www.macgregor.com
Spring 2015
Semi-electric subsea crane offers energy-saving benefits page 2
45 winches serve 10,000-tonne SWL Korean heavy-lift floating crane page 4
Pusnes offshore mooring systems combine low maintenance and a long service life page 6
Energy savings
over a ship’s lifetime benefit efficiency and the environment MacGregor’s new 150-tonne SWL semi-electric knuckle boom crane combines the good handling characteristics of this type of offshore crane with the environmental benefits offered by electric drive technology, such as the ability to regenerate electricity during lowering operations, which reduces a ship’s overall power consumption High power, high precision water cooled permanent magnet electric motors drive the crane’s main and whip winches
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acGregor has launched a 150 tonne SWL semi-electric offshore crane, aimed at offshore operators keen to reduce their operating costs and improve their environmental performance. The only difference that the crane
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MACGREGOR Newsletter, Spring 2015
driver in the cab will notice is that the new crane is quieter. It offers the same easy operability and fine control as existing models. But those responsible for balancing the books will appreciate the reduced operating and maintenance costs.
Essential hydraulics improved While the majority of the crane’s movements are electrically powered, it retains hydraulic cylinders to control jib movements because there are currently no electrical actuators capable of delivering the forces needed. However, MacGregor has
incorporated significant improvements in the crane’s hydraulic equipment. It benefits from leak-free cylinder gaskets, developed as a standard solution for all MacGregor knuckle boom cranes. It can be operated with environmentally friendly hydraulic oil if necessary. Biodegradable oils are now a fully acceptable alternative to traditional hydraulic oil. MacGregor has also reworked the hydraulic power unit (HPU), reducing the number of components to maximise efficiency. MacGregor questioned the traditional requirement to run the HPU continuously during crane operations. “We have developed start-stop technology similar to that used by the automobile industry to reduce emissions from cars,” says Baard Trondahl Alsaker, Research and Development Director, MacGregor Offshore Load Handling. “During a typical subsea lifting operation, the crane lifts a load from the vessel’s deck, positions it over the sea, and then lowers it. During the lowering phase the slewing and luffing motions are not used, so our auto shut off function stops the HPU. If the crane operator makes a control demand that involves the hydraulic actuators, the HPU starts up again, automatically and immediately.”
Regenerative capacity for lifetime savings A major feature of the new crane is the
Newly-developed MacGregor semielectric subsea crane offers owners and operators environmental, functional and commercial benefits
regenerative capacity of its electric winch. Operations that involve more lowering than lifting can easily generate far more energy than they consume. But not all vessels can take full advantage of energy generated by modern electric cranes and other electrically powered equipment. Consequently, the new crane works to best advantage when installed on a modern vessel equipped with battery banks and optimised for seamless power retrieval, storage and distribution. In this environment, the crane’s regenerative capabilities will significantly reduce a vessel’s lifetime energy costs, as well as reducing the initial installed power generation requirements. This will be very attractive to offshore operators determined to take full advantage of the energy saving potential of their new vessels. “Our clients are always concerned about minimising their operational running costs; this was a major driver in the development of our new crane. Fuel is expensive and it has a big impact on operational costs,” says Mr Alsaker. “It can take less than two years to build a vessel, but that vessel will be in service for 20 to 30 years. A little more initial capital expenditure can deliver decades of reduced operational costs.” Potential savings are dependent on how often and for how long the crane is used and the nature of the operations. MacGregor will offer a calculation tool All motor control and cooling systems are housed in dedicated container units
that prospective customers can use to discover their projected annual savings by entering their expected lifting sequences.
Solutions minimising power consumption should drive development The new crane will be used primarily in the oil and gas industry. “We have all to gain from getting the oil from the reservoirs to the end users without expending more energy than is strictly necessary. Solutions that minimise power consumption should always be the driver for development,” says Mr Alsaker. “I am sure the industry is ready to make the changes necessary to reduce costs, including investment in modern ships equipped with energy saving equipment like our new crane. “The current downward adjustment in the oil price will be a major incentive. Forward looking industry players are likely to adapt by making changes that can sustain their business at a lower cost.” MacGregor is offering its new semielectric crane with a SWL of 150 tonnes because this is currently the most popular size of crane in its market segment. The technology is generic, so other cranes will become available. The size of cranes offered will be market driven, says Mr Alsaker, noting that the bigger the crane is the more you can expect to gain from the semi-electric technology, especially as ship design will focus increasingly on integrating all power consumers in one common system to store and retrieve energy.
MACGREGOR Newsletter, Spring 2015
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MacGregor extends
heavy lift vessel portfolio MacGregor’s supply of 45 winches for a 10,000 tonne SWL floating crane demonstrates its ability to meet the needs of specialist vessels being developed to meet market demands We won the contract because MacGregor offers the most advanced winch and crane technology” Francis Wong
MacGregor 90 tonne electric main hoisting winch ready for installation on Hyundai HLV-10000
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MACGREGOR Newsletter, Spring 2015
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acGregor’s offshore deck machinery business has completed a major winch supply contract for the Korean offshore market. MacGregor delivered 45 electric variable frequency drive (VFD) winches and a full control system for the heavy-lift crane barge Hyundai HLV-10000, one of the world’s largest heavy lift vessels. Hyundai Samho Heavy Industries Co Ltd, a subsidiary of Hyundai Heavy Industries, built the
massive floating crane to meet the increasing demands for heavyweight shipbuilding support activities, along with offshore lifting operations. “We won the contract because MacGregor offers the most advanced winch and crane technology and has a good track record for all types and sizes of winches and cranes from merchant ships to offshore support vessels,” says Francis Wong, Head of Sales and Marketing, Offshore Deck Machinery at MacGregor. “Product quality, reliability and worldwide service support were key factors in our success against the competition.” Hyundai HLV-10000 is an important new vessel. Its lifting capacity of
10,000 tonnes means that Hyundai Heavy Industries will be able to install bigger blocks onto offshore facilities, minimising the risks of working at height. “The methods employed in building, repairing and converting ships and offshore structures are changing,” says Mr Wong. “The prefabricated blocks which are combined to build ships and other offshore structures are becoming bigger and heavier. This drives the need for cranes on this scale.” He says there are also significant economic advantages for shipyards. “This new crane will reduce overall construction times, resulting in major financial savings. Hyundai Heavy Industries suggests these could be as much as 24 billion Korean won (US$21.9 million) per annum.”
Acquisitions strengthen MacGregor’s position in offshore market Thanks to the recent addition of portfolios from Hatlapa and Pusnes, MacGregor is now the biggest offshore deck machinery and load handling solution provider for the offshore market, says Mr Wong. “We already hold leading positions in several offshore market sectors. For example, we have strengthened our position in the mid-sized and large anchor handling market as a result of our ability to provide
packages including low pressure hydraulic winches, electric winches and advanced safe deck handling solutions. “We aim to acquire major market shares in selected ship types, including anchor handling tug/supply vessels, multipurpose platform supply vessels, offshore construction vessels, research vessels, mobile drilling units and floating production units.” There are good reasons for owners, operators and shipbuilders to consult MacGregor when planning their offshore projects. Through the combined experience of its strong market brands, MacGregor has unrivalled in-house knowledge of winches and cranes for all offshore applications. “Today we are in an improved position to develop fully integrated valued added deck and cargo handling solutions for selected shiptypes by better understanding our customers’ business processes and operations,” says Mr Wong. “Bringing Pusnes and Hatlapa together under the MacGregor umbrella offers a very attractive one-stop-shop for many offshore applications. It remains our aim to build on our well tried offshore equipment by driving innovation and new technology with the aim of developing the best solutions in collaboration with our customers.”
Winch delivery in detail Hyundai HLV-10000 is 182m long x 70m wide x 11m in depth. It is equipped with a double truss jib crane. Each jib has a 5,000 tonne lifting capacity to give a total lifting capacity of 10,000 tonnes. MacGregor’s delivery of 45 electric VFD winches and a full control system included: • 11 x 160 tonnes line pull/484 tonnes brake holding with 1,200m of 63.5mm diameter steel wire drum capacity. These winches are used for positioning and mooring. • 16 x 90 tonnes main hoisting winches • 8 x 150 tonnes jib hoisting winches
• 10 x 40 to 60 tonnes auxiliary hoist winches • Several common DC bus drives (motor inverters and brake resistors) in the 160 to 710kW (440V) power range and the vessel’s PLC based control system Delivery, installation, testing and commissioning of the MacGregor equipment was completed in early 2015 at the Samho yard.
The case for electric winches Electrical winches consume 25 to 30 percent less energy than equivalent hydraulic winches. During lowering mode, electric winches
generate energy rather than consume it. Shipyards benefit from reduced installation costs for electric winches as they eliminate the need for complex pipework and flushing operations. Adopting a parallel multi drive system offers greater redundancy and reliability, reducing the likelihood of downtime. Maintenance costs for electrically driven winches are lower and diagnostic work is easier thanks to sensors and proximity switches. Their impact on the environment and their consumable requirements are less than those of hydraulic winches.
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Order book growth for Pusnes
fourth generation bow loading systems
Pusnes bow loading system installed on the shuttle tanker Rio 2016 owned by Tsakos Energy and Navigation
MacGregor’s Pusnes brand continues to grow its market leading references for offshore shuttle tanker bow loading systems with the third order for a series of 157,000 dwt shuttle tankers contracted by Tsakos Energy and Navigation 6
MACGREGOR Newsletter, Spring 2015
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acGregor has signed a contract with South Korean shipyard Sungdong Shipbuilding & Marine Engineering Co Ltd to supply a Pusnes bow loading system for a third 157,000 dwt Suezmax DP2 shuttle tanker for Tsakos Energy and Navigation Ltd. There is an option for a fourth tanker. Working in cooperation with the shipyard, the Greek headquartered tanker specialist previously specified Pusnes loading systems for two earlier shuttle tankers, the Brasil 2014 and Rio 2016, delivered in 2013. The two vessels are operating under 15-year time charters to a Brazilian national oil company that will also charter the newly
contracted vessel. Delivery of the new vessel is scheduled for the first quarter of 2017. If the option for the fourth tanker in the series is exercised, it will be delivered in the final quarter of 2017. With references for more than a hundred deliveries since 1977, Pusnes is the market leader in offshore bow loading systems. The system adopted for the Tsakos tankers is fourth generation, benefiting from the brand’s long experience of working with shipowners to provide optimised solutions. Stein Are Andersen, Sales Manager, Offshore Loading Systems, says that in addition to being robust and reliable, the Pusnes solution has the key advantage of being able to remain in service while essential maintenance is carried out. “This means that there is no need for scheduled off hire days for servicing the equipment.” Shuttle tankers operate in a highly specialised sector that calls for state of the art vessels specifically designed for transporting crude oil from offshore oil fields. Typically, such vessels are committed to industrial projects for long periods, functioning in complex operational environments. The Pusnes bow loading suite allows tankers to ship oil directly from offshore oil fields while holding station by means of dynamic positioning systems. The Pusnes system enables a safe and secure connection for the hose from an offshore installation to the shuttle tanker. If necessary, this connection can be
Further orders for Pusnes bow loading systems
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n addition to the Tsakos contract, MacGregor has secured three further orders for up to twelve Pusnes shuttle tanker bow loading systems. Knutsen NYK Offshore Tankers has ordered two (option two) 156,000 dwt Suezmax shuttle tankers from Hyundai Heavy Industries of South Korea against a long term
quickly and safely disconnected without Together, they enable a shuttle tanker to creating surge loads in the hose, eliminatsafely and efficiently load oil from an offing the risk of environmental damage from shore production or storage facility. an oil spill. Hose handling system. A 20 inch In common with the two previous diameter bow loading coupler is located Tsakos shuttle forward on the tankers, the newly ship’s centerline. The In addition to being ordered vessel also coupler receives the robust and reliable, Pusnes hose end from the features Pusnes bow loading systems deck machinery offloading vessel/ have the key advantage including mooring platform (FPSO, of being able to remain winches, windFSO). A vital part in service while essential lasses and hydrauof the system is the maintenance is carried out” Pusnes moment free lic power units. Stein Are Andersen This continues a bow loading coupler strong relationship which allows the between Tsakos and Pusnes. Twenty two coupler to follow the movement of the vessels of various types in the Tsakos fleet hose. The system includes a hose winch for are fitted with Pusnes equipment. pulling in the hose and storing/handling “This means a lot to us as we strive to the rope during loading, connection and be the reliable and preferred partner for disconnection phases. our customers. It gives us a great sense of Hawser handling system. A roller achievement,” says Mr Andersen. “Our fairlead and a chain stopper located on the goal is to have satisfied customers by proplatform deck are operated together with viding innovative products with proven a twin drum traction winch for moortechnology that will meet not only their ing purposes during tandem loading. The requirements, but also those of the relchain stopper is a hydraulically operated, evant authorities, in terms of safety, enviself-locking type, and it can be released ronmental protection and cost-effective under full design load. Aft of the chain solutions.” stopper is a guide roller with a built-in load cell which operates together with a traction winch. The system also includes a The Pusnes bow storage reel or bin for storing the messenloading system The Pusnes bow loading system consists of ger line during loading. The traction winch can also be used for pulling in the loading two integrated systems, the hose handling hose after the mooring is completed. system and the hawser handling system.
charter to a subsidiary of British Gas. Knutsen NYK is a partnership between Knutsen OAS Shipping of Norway and Japanese operator Nippon Yusen Kaisha. The partnership operates a fleet of seven shuttle tankers tied to long-term fixtures involving projects in the North Sea and Brazil, which is where British Gas plans to deploy the newbuildings upon completion. MacGregor is to supply Pusnes Arctic bow loading systems for retrofitting to a pair of icebreaking tankers owned by the Greek specialist tanker operator Roswell tankers. The two 19,900 dwt vessels are the 2000-built tankers
Ice Condor and Ice Eagle, both of which comply with Ice Class F/S: 1 A Super and are designed to operate in extreme ice conditions without the assistance of icebreakers. MacGregor also has a contract with Samsung Heavy Industries to supply Pusnes Arctic bow loading systems for a series of six shuttle tankers for Russian owner Sovcomflot. The 42,000 dwt vessels will have icebreaking capabilities for operations in the Russian Arctic in temperatures down to minus 45 deg Centigrade. The orders where contracted in late 2014, with delivery scheduled throughout 2016.
MACGREGOR Newsletter, Spring 2015
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Contacts MacGregor Group
Tel: +358-20-777 4500 macgregor@macgregor.com
www.macgregor.com
MERCHANT SHIPS Auxiliary and Machinery Systems MacGregor Hatlapa GmbH & Co. KG Tornescher Weg 5-7 25436 Uetersen, Germany Tel: +49-4122-7110 • +49-172-981 3292 Hatlapa.info@macgregor.com MacGregor Pusnes AS 368 Skilsøveien, Pusnes, NO-4818 Faervik, Norway Tel: + 47-370-873 00 pusnes@macgregor.com MacGregor Pusnes AS Dokkveien 8, Porsgrunn PO Box 1714 NO-3998 Porsgrunn Norway Tel: +47-35-93 12 00 porsgrunn@macgregor.com Bulk Selfunloaders MacGregor Sweden AB PO Box 914, Gesällgatan 7 SE-745 25 Enköping, Sweden Tel: +46-171-232 00 crasales@macgregor.com Cargo Material Handling MacGregor Sweden AB Sjögatan 4 G SE-891 85 Örnsköldsvik, Sweden Tel: +46-660-294 000 crasales@macgregor.com Cargo Stowage & Securing MacGregor Finland Oy Hallimestarinkatu 6 FI-20780 Kaarina, Finland Tel: +358-20-777 4500 drycargosales@macgregor.com
Offshore Mooring and Loading MacGregor Pusnes AS 368 Skilsøveien Pusnes, 4818 Faervik, Norway Tel: + 47-370-873 00 pusnes@macgregor.com Offshore Deck Machinery MacGregor Pte Ltd 15 Tukang Innovation Drive, Singapore 618299 Tel: +65-6597 3888 ofs.sgp.salesmfg@macgregor.com Triplex Products Triplex AS Henda, 6530 Averøy, Norway Tel: +47-71-513 900 post@triplex.no
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Note • = 24-hour service numbers Printed: 21 April, 2015. For an up-to-date list, please visit our webpage
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