Macgregor newsletter spring2016

MacGregor innovations serve booming offshore wind energy market page 8

Remote operators rely on good service page 2

Subsea cranes that realise their full lifting potential page 5

Photo: Statoil

www.macgregor.com

Spring 2016

Remote operators rely on good service Prioritising through-life equipment support is high on the agenda for MacGregor’s Global Lifecycle Support division; at its head is John Carnall, who explains why good service support is key to the long-term success of its offshore customers’ businesses

Effective training extends the useful lifetime of equipment; MacGregor can arrange worldwide training courses at specialist centres or on board a vessel

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MACGREGOR NEWSLETTER, SPRING 2016

The most effective way to maintain and service offshore assets is through planned maintenance agreements”

John Carnall, Senior Vice President, MacGregor Global Lifecycle Support

John Carnall

W

e know that it is impossible to entirely eliminate the chance of breakdowns.

These can be the result of human error, environmental conditions or mechanical failure. On the rare occasions when they occur, it is vital to restore normal service as quickly as possible. This is particularly relevant in the offshore industry where downtime is measured in millions of dollars rather than thousands.

Some may question whether it is financially viable to have one service engineer locally available in a region with perhaps only three offshore rigs. MacGregor’s answer is: can we afford not to?

Tough times in the market are putting pressure on some essential services. While others in the industry are looking to economise, MacGregor is taking the opposite approach. It is focusing on improving its aftersales performance by investing in a number of areas; new customer service initiatives, training service personnel to the highest standards possible, increasing its global presence, and developing the use

of ‘smart’ technology. MacGregor’s Global Lifecycle Support division underpins this strategy for prioritising through-life equipment support and the highest availability of genuine spare parts on a global scale.

Minimising downtime The most effective way to maintain and service offshore assets is through planned maintenance agreements, which ensure that equipment is maintained in good order at the optimum time, minimising the risk of accidents and downtime. It is all about who shoulders the greatest burden of risk, the customer or is it transferred to MacGregor through service contracts.

Our preventive and planned service products make it easier to schedule services; they guarantee that parts are in place and are very cost-effective for the customer. They also take a lot of the stress out of managing the huge service requirements for large fleets.

For preventive and predictive

maintenance, MacGregor customers can take advantage of MacGregor Onboard Care (MOC) agreements. We are in the process of developing a new MacGregor Onboard Care contract that will simplify service commitments for customers even further. It will be available later this year.

Remote diagnostic systems In addition to MOCs, MacGregor offers offshore operators immediate technical support services via OnWatch, a secure online remote diagnostic system. By their very nature offshore operations are often remote so this service can prove invaluable for customers operating advanced offshore products, such as our active heave-compensated cranes, launch-andrecovery systems and module handling systems.

We are currently developing a new ‘light’ version of OnWatch designed for those operators needing trouble-shooting assistance for a wider range of offshore equipment. We will introduce this to the market this year.

MACGREGOR NEWSLETTER, SPRING 2016

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Local engineering consultants are the interface between the customer and MacGregor

We have also recently appointed Paul Glandt as a new regional director for the Americas region to support the local marine and offshore industries.

Ships are mobile assets and one of the biggest issues today is that you cannot be connected to a ship at all times. A key part to our overall service strategy is improving electronic communications. Cargotec’s strategic acquisition of Interschalt maritime systems in March this year is a step forward in developing our communication capabilities.

Quality and safety are integral aspects of all our deliveries and have to be our differentiating qualities in the offshore industry when downtime is so costly. We see that delivering a safety culture as part of our organisation is both an employee commitment and a commercial advantage. We want to be relied upon as a trusted partner within the industry. You can order spare parts over the internet, but you do not know about the quality of those spares.

Insisting on genuine original manufacturer spares is part of our integrity as a supplier.

Cost-effective strategies

Local availability of expertise

MacGregor will always try to repair parts, only replacing them if necessary.

However, remanufacturing of parts is a growing trend in the offshore industry, and sometimes remanufacturing for reinstallation can be the preferred approach.

We have now sourced specialist partners to carry out this remanufacturing work, offering the equipment back to customers on a ‘good as new’ basis. This can be an extremely cost-effective strategy for some operators. Lead times for the remanufacturing of parts vary depending on the component.

Our local engineers should be the first line of intervention. We will achieve service excellence by raising the capabilities of these local consultants. Often a ­problem can be quickly resolved simply with an adjustment or the replacement of a sensor. Traditionally a service engineer would have been flown from the product company. They would assess the problem, fly back and then discuss their findings and potentially order a new part, which would then have to be flown out and fitted. This approach was thorough but slow. In today’s market we aim to make

Improving communications

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Safety is part of our culture

MACGREGOR NEWSLETTER, SPRING 2016

We see that delivering a safety culture as part of our organisation is both an employee commitment and a commercial advantage” John Carnall

this process much more rapid through the local availability of an engineering consultant with access to genuine spare parts. These experts will be the interface between the customer and MacGregor.

We want to train and equip them so that they can deliver local services as close to customers as possible, contributing to the delivery of 100 percent uptime.

We are planning to equip our local service consultants with smart devices that provide access to all available relevant information, from technical data to parts availability. We are implementing this strategy in stages.

We do not need to invent anything new; we just need to be able to use what is already available to our best ­advantage. No one knows exactly what today’s technological advances will enable us to deliver tomorrow, but I have insisted that all our products, new ones entering the market and existing ones, are fitted with – or can be retrofitted with – technology that will enable remote condition monitoring.

We have to be ready, our products have to be ready, because one day we will know the full potential of today’s technological capabilities and I want to ensure that MacGregor’s customers will reap the benefits.

Subsea cranes

that realise their full lifting potential MacGregor’s new offshore crane overcomes the problem of wire rope weight when handling loads at significant depths; it combines MacGregor’s proven crane technology with Parkburn’s fibrerope handling expertise

R

ecognising that the offshore market is continually extending its operations into deeper waters, MacGregor has, for some years, been directing its research towards finding the ideal solution to help operators overcome the significant challenges presented by handling heavy loads in deep and ultra-deep water. One significant advance is MacGregor’s dedicated fibre-rope offshore crane, called FibreTrac. It allows operators to use the full lifting potential of the crane, regardless of water depth.

“The greatest advantage of fibre rope used

MACGREGOR NEWSLETTER, SPRING 2016

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Key features of MacGregor’s FibreTrac offshore crane • • • • • • • • • • • • • •

Smaller cranes can do the work of much larger wire-rope cranes in deeper waters Reduced rope wear and greater efficiency Suitable for retrofitting onto existing subsea cranes Available as digitally-controlled electric-drive or hydraulic-drive units Traction winch design minimises heat build-up in the rope Excellent rope spooling and storage – both at low and high tension Unlimited length/depth No fleeting forces in rope Can accept spliced rope and a variety of rope sizes and types Can accept wire rope with a change of sheaves Rope condition management system Rope and sheave cooling Highly efficient electric-drive version available Perfect solution for integration on new power-smart vessels

in the context of ultra-deep water load handling is that it weighs virtually nothing in water, so regardless of the length of rope paid out, it does not add anything to the load experienced by the crane,” says Ingvar Apeland, Director, Load Handling, MacGregor. “This is in complete contrast to the situation with wire rope, where the ever increasing weight of wire paid out limits the load permissible in relation to depth. So we are talking about an important advance for handling loads at depth.”

Combined expertise The crane was developed through a cooperation agreement combining MacGregor’s proven offshore crane technology with the fibre-rope tensioning technology perfected by the UK company,

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MACGREGOR NEWSLETTER, SPRING 2016

Parkburn Precision Handling Systems.

“Parkburn has spent over 15 years perfecting the deep-water handing systems required in fibre-rope cranes,” continues Mr Apeland. “MacGregor recognises that by partnering with experts in specific technology areas, it can deliver solutions that exceed its own capabilities. We see ourselves as being able to integrate the best technologies available to deliver systems with industry-leading capabilities.

“During our design process, we carried out a detailed review of drum winch options and soon recognised the challenge of controlling the forces and fatigue induced by the spooler during high-load, high-speed multi-layer spooling operations. The review directed us towards a traction-type device. However, conventional traction winch systems posed other

FibreTrac features a simple-to-operate fibre-rope lifting system that employs Parkburn’s unique technology

issues such as size, weight and an aggressive de-tensioning profile, which lead us to look for other options.

“The result was the MacGregor FibreTrac, which overcomes the issues of handling fibre rope and features a simpleto-operate fibre-rope lifting system that employs Parkburn’s unique technology.”

FibreTrac’s traction winch consists of two interlocking drums slightly angled and offset in relation to each other. The drum geometry creates a natural and stable helix without generating any fleeting forces, so the rope does not twist on the drum as it is gently de-tensioned. The winch system can be delivered with digitally-controlled electric or ­hydraulic drive units. Features include integral active heave-compensation and power regeneration capabilities.

The open design of the winch also assists with rope cooling, further assisting in eliminating the heating and degradation problems associated with on-load fibre ropes stored on winch drums. Importantly, it can accommodate non-uniformities resulting from splices in the rope.

Meeting market needs The FibreTrac crane is initially available as a 150-tonne fully heave-compensated knuckle boom crane with the capability of reaching depths of 4,000m, but the technology will be extended to the complete range of MacGregor subsea cranes.

The MacGregor fibre-rope technology is also suitable for retrofitting onto existing subsea cranes. “This enables an operator to upgrade its fleet without having to build new vessels. This in turn reduces costs in the industry; an important responsibility for all parties within the sector as a whole.”

MacGregor’s active heavecompensated gangway has three compensating motions and offers operators the means of safely transferring personnel in extreme sea states

Three-axis technology advances applied to personnel gangways

M

acGregor has continued to develop its active heave-compensated electrohydraulically-operated gangway to offer operators the ability to safely transfer personnel in extreme sea states.

As standard, MacGregor’s active heavecompensated gangway has three compensating motions designed for the efficient and safe transfer of personnel to fixed offshore installations. However, to compensate for

extreme movements, it is now possible to upgrade the gangway to include active heave-compensation on the gangway’s pedestal to compensate for roll and pitch motions. There is also an option available for a variable-height telescopic pedestal for operations exposed to tidal conditions.

The advance is based on MacGregor’s three-axis crane technology (page 10). The system has a small footprint, and its unique

design allows the gangway to be used during all compensation movements and in all positions. To guarantee safety, it has multiple redundant, real-time sensors that work together with the control system. The maximum length of the gangway is 28m and the minimum is 20m.

All MacGregor offshore gangways are fully compliant with DNV-ST-0358: 2015 certification for the transfer of personnel.

MACGREGOR NEWSLETTER, SPRING 2016

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MacGregor innovations serve

booming offshore wind energy market

MacGregor has developed a full three-axis (x, y and z) heave-compensation offshore crane, which is ideally suited for maintenance work on wind turbines and other fixed installations.

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MACGREGOR NEWSLETTER, SPRING 2016

T

he fastest growing renewable energy sector is the offshore wind farm industry.

The European Wind Energy Association (EWEA) says that 3,019MW of new offshore wind power capacity was connected to the grid during 2015 in Europe, representing a 108 percent increase over 2014 and the biggest annual addition to capacity to date.

Wind turbine orders for 2015 were up on 2014 figures, indicating good growth beyond 2016 and a year-on-year increase of 75 percent, says the EWEA. There are currently 3,230 wind turbines installed and grid-connected, making a cumulative power generation capacity of 11,027MW; 419 of these turbines were erected in 2015 alone.

In the mid-term, the EWEA expects the total installed grid-connected capacity to increase in Europe to 12.9GW. However, it has identified 26.4GW of consented offshore wind farms in Europe that could be constructed over the next

Photo: Alan O Neill/Statoil

Last year Europe saw a 108 percent increase in offshore wind power generation and a 75 percent growth in wind turbine orders; with a pipeline of longterm power-generation potential, MacGregor is well positioned to support this burgeoning market decade. Of these, the UK has the largest pipeline of consented wind farm projects, standing at around 11.9GW. MacGregor is well positioned to serve this buoyant market, not only in equipment deliveries to innovative new wind farms, but also though developing pioneering solutions for their safe and effective service and maintenance.

Securing the first floating wind farm At the end of 2015 MacGregor won an order for Pusnes mooring systems for the world’s first floating offshore wind farm; Statoil’s Hywind pilot park in Scotland, UK. Hywind will cover an area of just over 4km² near Buchan Deep, 25km off Peterhead in Aberdeenshire, on Scotland’s North Sea coast. It is designed to demonstrate cost-efficient solutions that will enable the commercial capture of wind energy in deep-water environments.

Statoil says that the technology to be used

in the project has been tested for six years with excellent results in a demonstration project off the coast of Norway.

MacGregor is contracted to deliver a Pusnes substructure mooring connection system to each of the pilot project’s five new floating wind turbines. The ballaststabilised turbine structures will each be equipped with a three-point mooring system employing site-specific anchors.

MacGregor plans to complete deliveries by the end of 2016 and installation of the wind turbines is scheduled for 2017.

“This contract represents a step change for MacGregor in terms of entering

This contract represents a step change for MacGregor in terms of entering a new industry sector” Jan Martin Grindheim

MACGREGOR NEWSLETTER, SPRING 2016

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wind turbines require regular inspeca new industry sector,” says Jan Martin tions and maintenance. MacGregor is at Grindheim, Director, Floating Solutions the forefront of developing technology at MacGregor. “The project hinges on applying proven technology in new appli- to deliver this vital service in a safe and efficient manner. cations. MacGregor was chosen for the A notable example is a first-of-its-kind task because of its long history of designoffshore crane that has a full three-axis ing and delivering very reliable Pusnes (x, y and z) heave-compensation system mooring solutions for offshore ­floating that can keep a suspended load fixed in production units operating in harsh position relative to the seabed.

North Sea conditions.”

The crane was specifically developed “Statoil is proud to develop the to be able to land containers of tools and world’s first floating wind farm, further equipment to small platforms at the top increasing the global market potential of offshore wind turbine foundations for offshore wind energy,” says Stephen with little margin for error. These tools Bull, Statoil’s Senior Vice President for are used to install power cables and other Offshore Wind. “We are very pleased with this contract awarded to MacGregor. apparatus before the rotating parts of the windmill are We are excited that installed. high quality oil and “The landgas suppliers in both The wind turbines will ing platforms Norway and Scotland stand at an overall height are about 20m are able to capture the – from the seabed to the above the water growing opportuniturbine blades – of around ties offered through 258m, which is nearly three and they are only a few square new renewables times the height of the growth.” metres, so precise Statue of Liberty in New The 6MW wind load handling is York” turbines will have necessary,” says Jan Martin Grindheim a total powerIngvar Apeland, generation capacity Director, Load of 30MW and provide enough electricity Handling at MacGregor. “Although for 20,000 UK homes. They will operate MacGregor’s standard active heave-comin waters over 100m deep which experipensation (AHC), supplied through a ence an average wave height of 1.8m. “To crane’s winch, compensates for a vessel’s give some idea of the scale of the provertical movements; a greater degree of ject, the wind turbines will stand at an precision was required in this case. overall height – from the seabed to the The crane is also ideally suited for turbine blades – of around 258m, which maintenance work on wind turbines and is nearly three times the height of the other fixed installations.

Statue of Liberty in New York,” adds Mr “In addition to compensating for vertiGrindheim. cal motions with the winch, we needed to develop new technology to compensate for the vessel’s pitch and roll movements. If Keeping the turbines turning you can compensate for these motions, you Regardless of the difficulties imposed by can ensure that the crane’s pedestal remains their height and exposed positions, all

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MACGREGOR NEWSLETTER, SPRING 2016

vertical in relation to the sea bed, so that it is parallel to the windmill structure.”

MacGregor’s solution involves hydraulically tilting the crane’s foundation.

The crane has an outer steel foundation welded to the deck at the centre line of the vessel. “Although all areas of the vessel experience the same angular movements in a seaway, positioning the crane at the centre of the vessel minimises the actual physical displacement of the crane and its load,” explains Mr Apeland.

The fixed foundation is connected to an internal foundation system supported by a hydraulically-actuated twodirectional motion compensation system employing four high-speed hydraulic cylinders. These cylinders are arranged in two pairs; one pair is sufficient to provide full system functionality, so this provides a good level of redundancy. Each cylinder is fitted with a positioning sensor, to provide real-time feedback to the control system.

The crane has a safe working load of five tonnes at a 25m outreach and features a telescopic jib, operated by a hydraulic cylinder system, to achieve the required combination of lifting height and compactness when not in use.

A motion reference unit (MRU) is the primary sensor for calculating heave motion for the winch. In addition, a second MRU is used for pedestal compensation.

The jib’s luffing and slewing controls remain fully functional with the threeaxis compensation activated, ­making it possible to maintain precise load positioning without shutting down the compensation mode or moving the vessel.

“While a similar operational end result might have been achieved making use of the crane’s luffing and slewing functions to control the position of the head of the jib, it would have resulted in a more

to look for lower cost solutions that compromise on optimal performance. In this challenging climate, MacGregor recognises that any investment must deliver distinct operational advantages,” adds

Mr Apeland. “The three-axis heave-compensated subsea crane does exactly that, offering safe, quick, accurate load handling and unique operational capabilities, even in high sea states.”

MacGregor was chosen for the project because of its long history of designing and delivering very reliable Pusnes mooring solutions for offshore floating production units operating in harsh North Sea conditions

Photo: Helge Hansen/Statoil

complex solution and it would have been difficult to achieve the required speed of response.”

“In today’s economic climate the need for cost savings is driving some owners

MACGREGOR NEWSLETTER, SPRING 2016

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Contacts MacGregor

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 Norway AS 368 Skilsøveien, Pusnes, NO-4818 Faervik, Norway Tel: + 47-370-873 00 pusnes@macgregor.com MacGregor Norway AS Dokkveien 10, 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 Securing Systems MacGregor Germany GmbH Reichsbahnstrasse 72 DE-22525 Hamburg, Germany Tel: +49-40-25 444 0 lashingsalesorder@ macgregor.com MacGregor Pte Ltd No 15 Tukang Innovation Drive, 618299 Singapore Tel: +65-6597 3888 lashingsalesorder@ macgregor.com RoRo MacGregor Sweden AB PO Box 4113 SE-400 40 Gothenburg, (J A Wettergrens gata 5, SE-421 30 Västra Frölunda), Sweden Tel: +46-31-850 700 rorosales@macgregor.com roroconversion@macgregor.com

OFFSHORE Offshore Load Handling MacGregor Norway AS Andøyfaret 15, NO-4623 Kristiansand Norway Tel: +47-91-686 000 ofssales@macgregor.com Offshore Mooring and Loading MacGregor Norway 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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Updated: 15 April 2016 For an up-to-date list, please visit our website

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