May 2017 | Hamburg, Germany
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November 2016 – August 2017 | Germany/Denmark/UK – Northern Ireland
Time flies. Seven years ago, SAL was nominated for the first delivery to the Walney Project. Back then MV Annette transported foundations from Rostock to Barrow in Furness. It becomes clear how the dimensions have changed within these few years – in 2010 our type 161 vessel (2 × 350 t SWL) was adequate, but now a type 183 (2 × 1000 t SWL) is needed to ship these colossal structures.
SAL is back on the job for Walney once again.
MV Svenja is currently playing a fundamental role in the extension of the Walney Offshore Windfarm, located in the North West of England. At the moment, the vessel is transporting a total of 87 colossal Monopiles (MPs) from Rostock to Belfast. In addition 87 Transition Pieces (TPs) will be carried by MV Svenja from Tees and Aalborg to the project harbor. With a height of up to 30 metres, a diameter of up to seven metres and a single weight of up to 579 tons, the TPs are amongst the largest ones ever built. It is an enormous job keeping our MV Svenja busy until summer.
The long-term project is characterized by several challenges. Two different types of cargo. Each requiring its own mobilization setting on board. To be shipped alternately. A tight schedule from customer side demanding flawless workflows for a pinpointed delivery. Three different loading ports. Limited possibilities at the Port of Rostock with only ten metres space forward and aft of the moored vessel. A sensitive cargo even if its appearance seem to tell the opposite.
Philip Stackmann, Project Manager, and Sebastian Wenzel, Project Engineer, give us some insight into the project.
Philip: “At the start of the project, we faced an exciting puzzle. We have a great variety of MPs with different diameters (varying at the respective conical and cylindrical parts), lengths and weights.”
Sebastian: “The Walney TPs are amongst the heaviest and tallest ever built. But we already proved our expertise in lifting and securing TPs within the Veja Mate project.
The real challenge is the handling and securing of the MPs. These are optimized for their final purpose being an offshore foundation for wind turbines. Their highest stability is in an upright position. To lift and ship them in a horizontal position is not what they are made for. The diameter to wall thickness ratio is so high that there is the risk of squeezing or deforming the piles during lifting and on the sea passage.”
A combination of special designed steel cradles with tailor-made wooden inlets serves as seafastening arrangement for the MPs. The cradles are installed within a kind of plug and play system. They are stowed between steel plates welded as stoppers and additional steel wedges fix them. Easy to install, easy to remove.
Thus, when the vessel’s crew changes the cargo setting from MPs to TPs, they can easily remove the steel cradles from the hatch covers and the tween deck. So, the TPs can be secured with extensive grillages on the tank top and MV Svenja sails with open hatch.
Philip: “We had to design a sea-fastening system that copes with the cargo variety and facilitates a quick handling. Moreover, we optimized the sea-fastening design in several design cycles. We found the perfect balance between safe, flexible handling and maximum workability in the North Sea during winter weather conditions.”
February 2017 | Taiwan – Japan
A true giant had to be shipped from Taiwan to Japan. With 650 tons being a comparatively lightweight, the sheer dimensions of this crane are much more impressive. It has a height of 56.2 metres and comes with a beam length of 78.2 metres. The overhang to both sides of the vessel provides a grateful subject for dramatic impressions.
But these impressive dimensions make the crane a sensitive structure. The bogies are some of the weakest points of the crane. They aren’t designed for high acceleration forces. So to prevent them from excessive loads during sea transport we strengthened them with structural steel section bracings. Lifting the crane was another challenge. The center of gravity was located at a high level. In addition the bogies were rotated 90 degrees to get them in line with the transport rail on deck of MV Lone. Overcoming challenging weather conditions, the crane was delivered safely to its destination in Nagasaki, Japan.
October 2016 – March 2017 | China – Saudi Arabia
Not only our 183 types are engaged in long-term projects. Since October 2016 our 161 A types MV Wiebke and MV Annegret have been performing sole charter shipments. Six trains of Cold Boxes and supplementing cargo had to be shipped from Shanghai, China to Jizan, Saudi Arabia.
With each shipment containing 15,500 frt tons, the complete volume of the project summed up to approx. 100,000 frt tons. The largest Cold Boxes measured up to 38 × 9 × 8 metres with a weight of up to 410 tons. While the accessories were loaded from shoreside, the heavy items came from barge. Apart from the mere technical issues, the operational management had to be adjusted carefully to fulfill all necessary requirements. Quick berthing at a designated berth in Shanghai was principal for the flawless performance. Strict coordination of all workflows to comply with all MLC regulations (Maritime Labor Convention) was another success factor for this project.
May – September 2016 | Aalborg/Denmark – Eemshaven/Netherlands
The future of energy production lies in the constant growth and development of renewable energy sources like wind. Several offshore wind parks are under construction, and SAL serves with its reliable and flexible vessels as a perfect project support for the complex construction processes. For the Veja Mate Offshore Wind Farm Project, MV Trina was engaged to transport Transition Pieces (TP) from the construction site in Denmark to the Netherlands.
The wind farm is located in the German North Sea. It consists of 67 wind turbines, each with a capacity of six megawatts and a rotor diameter of 154 metres. It will produce electricity for 400,000 German homes every year.
In twelve consecutive voyages, MV Trina transported 67 Transition Pieces (TP) together with corresponding platforms and anode cages – a total cargo volume of about 108,674 cbm. For this long-term contract, the Type 176 vessel was mobilized in Stralsund, Germany. All hatch covers and tween decks were discharged for the 22-metre high cargo. Special grillages were welded onto the bottom of the hold to ensure a stable and safe positioning of the TP’s. For the loading, SAL developed a special lifting tool, which was able to grab each Piece safely within the customer’s requirements.
The particular challenge in this transport was neither the weight nor the number of the cargo but the lifting height. The items had to be lifted vertically from pier into the cargo hold with the ship’s cranes. Sufficient planning and calculation ensured that the tight space between lower edge and deck’s surface did not cause trouble for the team involved.
The project was running from May till September 2016. SAL’s performance of a flawless support found high appreciation at our customer’s side. Pieter Poelsma, OWF’s Manager Transport & Logistics, stated:
“The commitment of SAL Heavy Lift GmbH to HSE, quality, workmanship, and eagerness to complete the project correctly and within the allotted schedule is greatly appreciated. The project was a great success. For future projects we therefore recommend SAL Heavy Lift GmbH and their services.”