ONSHORE CAPABILITIES FOR OFFSHORE WIND PROJECTS

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1 ONSHORE CAPABILITIES FOR OFFSHORE WIND PROJECTS WORLDWIDE HEAVY TRANSPORTATION AND LIFTING 1

2 Together, we are... Contents At the heart of ALE s business are our people: dedicated professionals who work with our clients to achieve the very best results. We employ imaginative people at all levels within the company, who focus on developing innovative solutions for the most complex projects. We challenge conventional thinking, aspire beyond accepted limitations, and don t stop until we have the smartest, most effective solution to each and every challenge. Our Innovation Series is just one example of our insistence on pushing the boundaries to create solutions that work best for our clients. Specialist Offshore Wind Experience Why ALE-Wind Services Onshore for Offshore Capabilities Engineering and Development Port Handling and Marshalling Bespoke Design Work ALE is a responsible business with a strong moral core, so the safety and wellbeing of the individuals we work with and the clients we work for is our single most important consideration. Minimising risk to our staff, our clients and members of the local community is a priority at the highest level of the company, and an ethos that permeates every aspect of our business. Handling of Jackets Handling of Monopiles Handling of Transition Pieces Maritime Services Handling of Nacelles, Towers and Blades 18 We haven t become one of the world s foremost experts in heavy transportation and lifting by thinking small. By investing in the latest technologies and employing the best people in the business, we ve grown over more than 30 years into a global leader with a presence across a breadth of sectors and markets. Our flexible approach suits any project, whatever its size or scale, and our clients know they can rely on us for commitment, innovation, delivery, service and an agile, proactive approach that gets results. Assembly Onshore for Offshore Projects HSQE Sectors & Services Equipment & Innovation Series Siemens Wind Blade, Hull_Photo Credits Siemens and Sean Spencer, Hull News and Pictures 2 3

3 Specialist Offshore Wind Experience We have the heavy lifting and installation capabilities to handle offshore wind components inside marshalling facilities. In fact, we provide over 30 different capabilities. We cover a broad range of different scopes, from all the different foundation logistics (of monopiles, transition pieces, jacket structures and pin-piles) to the activities related with the transportation and pre-assembly of tower structures (tower sections, blades and nacelles). ALE has the capabilities to provide assistance through all the logistics involved in the offshore wind industry during the planning and execution of each project, working with designers, fabricators, installation companies and developers. By having the best people and equipment in the market working in the offshore wind industry, we make a difference to our clients. We deliver a specialised turnkey project and integrated engineering service that can be fully customised to client requirements. With the combination of in-house experience from previous projects and the research of new developments, our analysis focuses on delivering cost and time savings to our clients while reducing risk in our operations. 4 5

4 Why ALE-Wind Services Based in strategic global locations, our people also have the expertise to understand the localised market conditions, challenges and regulations in line with international management. Onshore for Offshore Capabilities Port Handling and Marshalling 1 Complete service package includes bespoke solutions with project management capabilities 2 Simplified interaction single and fully-integrated supplier Handling of nacelles, towers and blades Design supply/ installation service 3 Highly-skilled, trained and experienced personnel competitive 4 Package optimises group resources Handling of transition pieces Maritime services 5 Global presence ability to work worldwide 6 Certified reputation of consistent high standards of quality and safety Handling of monopiles Handling of jacket structures 7 Bespoke design work 6 7

5 Engineering and Development With a pedigree in innovative engineering and an active Research and Development (R&D) facility, ALE has always been known for developing new solutions to meet future needs. By using our existing global footprint, Group engineering support and traditional business network to gather local knowledge, ALE works through complex technical and logistical solutions at an early stage to ensure we assist our clients to optimise the final kw price. Our engineering and development capabilities form a crucial part of the service we offer. ALE has contributed to many high-profile projects that have been right at the forefront of global trends in their sector. We are able to adapt to ever-changing industry requirements, evolving safety standards and scope changes as the project gathers definition during the design process. Whilst, at the same time, providing solutions which are as cost-effective and as safe as possible. As a result, we re flexible and work closely with our clients from an early stage to establish what s required and provide practical and customised engineering advice. This advice can lead to savings later, either in time or cost, as the changes are included in the design phase, instead of modifications later. Some of our engineering services typically include: FEED studies for prospective developers to evaluate the financial viability of a project Full analysis of the different marshalling scenarios, helping the installation companies/developers in the selection of their installation strategy Assistance during the design of different components (including the prototype phase) to ensure feasibility and reduce the logistic costs Planning simulations to assess different fabrication/assembly methodologies Advice on local regulatory requirements Design of bespoke tools and equipment that can be adapted to the new designs, reduce costs and enhance the safety during operations Marine engineering includes: Vessel selection Stowage plans Deck and longitudinal strength analysis Sea fastening calculations and design Structural integrity checks over the components to be transported Mooring analysis Ballast plans Towage plans Land-based engineering includes: Ground conditions assessment Quay studies (related with the capacity required and the tidal restrictions) Design of temporary structures (ramps, load spreaders and stands etc.) Swept path analysis Storage solutions design (sand bunds and temporary frames etc.) Lift studies for craneage activities Specialised lifting tools and methodologies designed to improve the workability factor with higher wind speeds, including sheerlegs and tailing frames Design of transport frames/saddles Design of bespoke transportation tools/solutions to improve efficiency (such as blade movers and SPMT arrangements for confined areas) 8 9

6 Port Handling and Marshalling From receiving the components off the vessel/barge to loading them again onto the installation vessel, ALE provides the turnkey package for the wind farm logistics. We have specialised transport and lifting equipment to optimise the space restrictions within the port terminals, and to save infrastructure and real estate costs. We always find the most suitable port transport solution; ALE has created bespoke hydraulic transport frames and saddles, blade carriers, new generation of SPMT engines for confined spaces and tailing frames in order to enhance the transport and assembly processes. ALE has invested in the latest technology to ensure that we meet our clients demands to handle the next generation of turbines. We manage and operate the full scope of port handling, including: Interaction with shipping agents Establish the most suitable transport route in typically congested areas Provide and operate specialist equipment for transporting every component Efficient delivery of components through the port customs Co-ordination of crew members and stevedore management Storage management of marshalling facility Inspections, damage assessments and documentation Supporting arrangements for storage Lashing and sea fastening 10 11

7 Handling of Jackets ALE has been working closely with designers and fabricators to develop a full set of tools and methodologies for assisting the transportation and manufacturing processes of complex offshore wind structures like jackets. The main solutions are related to: Jacking and lifting operations during the erection of jackets Modular transport frames that allow the jackets to move on-site and load them out without any extra temporary steelwork attached to the structure. Sea fastening design and provision Grillage design 12 13

8 Handling of Monopiles ALE knows the techniques and has the equipment to perform the barging, onsite transportation, storage, sea fastening, grillage support and load-out of monopiles or smaller diameter pin-piles for the jackets. The industry has changed rapidly over the past years, setting new boundaries for the size of monopiles increasing in height and heavier weights. Being part of this, ALE is constantly looking at the details in this evolution to review and develop the right solution for each project, adapting our services to the new ever-changing requirements. ALE has worked on the design of: Adjustable hydraulic saddles for monopiles transportations which reduce the height of the sand bunds Pin-piles handlers to store the piles at ground level, avoiding conventional methods using reach stackers, which are potentially high-risk because of their loss of stability Adaptable sea fastening grillage Besides the supply of conventional crawler cranes for the offloading of MPs onto the marshalling facilities, we can supply one of our modular sheerlegs that can be adapted in size to the project requirement when the ground loads might be a limitation and a SPMT load-in/-out is not possible 14 15

9 Handling of Transition Pieces ALE supports and improves on-site and sea/ river transport, storage activities and the logistics of the transition pieces (TPs) from the fabrication stage. We have proven experience providing services where we cover the whole handling package: Offloading the unprocessed tube sections Transporting the transition pieces horizontally during the different fabrication stages Upending the transition pieces using cranes and an in-house-designed tailing frame mounted on SPMTs Platform installation/commissioning of the full TPs On-site vertical transportation using the in-house designed TP handler, avoiding auxiliary steel TP load-out River/sea transport On-shore transport/storage inside the marshalling facility New innovative way to handle TPs 16 17

10 Handling of Nacelles, Towers and Blades ALE has successfully transferred the expertise from the onshore wind to the offshore wind industry by constantly working with the main turbine suppliers. We can provide the services to cover all onshore needs to support the marshalling and pre-assembly campaigns of an offshore wind farm. We work with clients who push the boundaries to achieve the most efficient way to run the operations. ALE has invested in the latest equipment and designed the most reliable tools to ensure efficiency, risk reduction and port terminal optimisation. From specially fabricated power packs with reduced dimensions, to working within the tower section or blade movers, ALE has a tool for every need

11 Assembly In addition to the transport activities, ALE has the experienced personnel and specialist cranes to perform all the activities related to the tower pre-assembly safely and within tight schedules to meet the installation vessel s needs. ALE works closely with clients and suppliers to enhance the operations, such as wide boom cranes technology and the utilisation of smaller cranes to handle larger capacity components. During the assembly phase, we can provide: Crane lifting and critical lift plans Lifting tools design Trained and experienced operators Co-ordination of the lifting and assembly operations with the bolting and electrical connections Full site and facilities management 20 21

12 Maritime Services ALE can provide all the services required to perform the full marine scope of work, from the barges/tugs supply and management, to the design and provision of sea fastening and grillage. We own and operate a global fleet of barges, from 70m x 22m up to 140m x 40m, while investing and constantly adapting to the market needs. One of our latest acquisitions in Europe has been a non-conventional L/B ratio barge which has a long, but narrow, body to fit up to six TPs while minimising the operational radius required for the installation vessel. Because of this, the barge can be moored in-between the quayside and the installation vessel. In addition, we have different grillage types and sea fastening systems, as well as the ability to re-design and modify this equipment, to suit different projects. For the final phase, we provide the maritime barge work: Trained and experienced personnel to plan, manage and execute any project worldwide Ability to navigate and co-ordinate maritime transportation with third party agents or authorities Design, commissioning and fabrication of high-quality auxiliary steelwork Wide range of barges and the expert advice when considering the project characteristics and location Ballast pumps, hoses, winches and ramps to perform load-in and load-out operations 22 23

13 Onshore for Offshore Project Experience 24 25

14 Multi-Service Operations and Handling of Offshore Wind Components, UK Project Scope : Port Handling» Load-in and Load-out» Crane Lifting» Transportation» Storage ALE has successfully executed the onshore heavy lifting, transportation and pre-assembly for offshore wind operations in Hull, Great Yarmouth, Belfast and Nigg in the UK, Oostend in Belgium and Sasnitz in Germany. As part of a multi-service operation, ALE received hundreds of offshore wind components, before performing the port handling and pre-assembly, transportation, and the load-out for the Dudgeon, Race Bank, Walney Extension, Gallopher, Rentel and Beatrice. With some rotor blades as long as 75m and nacelles as heavy as 360t, ALE adopted a Ro-Ro process (where possible) instead of lifting, to provide a safer and more cost-effective method. ALE utilised a range of equipment to carry out this complex scope of work, including SPMTs and specialist high capacity crawler and telescopic crawler cranes

15 Jacket Transportation, UK Project Scope : Port Handling» Transportation» Crane Lifting» Storage ALE has successfully moved the 28 jackets, weighing 1,080t, in North East England, UK. The jackets, measuring up to 80m high, was transported using SPMTs and two transport beams, measuring 22m in length. Instead of welding beams to the jacket, ALE came up with a new design using a hydraulically actuated beam extension. Each transport beam had hydraulically actuated extensions which when retracted allowed the beams to be positioned on the SPMTs and driven between the legs of the jacket. When retracted, the extensions were contained within the section of the main beam. To extend, integrated hydraulic rams were used to push the extensions out. The extensions were located on each end of the beam and extended 400mm each side. When extended the beams are able to bear under the annulus ring of the pile stabber, allowing the SPMTs to pick up the full jacket using the integral hydraulic suspension. The jacket was transported 100m to a different location onsite, where they would be offloaded by a crane. Mechanical and Electrical Installation of a Floating Foundation, France Project Scope : Port Handling» Transportation» Crane Lifting» Storage ALE has completed the mechanical and electrical installation of a wind turbine generator onto a floating foundation at Saint Nazaire, France. This is France s first floating windmill, part of the commissioning works of the new FLOATGEN prototype. A floating foundation was afloat and berthed at the Quai des Charbonniers, Saint Nazaire. Each of the windmill s components was lifted by a mobile crane and an auxiliary crane was also required to erect and lift the two tower sections in tandem. In order to maintain the stability of the floating foundation, ALE performed ballasting operations on the foundation during the operation. Four submergible pumps were used to supply water to the ballast tanks situated at the corners of the floater. Once the windmill was fully mounted on top of the floating foundation, the electrical components and cables were connected and assembled, and the client s sensors and measuring equipment were installed. ALE coordinated the lifting and ballasting operations as well as the mechanical and electrical installations, which were performed simultaneously. This was a unique job for ALE, who were able to provide a bespoke solution for this challenging operation within a limited timeframe

16 Greater Gabbard Port Handling, UK Project Scope : Port Handling» Transport» Cranes ALE has successfully handled, transported and installed wind components as part of the Greater Gabbard wind farm, located in the North Sea off the coast of Suffolk. ALE received the offshore wind components, stored them and redelivered them to installation vessels as and when required. ALE created a purpose-built site for the EPC contractor which enabled large quantities of wind farm components to be stored for any period of time to fit the offshore installation schedule. ALE minimised the risk of weather delays and issues associated with working at height by developing innovative handling solutions which reduced dependency on cranes and increased the speed and reliability of the operations. Because ALE components require only a small access area around them far less than larger crawler cranes would require ALE s handling solutions also helped to maximise the use of available land. Once completed, the Greater Gabbard wind farm consisted of 142 wind turbines with a total capacity of around 500MW. Lifting, Transportation, Roll-up and Jack-up of Offshore Wind Components, UK Project Scope : Port Handling» Cranes» Jacking» Roll-up» Load-out As part of a major wind farm project, ALE were given the scope of lifting components, performing multiple site moves, rolling-up and jacking-up the jacket, and loading-out the jacket and topside at the fabrication site in Lowestoft, Suffolk. During the project ALE lifted hundreds of components using cranes, telehandlers and chainblocks. The site moves were also performed using 16 axle lines of SPMT in a configuration of 4 file 8. One of the most critical scopes of the project involved the roll-up and jack-up of a jacket, weighing 954t. Prior to the roll-up operation, four jacking towers were set-up with the first layer of bracing, which saved several days of set-up/installation time. The roll-up was carried out using ALE s AK912 and the LR cranes. The jack-up operation took place one day after the roll-up and utilised ALE s Mega Jack 800 to jack-up a 954t jacket to 14m high. To perform the jack-up, suction buckets were positioned under each of the jacket legs and SPMT trailers were used to manoeuvre them into place. The Mega Jack 800 held the jacket in place whilst the suction buckets were welded to the jacket by the client s operatives. The success of the project depended upon the high level engineering and design works carried out by SLP and ALE and close collaborative working with STDL to get the jacket ready for planned sail away on schedule

17 HSQE ALE recognise that the wind sector presents challenges in terms of managing risk. Our passion is fuelled by our history and foundation in protecting our people, environments and assets all over the globe. We have acquired a track record of over 30 years of evolving risk management though maturing legislation, international standards and client requirements. We are committed to leading the industry and influencing our clients and subcontractors in a united approach to achieving an incident and injury-free mindset. In order to achieve this, we invest in our internal infrastructure and wind-specific training to maintain our competitive advantage and adopt industry best practice. We have ensured that our core systems, which shape the way we operate globally, are certified and proven to comply with ISO 9001 and 14001, as well as OHSAS We know that it is imperative to not only attain the certification, but to also have a robust assurance process in place to ensure that the standards are met and upheld. We see the value in a safer working environment for all and we want to capitalise on our history and better mitigate industry risks. At ALE, we stand by the fact that together we are safer

18 Sectors Equipment Civil Minerals & Metals Nuclear Offshore Oil, Gas & Petrochemical Ports Power Generation Renewables Shipyards Skid Systems Weighing Systems Ballast Systems Jacking Systems Barges Auxiliary, Ancillary & Access Equipment Lifting Systems Services Cranes Transportation Specialist Crawler Mobile Girder Frame Modular Trailers SPMT SPT Ballasting Crane Lifting Engineering Jacking Lifting Systems Load-In & Load-Out Logistics Marine Engineering Offshore Installation Innovation Series Skidding Transportation Turnkey Operations Weighing Mega Jack AL.SK Cranes All Terrain Transporters Hydro Deck Mega Jack

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