MacGregor

Three Axis compensated

Crane for Wind turbine

Services

09.09.2014Klaus Høj Henriksen – Hydraulic Project Engineer

MacGregor – part of Cargotec

Cargotec is a leading provider of cargo handling solutions. Our products are present in every major cargo hub worldwide. They are used in ships, ports, terminals, distribution centres, heavy industry and in on-road load handling globally.

Cargotec's business areas MacGregor, Kalmar and Hiab are recognised market leaders in their fields.

Cargotec Group Sales 2013: EUR 3.2 billion €

Approximately 11,000 employees

Cargotec and its business areas have operations in more than 120 countries and in more than 750 sales and service locations worldwide

With this unique global coverage, customers can be served locally ensuring the continuous operation of their products

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Kristiansand site:

Advanced Load Handling & Offshore Service Cargotec acquired Hydramarine A/S in 2007, today forming MacGregor

Norway

R&D, Sales, Design, Sourcing, assembly, testing, installation, training

center, service

Employees: ~700 in Norway (~250 in Kristiansand)

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MacGregor Norway

Everything for load handling on-board and offshore

Moving into a New Market

Offshore Crane for wind turbine services

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Moving into a New Market

Offshore Crane for wind turbine services

Current technologies for load handling to Offshore Wind Turbines

Fendering systems (boat ramming into the foundation)

Gangways (ship deck to platform)

Relatively small compensated cranes

Crane on hexapod with 6 DOF compensation system

Etc.

All compensated systems currently in service have a small payload

and range

Max payload ~0.5 ton @ 6m distance

The New MacGregor Crane for Offshore Wind Turbine Services

beats this by a factor of 10!

3 DOF compensation system

Max Payload: 5 ton @ 25 m distance and 35 m above deck

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Customer Request for

Service and installation vessel for wind turbines

Customer requirements

Work in harsh weather and sea conditions (HS=3)

Load: 5 ton, cubic formed container ~2.5x2.5x2.5m

Fixed unloading platform

Extremely small landing area, located well above sea level

Resulting concept:

Telescopic, slewing and luffing crane 360° slewing angle,

25m max outreach

35m lifting height

5 ton winch mounted on jib

Snubber on crane tip Removes pendulum effects

3-axis motion compensation system

Crane tower to be kept vertical and load kept at specified height

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Why use a 3D compensation system?

Disadvantages of alternative technologies

Jack-up with fixed crane

Vessels are often big and slow

For small lifting operation the jack-up time is significant

Energy And fuel consumption are high

Etc.

A standard offshore Crane without 3D compensation system

The Lifting operation in question, can only work in good weather conditions

High risk for crew handling the load

High risk of damage to equipment in unloading area

Etc.

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Emerging Challenges

Concept analysis

Several design iterations were performed

Simulation Model

Comparison with test results

DNV demanded a dynamic load factor of 2.7

Crane size increased from 1.6m tower diameter to 2.2m

Weight of crane goes up

All hydraulic and electrical components increases in size

Paradigm: Design the compensation system for a worst case scenario: If the compensation system doesn’t work!

When the system works; some components only uses 10-30 % of their performance

Risk analysis – Risk of heavy damage to material if essential components malfunctions

Critical components are run through a self-test cycle before entering compensation mode

Redundancy and double sensors circuits

Test condition

Not possible to test compensation system while crane was assembled on land, (would require an enormous

hexapod)

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Three-axis motion compensation crane- first of its kind Offshore wind Turbine supply and

maintenance operations

Subsea and ship-to-ship operations

Telescopic or knuckle- jib

2-axis hydraulic motion compensation system on pitch and roll

Active heave compensation (3rd axis) on heave

Constant tension

Motion reference unit (MRU)

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Winner of:

Offshore Support Journal's (OSJ)

Innovation of the Year award.

3-axis Compensation system

Heave

Hydraulic 5t winch with conventional

Active Heave Compensation system

Pitch & Roll

Hydraulic cylinders connected

between pedestal and crane tower

Motion reference unit (MRU) as sensor

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Achievement

Position a hanging load onto the

small landing area on a fixed

platform

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2014_5_3-axis-

crane_overview.mp4