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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
16 September, 2014 2
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)
16 September 2014 3
16 September, 2014 4
MacGregor Norway
Everything for load handling on-board and offshore
Moving into a New Market
Offshore Crane for wind turbine services
16 September 2014 5
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
16 September 2014 6
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
16 September 2014 7
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.
16 September 2014 8
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)
16 September 2014 9
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)
16 September 2014 10
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
16 September 2014 11
Achievement
Position a hanging load onto the
small landing area on a fixed
platform
16 September 2014 12
2014_5_3-axis-
crane_overview.mp4