Energising the transition

The race to renewables is dominating the energy sector – and making it both more innovative and varied. New techniques and new types of equipment, not least in lifting, are constantly appearing. Here are just some.

Nuclear, of course, is a major non-fossil source of energy and the UK’s new Hinkley Point C station on the west coast of England continues its long progress towards commissioning. Approval was given in 2016; site clearance and construction began in 2017; and at the end of 2023 a spectacular lift by the largest crane in the world marked a major stage towards completion.

Sarens’s SGC 250, nicknamed ‘Big Carl’, has a capacity of 5,000 tonnes in a single lift. On 15th December 2023 it raised the lid for the station’s first reactor successfully into place. The steel dome weighed 245 tonnes and is 14 metres tall; it now sits on top of the 44-metre-high reactor building.

The dome is the top part of the reactor building’s inner containment, a steel cylinder encased in concrete. 47m in diameter, it is wider than the dome of St Paul’s Cathedral.

It is made up of 38 prefabricated panels which were shipped to Hinkley Point and welded together in an onsite factory. Prefabrication and modular construction are key features of the station’s construction.

The lift started at 07:20, a time carefully planned to take advantage of a weather window to allow the hour-and-a-half long manoeuvre to be completed in low wind conditions.

Earlier in December the 750 tonne Polar Crane, that will serve the reactor during its working lifetime, was lifted into place – again by Big Carl – in a single piece and set in place above the reactor building’s third and final steel liner ring. This internal crane will rotate 360° above the reactor and be used for refuelling and installing equipment.

The major milestone lift of the roof closes the building, allowing the first nuclear reactor – there will be two at the site – to be installed. 10,000 workers and 3,500 British companies are building the station, which is planned to provide zero-carbon electricity for six million homes once it is running in, according to the most recently-announced schedule, 2028. A video of the lift can be seen here: www.youtube.com/ watch?v=s2GkK1TQzCc

Heavy lifting was also involved in another fossil-alternative power station in the UK: a new waste-to-energy plant at Skelton Grange, near Leeds. It is on part of the site of two former coalpowered stations, now demolished. A turbine and generator at the new plant were successfully transported, offloaded, and installed by specialised haulage and lifting company Allelys.

The lift and installation were through the roof of the uncompleted new hall and complex planning and transport were required.

The turbine, weighing 160 tonnes and measuring 7.8m x 5.35m x 4.6m arrived into Goole docks, where Allelys discharged the vessel using its Liebherr LG1550 mobile crane. It was then positioned onto stools at the port for temporary storage. Once the site team were ready to receive the component Allelys built a 24-axle girder frame trailer around the stools to self-load the cargo ready for transport to Skelton Grange.

“Prior to the transport phase, Allelys completed route surveys and transport arrangement designs as well as swept path analysis for the journey through the site. Our engineering reports identified two structures that needed to be negotiated on site, at Wyke Beck Bridge and Effluent Culvert,” explained Garnaud Tsika, commercial manager at Allelys.

“We completed assessments on both of these structures prior to project award. These showed that using a 16-axle girder frame, typical for the size and weight of this unit, wasn’t suitable. We therefore designed a solution to use a bigger and lighter frame to overcome these challenges, which enabled the route to be cleared.”

The transportation stage included a night-time closure on the A1 trunk road to open up the carriageway central reservation and allow the transport to cross over and join the M1 motorway, Britain’s major north-south route.

At the site the turbine was trans-shipped from the girder frame onto a 12-axle SPMT due to the restricted space available. It was transported to within the radius of Allelys’ LG1550 crane and lifted into the turbine hall.

Allelys also received the second component at the site, a 96t generator, where it was temporarily stooled off and then transported using the same 12-axle SPMT, to the crane location for lifting.

“The turbine hall was still in construction and there was a number of restrictions that we needed to adhere to,” explains Tsika. “They included the precise planning that was required to modify the crane location and position the outriggers due to nonload bearing areas.” The height of the building was 22.3m so the LG1550 was rigged in luffing jib configuration. The turbine was lifted and installed first, followed by the generator, with both being lifted directly onto their final positions with the meticulous precision that was required to negotiate the limited clearance.

OFFSHORE WIND

Wind is one of the world energy game-changers, both on- and offshore. Offshore wind is involving huge effort and investment globally – see, for example, the box on p34 – with, so far, one curious exception: there are currently only 12 wind turbine generators off the entire Eastern coast of the USA.

Regulatory ambivalence during the Trump presidency gave way to an optimistic target under the Biden administration of building 30 gigawatts of offshore wind by 2030; but after initial enthusiasm, rising costs and disputes over the price that generating companies could charge for electricity has led to cancellations of over 3GW of large offshore projects off the coasts of New Jersey, Massachusetts, Rhode Island and Connecticut.

One large project that is going ahead, however, is the Coastal Virginia Offshore Wind (CVOW) farm, a 2.6-gigawatt offshore wind energy project of 176 wind turbines with three offshore substations, between 26 and 40 miles off the coast of Virginia Beach. Over the next two years Sarens will receive and load out the monopiles and the transition pieces, jackets and topsides for the substations.

Sarens’ on-site involvement commenced in October 2023 with the arrival of the vessel SunShine after the Sarens team in Rostock, Germany, had successfully loaded it with the first eight monopiles.

Over three days the Sarens team successfully unloaded the monopiles, swapped out the shipping saddles, moved the piles to storage, and returned the shipping saddles to the vessel.

Construction at the site will be finished in time to receive the transition pieces in early 2024. With those eight units safely at the storage site there are therefore currently 168 more monopiles to be transported across the Atlantic, unloaded, stored and installed.

MONOPILE GRIPPER

For offshore wind innovations continue apace. In February, Huisman announced the signing of a contract with Danish offshore windfarm installer Cadeler for the design and production of a Monopile Gripper. Huisman already has 13 main cranes and auxiliary cranes already on order by Cadeler.

The Gripper, with a substantial 13-metre diameter, is engineered for the efficient and controlled installation of monopiles ranging in length from 80 to 120 metres, with a weight of up to 3,000 tonnes. Notably, this gripper can be entirely stored on deck, facilitating future maintenance procedures and thus operational longevity.

An interesting feature is an option for the integration of a noise mitigation system. This is designed to minimise the impact of noise on sea life, showing both companies’ commitment to environmentally responsible practices. Production of the Gripper will take place at Huisman’s production facility in China.

"This new contract with Huisman solidifies our strategic commitment and collaboration in pushing the boundaries of what's possible as we prepare for the future of offshore wind farm construction,” says Mikkel Gleerup, CEO of Cadeler. “If we are to reach our global goals for renewable offshore wind energy we will need cutting-edge technologies and scale, which our strengthened partnership embodies."

"A long-term partnership like this one enables us to remain at the forefront of delivering stepchanging solutions that contribute to the advancement of sustainable energy projects worldwide,” adds David Roodenburg, CEO of Huisman.

The gripper, a first for Cadeler, will play a key role in delivering on the North Sea Hornsea Three project. Huisman also successfully delivered two Motion Compensated Monopile Grippers for DEME's Orion and Boskalis' Bokalift 2 installation vessels. Currently, Huisman is in the process of building one for Heerema's Thialf semi-submersible crane vessel.

Offshore monopiles have also been the focus of Utrecht, The Netherlands-headquartered heavy lift and transport specialist Mammoet. The company has developed a new jacking and cradle system that can lift large monopiles higher, allowing more sea transports to take place using existing support structures.

COST REDUCTIONS

According to Mammoet the system minimises upgrades to grillage and sand bunds, helping customers to reduce costs as Mammoet customers don’t need to build new storage facilities/transport facilities for these larger components.

This is particularly pertinent against the backdrop of several high-profile offshore wind projects which have been put on hold recently due to rising supply chain costs.

The new jacking and cradle system adds 60cm of additional stroke over and above the standard SPMT systems.

The system comprises two elements: jacking spacers that sit between SPMT modules to generate greater stroke, and hydraulic, foldable saddles that cradle the monopile so it can be supported at higher points to prevent excessive ovalization.

Each jacking spacer has a capacity of 430 tonnes split across two towers – with multiple units in use per transport configuration. The system slots between SPMT modules, so transport configurations maintain the same minimum ride height. This enables grillages and sand bunds to remain as low as possible – again saving on costs.

Each monopile saddle has a capacity of 1,000t and can handle monopiles up to 12m diameter.

By using the system, Mammoet says its customers can maintain the existing methods of supporting and moving monopiles, even as they grow from 8m to 10m diameter, and beyond. This reduces wholeproject costs right through the fabrication, shipping and storage supply chains.

Also in offshore wind, Mammoet is ‘making waves’ in Rotterdam with the erection of its 3,200 tonne capacity PTC 210 ring crane at its Schiedam yard.

The crane is being used to install the cranes that install wind turbines. Specifically, it is being used to remove the existing leg cranes from two of Cadeler’s jackup vessels and replace them with new high-capacity ones. More on this in next month’s special report.

In the nuclear (decommissioning) sector Mammoet has achieved a ‘world first’ extracting a reactor and internals in three parts using custom strand jack. It assisted Orano USA with the extraction of a sectioned 540-tonne nuclear reactor vessel (RV) at the shutdown Crystal River Unit 3 pressurised water reactor site in Florida, USA. The removal of the RV is part of the accelerated decommissioning of the facility, which began generating electricity in 1977.

It's not just renewables that the company is active in. In the oil and gas sector, for example, Mammoet was extensively involved in the construction of the Dangote Petroleum Refinery in Nigeria, which has now started production.

It has also just entered into a strategic partnership with Aertssen Machinery Services (AMS), the Belgian heavy-lifting company, to provide heavy lifting and transport solutions to industry sectors, including oil and gas, in Qatar.

And in September 2023 Mammoet announced the successfully completion of jacking, loadout and floatover operations for a 19,600 tonne offshore platform as part of the Azeri Central East (ACE) project, the next phase of the development of the BP-operated Azeri-Chirag- Deepwater Gunashli (ACG) oilfield in the Caspian Sea.

ONSHORE WIND WORK

Onshore wind turbines may be smaller in scale than offshore but their erection and transport also present considerable challenges.

To meet some of these challenges Liebherr is introducing a new crane that is aimed squarely at wind work. Its LG 1800-1.0 offers greater lifting capacity than its predecessor model, the LG 1750. Like that crane the new model has a lattice boom mounted on a wheeled crane chassis. The design, says Liebherr, combines the mobility of a mobile crane with the load capacity of a crawler.

The crane can now lift up to 800 tonnes. This is more than its predecessor and just as much as its crawler crane counterpart the LR 1800-1.0.

Part of this capacity increase is due to the folding beams it uses. In contract to the crane’s previous model these are not telescopic; this is because the required support base (13 x 13 metres) is sufficient for the LG 1800-1.0 to achieve its load capacities.

The new crane does, however, have one more axle than its previous version, making a total of nine. For these Liebherr is using its standard LTM crane axles. As a result the crane has an individual axle load of just ten tonnes, which makes it suitable for use on public roads worldwide.

In situations where even lighter road weights are required the crane has a flexible system enabling the removal of crane support sections.

Carrying just two supports the total transport weight goes down to 70t; without any supports transport weight is around 50t. Liebherr has developed a quick coupling system for attaching and removing the supports.

For special appeal to the wind sector Liebherr has designed the chassis to have a width of three metres for greater manoeuvrability, and the crane the can tackle slopes of up to 25 percent gradient.

The LG 1800-1.0 uses a similar boom system to that of the LR 1800-1.0 and can be used with and without a derrick. There is a main boom up to 180 metres long and a main boom luffing jib combination with up to 108 metres of main boom and 102 metres of luffing jib, with which a maximum hook height of 208 metres can be achieved. Thanks to optimised wind power boom systems, for example, it is possible to work with a boom of 174 metres and an 18-metre-long lattice type fixed jib at hub heights of 180 metres.

The WindSpeed Load Charts, with different permissible wind speeds of up to 13.4 m/s, are designed to provide increased flexibility and safety in gusty operating conditions. The LG 1800-1.0 will be launched in the first half of 2024.

TOWER TRANSPORTATION

For onshore wind tower transportation special trailer and semi-trailer manufacturer Faymonville has just launched a wind tower adapter with free rotation device mounted on a 4+7 dolly trailer that can be used for transporting large wind turbine towers weighing up to 100 tonnes on winding roads. The new model fills the last gap in its existing range, says Faymonville.

The vehicle is based at the front on a four-axle dolly with air suspension – optionally with 17.5” or 22.5” tyres – which can be configured for 6×4 and 8×4 or 8×4 and 10×4 tractor units. “For the first time ever, 10×4 machines can take on such missions,” says Faymonville product manager Rainer Noe. “The different base variants and tyre options make the concept extremely interesting for the user.”

Two installed tower adapters facilitate connection to the tower segments in three-point or fourpoint clamps without an additional frame. In the basic version, the components are conceived for internal diameters from 2,650 to 5,400 millimetres. “And an extension to 6,300 millimetres is available if even larger tower segments need to be moved,” says Noe, describing the solution for possible XXL versions.

The two adapters are designed for maximum flexibility, as segments with an external flange can also be accommodated. Even the transport of various machine houses is possible with this system. The vertical stroke of 1,600 millimetres facilitates passing over high obstacles along the route, such as roundabouts, crash barriers or road boundaries.

“We are the only supplier on the market with a hydraulic suspension,” says Noe. “This principle is used to raise or lower the self-steering trailer on one side, thereby increasing the stability of the convoy considerably in critical passages.

“The steering system has four steering cylinders for the front steering and four for the rear steering. For further optimisation of the safety aspect, the vehicle width is set to 2,750 millimetres.”

Hydraulic and mechanical locking systems prevent inadvertent lowering or retraction of the adapter. The general handling is intuitive and simple. When handling the adapter, the user is always in a safe area due to the standard remote controls and has a perfect overview when loading and unloading.

In conclusion, we see the transition to sustainable and renewable energy resources is being fuelled by the innovative solutions of manufacturers and concerted efforts of end users across the lifting and transportation sectors. Specialist lifting and transport companies, in particular, have emerged as pivotal players in this transformative journey, as demonstrated by their contributions to various projects spanning nuclear, waste-to-energy, offshore wind, and onshore wind sectors.

As the energy landscape continues to evolve, collaboration and innovation will remain essential in overcoming obstacles and realising the full potential of sustainable energy sources. The achievements highlighted across these diverse projects and products serve as a testament to the collective determination and creativity driving the transition towards a cleaner, more sustainable future. 

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NEKKAR TO DELIVER OFFSHORE KNUCKLEBOOM CRANE FOR WINDFARMS

Norway’s Nekkar group has been awarded a contract to deliver an offshore crane to a newbuild cable-lay support vessel that the Turkish Sefine Shipyard is building for Norwegian shipowner Agalas.

Techano Oceanlift, recently acquired by Nekkar, will deliver a 70-tonne offshore crane capable of performing both subsea installation and removal operations as well as 3D-compensated topside lifting operations in wind farm developments and operations. The contract value is approximately EUR 4 million.

The knuckleboom crane is equipped with an active heave compensated (AHC) winch with 2,000 metres of wire for subsea operation, and a separate three-tonne 3D active motion compensated lifting tool, for topside lifts. The crane features Intellilift’s control system and motion compensating system.

“We have developed a crane that is ideal for vessels operating on offshore wind farms,” says Øystein Bondevik, director of business development and sales at Techano Oceanlift. “It can perform subsea lifting operations and is capable of supporting wind farm operations, lifting equipment and tools necessary to operate and maintain wind turbines. It offers a flexibility that improves the commercial potential for the shipowner while it also reduces operating costs for operators of wind farms.”

It was Nekkar’s recent acquisition of Techano Oceanlift that enabled the crane contract. Techano Oceanlift has extensive industry experience with product delivery and project execution within the renewables, aquaculture and marine industries.

The strategy for the add-on was to combine Nekkar’s in-house automation, electrification, and software competence, with Techano Oceanlift’ maritime specialisms in handling and lifting. Nekkar’s subsidiary company Intellilift will deliver the crane’s digital control system, leveraging sensors, cameras, and software.

“Our joint ambition is to deliver smart, lightweight, and energy efficient lifting and handling solutions that are fully automated and digitised, capable of challenging the incumbent solutions in the market. This contract demonstrates that bringing Techano Oceanlift into Nekkar was a good enabler for both parties,” adds Ole Falk Hansen, CEO of Nekkar ASA.

Techano Oceanlift will conduct the engineering and project management from the group’s headquarter in Kristiansand, Norway. The completed crane will be delivered in 2024.

Dutch crane and transport specialist Verschoor has expanded its fleet with the addition of a Liebherr LR 11000. The company has already used the crane to install two wind turbines at the Vanikum wind farm near the Dutch border.

The company purchased the crane in order to futureproof its capability to instal increasingly taller wind turbines with corresponding hub heights and heavier nacelles.

For the work at Vanikum the LR 11000 assembled various components, such as the tower sections, nacelle and rotor blades, at a height of 169 metres.

The heaviest single component it lifted was the gearbox which weighed 117 tonnes. The crane was set up for the lifts with a 168-metre-long main boom and a 15-metre lattice type fixed jib.

According to Liebherr, the LR 11000 is characterised by its economical transport concept and is designed for a transport width of 3.5 metres and a transport height of 3.2 metres.

The V-frame with its adjustment distance of 17 metres moves the derrick ballast into the required position and reduces the workload for ballast handling.