

MP L

ength

m58 - 6

844 - 6

1

MP P

enetratio

nm

28 - 3

323 - 3

7

TP H

eig

ht

m25

MP W

eig

ht

mt

510 - 6

76

375 - 5

31

TP W

eig

ht

mt

220

Curr

ent (M

ax.

)kn

3.0

2.5

Tid

ual r

ange

m H

AT-L

AT

43

Key issues

�Safety and quality -

maxi

mis

ed b

y S

HL’s

adhere

nce to industry

sta

ndard

s

�Project installation schedule -

optim

ised b

y S

HL’s

ow

n insta

llation v

essels

,

equip

ment and s

killed, exp

erienced o

ffshore

cre

w

�Project bankability -

maxi

mis

ed b

y S

HL’s

20 y

ears

offshore

insta

llation

experience a

nd s

trong b

ala

nce s

heet

�Installation budget -transpare

nt due to S

HL’s

Lum

p s

um

insta

llation

contract, inclu

din

g w

eath

er risk

�Interface risk -

min

imis

ed b

y S

HL’s

ext

ensiv

e e

xperience a

s a

n insta

llation

pro

ject m

em

ber

�Foundation and installation solution –

optim

isation e

nsure

d b

y S

HL’s

ow

n

in-h

ouse e

ngin

eering e

xpertis

e

26

Greater Gabbard offshore wind farm

�S

econd larg

est offshore

win

d farm

(504 M

W, 140 turb

ines, are

a o

f146 k

m2)

with larg

est fo

undations to d

ate

(up to: W

680 m

T / L

70 m

/ D

6.3

m)

�lo

cate

d in the N

orth S

ea,

25km

off the S

uffolk

coast

�D

evelo

ped b

y S

SE

in a

join

t ventu

re

with R

WE

npow

er re

new

able

s

�Tra

nsport a

nd insta

llation o

f 140 foundations a

nd tw

o s

ubsta

tions;

subcontracte

d b

y Flu

or Lim

ited to S

HL

�In

sta

llation s

plit

over tw

o s

easons d

ue to p

iling restric

tions

27

3.1

Case

stu

dy

–G

reate

r G

abbard

Vessel size and sufficient lift capacity improves

safety, efficiency and creates high workability

28

Robust offshore

tra

nsf

er

Ow

n p

iling h

am

mers

Excelle

nt w

ork

ability

Fast & S

afe

handlin

g

3.1

Case

stu

dy

–G

reate

r G

abbard

Greater Gabbard -Net duration

Average 16 hours / m

ono pile

Dyneema Fiber Slings

High density PE liner plates

29

3.1

Case

stu

dy

–G

reate

r G

abbard

�P

erform

ance-d

riven c

ontracts

drive innovation, safe

ty a

nd low

er costs

�N

et dura

tion (avera

ge): 1

6 h

ours

/ m

ono p

ile

�A

vera

ge p

ile d

rivin

g: 2.8

hours

�G

ross d

ura

tion (avera

ge): 0

.9 d

ay

(sum

mer)

–2.1

day

(win

ter)

/ m

ono p

ile

30

High workability created flexibility and

delivery, 8 weeks ahead of schedule

�A

ll m

ono p

iles insta

lled w

ithin

tole

rances, 8 w

eeks a

head o

f schedule

�39 m

ono p

iles insta

lled in J

uly

; 23 m

ono p

iles insta

lled in J

anuary

(W

inte

r)

�C

ontinued d

uring W

inte

r; p

ossib

le d

ue to h

igh w

ork

ability

�Fix

ed p

rice lum

p-s

um

contract pro

vid

ed fle

xibility

on s

chedule

�B

oth

substa

tions insta

lled in 8

-9 d

ays

(each)

�Topsid

es w

ere

insta

lled fully

com

mis

sio

ned a

nd teste

d

�Tra

ditio

nal substa

tion d

esig

n

(jacket &

topsid

e) in

sta

lled w

ith H

LV

to m

eet pro

ject schedule

and c

reate

flexib

ility

3.1

Case

stu

dy

–G

reate

r G

abbard

31

Sheringham Shoal

Challenging installation conditions

�317 M

W (88 turb

ines, A

rea o

f 35 k

m2)

�D

evelo

ped b

y S

cira (Join

t V

entu

re b

etw

een S

tato

il and S

tatk

raft)

�Locate

d in the G

reate

r W

ash, 17 -

23km

off the N

orfolk

coast (1

4 -

24 m

LA

T)

�C

ontract w

ith S

eaw

ay

Heavy

Lifting repla

ces the M

aste

r M

arine a

nd

MTH

øjg

aard

contract re

late

d to the rem

ain

ing s

ubsta

tions a

nd foundation

insta

llation w

ork

�Tra

nsport a

nd insta

llation o

f (r

em

ain

ing)

�66 m

ono p

iles

(up to 5

30m

T / 6

1 x

5.7

m)

�71 tra

nsitio

n p

ieces

(220m

T / 6

1 x

5.0

m)

�tw

o s

ubsta

tions

(each 1

,000 m

T)

3.2

Case

stu

dy

–Sheringham

Shoal

Inshore transfer (M

ono Piles)

32

3.2

Case

stu

dy

–Sheringham

Shoal

Inshore transfer (Transition Pieces)

33

3.2

Case

stu

dy

–Sheringham

Shoal

Deck layout (1)

34

3.2

Case

stu

dy

–Sheringham

Shoal

Deck layout (2)

35

3.2

Case

stu

dy

–Sheringham

Shoal

Deck layout (3)

36

3.2

Case

stu

dy

–Sheringham

Shoal

Deck layout (4)

37

Courtesy

of Sta

toil

3.2

Case

stu

dy

–Sheringham

Shoal

38

Pile upending (Lifting tool)

3.2

Case

stu

dy

–Sheringham

Shoal

Pile driving

39

3.2

Case

stu

dy

–Sheringham

Shoal

Pile verticality m

easurement systems

40

Along pile wall (Mini tilt)

Top of pile

Top of hammer sleeve (Octans)

Side of hammer sleeve (Cilinders)

3.2

Case

stu

dy

–Sheringham

Shoal

Transition Piece Installation

41

3.2

Case

stu

dy

–Sheringham

Shoal

42

Sheringham Shoal; installation completed

3 weeks ahead of schedule

�M

aid

en p

roje

ct fo

r H

LV

Ole

g S

trashnov

�Tra

nsport o

f fo

undations fro

m F

lushin

g

to o

ffshore

location o

n H

LV

deck

�B

oth

substa

tions topsid

es s

uccessfu

lly

insta

lled in 2

days

(M

ay

2011)

�Foundation insta

llation (M

ono p

ile +

TP

)

(tra

nsport, le

velling, gro

uting inclu

ded)

�M

ay

2011:

15

�June 2

011:

20

�July

2011:

16

�A

ugust 2011:

15 (

finis

hed 2

1-0

8-2

011)

�A

vera

ge

1.7

day

/ fo

undation

Courtesy

of Sta

toil

3.2

Case

stu

dy

–Sheringham

Shoal

43

Sheringham Shoal-Net duration

�N

et dura

tion (avera

ge): 1

8 h

ours

/ foundation

�A

vera

ge p

ile d

rivin

g: 2.2

hours

�G

ross d

ura

tion (avera

ge): 1

.7 d

ay

/ fo

undation

3.2

Case

stu

dy

–Sheringham

Shoal

Index

1)

Introduction S

HL

2)

Com

parison O

il &

Gas

3)

Case s

tudy

�G

reate

r G

abbard

�S

heringham

Shoal

4)Jacket installation

5)

Turb

ine insta

llation

6)

Substa

tion insta

llation

7)

To c

onclu

de

44

Jacket Installation –Noise M

itigation

45

�A

llow

able

subsea n

ois

e levels

160dB

at 750m

dis

tance

�P

ile d

rivin

g h

am

mers

pro

duce >

166dB

at th

is d

ista

nce

�N

ois

e m

itig

ation required.

�A

ir b

ubble

scre

ens

�S

ingle

or double

wall

sile

ncer in

com

bin

ation w

ith a

ir b

ubble

s

Pic

ture

courtesy

of IH

C H

ydro

ham

mer

�P

ost piling p

rovid

es c

halle

nges for nois

e m

itig

ation a

nd insta

llation a

ccele

ration

Jacket installation + Post piling

46

�U

se a

tem

pla

te, com

bin

ed w

ith a

vib

rato

ry a

nd im

pact ham

mer

Jacket installation + Pre piling

47

48

Jacket installation + Pre piling

Tripods and Piles on HLV

49

Jacket installation + Pre piling

Use of Silencer Frame

50

Jacket installation + Pre piling

Installation of Piles

51

Jacket installation + Pre piling

Installation of Piles

Jacket installation + Pre piling

Install Tripods onto Piles

52

Jacket installation + Pre piling

Deck Layout

53

Index

1)

Introduction S

HL

2)

Com

parison O

il &

Gas

3)

Case s

tudy

�G

reate

r G

abbard

�S

heringham

Shoal

4)

Jacket in

sta

llation

5)Turbine installation

6)

Substa

tion insta

llation

7)

To c

onclu

de

54

Current way of turbine installation is not

the way forw

ard

55

Current way of turbine installation is not

the way forw

ard

56

�C

urr

ently

turb

ines a

re m

ain

ly insta

lled w

ith jack-u

p v

essels

�C

urr

ently

turb

ines a

re m

ain

ly insta

lled o

ffshore

in 5

-6 lifts

�C

urr

ent tu

rbin

e insta

llation d

ura

tions e

xceed 1

week o

r m

ore

�Futu

re p

roje

cts

are

further offshore

in d

eeper w

ate

rs in e

ven m

ore

challe

ngin

g s

oil

and w

eath

er conditio

ns

�Futu

re p

roje

cts

ask for at le

ast 1 turb

ine insta

llation / d

ay

(/pro

ject)

�C

urr

ent in

sta

llation m

eth

od n

eed to c

hange i.e

. to

deal w

ith these

requirem

ents

�In

sta

llation n

eed to b

e inclu

ded in the turb

ine d

esig

n; th

is m

ight re

quire s

light

changes/a

dditio

nal in

sta

llation a

ids

Turbine installation

57

Turbine installation

58

Index

1)

Introduction S

HL

2)

Com

parison O

il &

Gas

3)

Case s

tudy

�G

reate

r G

abbard

�S

heringham

Shoal

4)

Jacket in

sta

llation

5)

Turb

ine insta

llation

6)Substation installation

7)

To c

onclu

de

59

Traditional jacket topside design provides

maxim

um flexibility and m

inim

um risks

60

Index

1)

Introduction S

HL

2)

Com

parison O

il &

Gas

3)

Case s

tudy

�G

reate

r G

abbard

�S

heringham

Shoal

4)

Jacket in

sta

llation

5)

Turb

ine insta

llation

6)

Substa

tion insta

llation

7)To conclude

61

Summary and conclusions

�A

pply

the lessons learn

ed fro

m O

il &

Gas in O

ffshore

Win

d

�E

quip

ment sele

ction is k

ey;

not ju

st sele

ct equip

ment because itis

availa

ble

�W

ork

ability

of m

arine s

pre

ad is a

key

issue in d

evelo

pin

g o

ffshore

win

dfa

rms

�W

ind turb

ine s

hall

be (re

-)desig

ned takin

g into

account offshore

insta

llation

meth

ods

�D

evelo

p innovative (te

chnic

al) s

olu

tions to d

ecre

ase insta

llation tim

e, m

itig

ate

subsea n

ois

e levels

and m

inim

ise (w

eath

er)

dela

ys

62

Fib

er Slin

gs

(Gre

ate

r G

abbard

)

Offshore

Win

d Insta

llation:

“gro

ter, s

nelle

r, e

ffic

iënte

r”…

…

….a

n industry c

halle

nge !!

63

Thank you for your attention!

28/1

1/2

011

64

65

Offshore: groter, sneller,

efficiënter

10 november 2011

‘s-Hertogenbosch