wind energy brochure - ALE Heavylift

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ALE plays a vital role in the wind energy sector. Building on our experience in the power sector, we have used our knowl
WIND ENERGY BROCHURE

1 HEAVYSafer, TRANSPORTATION Together,WORLDWIDE we are Smarter, Stronger AND LIFTING

Together, we are...

Smarter

CONTENTS 04 Introduction

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.

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Front End Engineering & Design (FEED)

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Risk Management in ALE through HSQE

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Wind Energy

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Port Handling

14 Transport 16 Cranes

Safer

18 ALE is a responsible business with a strong moral core, so the safety and well-being 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.

20-31 Case Studies 32 Sectors 33 Services 34 Equipment 35

Stronger

Installation – Mechanical and Electrical

Innovation Series

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.

Together, we are Smarter, Safer, Stronger

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INTRODUCTION ALE plays a vital role in the wind energy sector. Building on our experience in the power sector, we have used our knowledge and expertise to develop smarter solutions to the challenges created by the increasing heights of wind turbines and associated components. ALE offers a bespoke Transport, Crane and Installation (TCI) package for the wind energy sector. The transportation phases of projects include route assessments, liaising with local authorities, providing specialist transportation equipment and facilitating the removal and replacement of any street furniture or structures that may obstruct the route. We own a fleet of specialised equipment that is specifically used for projects in this sector, such as retractable blade trailers and low profile wind tower adapters. Our qualified electrical and mechanical installation teams have the knowledge and experience to provide the most efficient solution on a project by project basis. We can also provide our clients with port handling services. This includes equipment inspection, damage assessment, storage facilities and loading or reloading of equipment to specialist transport.

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FRONT END ENGINEERING & DESIGN (FEED) 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. ALE is actively involved in the FEED process in all industry sectors. Over the years we’ve added to our world-class engineering skills-base through the acquisition of several successful specialist companies, and we now have more than 200 highly qualified engineers working in locations across the globe. This experience means we’re well equipped to support the full FEED process, by using our existing global footprint and traditional business network to gather local knowledge, ALE are able to work through complex technical and logistical issues at an early stage to eliminate expensive changes later on.

Our FEED 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 able to work closely with our clients from an early stage to establish what’s required and provide practical 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.

CANADA EUROPE

NORTH AMERICA

MIDDLE EAST

Some of our FEED services typically include, but are not limited to, the items below: • Physical route surveys to determine the maximum practical equipment weight and dimension information • Investigation of environmental conditions affecting the heavy lifting and transport discipline in order to reduce the civil infrastructure on site • Road layout and route improvement studies • Advice on local regulatory issues relating to the movement of large and indivisible loads to the job site

CASPIAN ASIA

• Design of rigging and lifting equipment • Selection of optimum shipping methods and identification of suitable vessels or barges • Logistical studies to ensure that transportation and installation scope supports the project schedule

SOUTH AMERICA

AFRICA AUSTRALIA

• Design and input of transportation support steel, lifting and lashing points

• Equipment lifting and installation studies to determine the most cost and schedule effective methods of sizing hard stands and placing equipment

Together, we are Smarter, Safer, Stronger

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RISK MANAGEMENT IN ALE THROUGH HSQE We recognise that the industries and sectors that we operate in present 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. ALE is cemented in a context of over 30 years of evolving Risk Management though maturing legislation, international standards and client requirements. We as ALE see the value in a safer working environment for all and we want to capitalise on our history and better mitigate industry risks. By investing in our constantly evolving internal infrastructure, we are able to maintain our competitive advantage with industry leading initiatives that allow us to implement and use breakthrough tools to identify, assess and act upon all levels of risk to our people, environments and assets. This has given us the ability to identify areas that require attention as well as nominate single areas of concern to target resources. ALE are committed to lead the industry and influence all of our clients and subcontractors in a united approach to achieving an incident and injury-free mindset. In order to achieve this, we have developed and adopted many of the leading systems and processes that are seen as industry best practice and available techniques. We have ensured that our core systems which shape the way we operate are certified and proven to comply with ISO 9001, 18001 and 14001. ALE 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 maintained. At ALE, we realise that this journey is not to be taken in isolation, therefore we stand by the fact that together we are safer.

Together, we are Smarter, Safer, Stronger

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WIND ENERGY ALE has the knowledge and experience to provide proactive risk management and engineering solutions for the installation of wind energy components worldwide. By working with the developer and/or the equipment supplier, ALE is able to tailor a full TCI package for the entire project and provide a single interface for all elements. Our involvement in the wind energy sector is one of the core elements of our business. We have the skills base and resources to contribute in the following areas: • The assessment of marine and port operations including storage, handling and the technical/commercial considerations associated with the receipt of cargo • Liaising with government agencies to establish suitable transport routes to site, including a full negotiability review, the assessment of street furniture and any secondary routes which may need to be considered • Project site access and installation methodology reviews • The compilation of a comprehensive document providing detailed risk analysis into operations including lead times, commercial, technical and operational considerations, as well as any further recommendations • Provides the full service, including transportation, cranage and installation solutions from the point of arrival to when it is fully erected on the final foundation

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PORT HANDLING ALE is well adapted and suitably equipped to manage the full scope of port handling, including: • Receiving the components from the vessel • Inspection and damage assessment • Supplementary cranes for the storage of items • Reloading to specialised transport equipment The offshore wind industry presents a unique set of challenges in comparison to the onshore industry, with the size and volume of equipment increasing dramatically. The challenge for offshore construction is matching the component manufacturing dates to a variable offshore installation schedule. The ideal solution is a local staging area with a fast, efficient and reliable handling operation, where a buffer stock of wind turbine equipment can be kept. This will minimise any risk of delay as deliveries to the offshore installation vessels will be made on a just-in-time basis.

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TRANSPORT As the towers grow higher and the diameter of the rotors increase to maximise the yield, ALE have invested in the latest technology to ensure that we can meet our clients’ demands. In addition to the transport equipment that ALE utilises across all market sectors, the fleet also includes specialist equipment for the renewable energy sector. This comprises of blade trailers and extendable trailers, as well as tower clamps and low profile wind tower adaptors which enable tower sections to be transported under standard bridges.

Together, we are Smarter, Safer, Stronger

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CRANES ALE recognise the importance of the main crane specification to the build rate and the overall success of the project. With numerous and varied cranes within our fleet, we are able to specify the most suitable crane for the project. Whatever the site location and layout, road type and topography, we have the crane solution to balance the engineering of the lifts, turbine and tower types. By investing in the largest wind energy specific mobile cranes currently in the market, ALE have the capability to install wind turbines up to 160m hub height with minimal civil infrastructure footprints. The cranes also have the benefit of being able to move on the narrower roads which are generally constructed on wind farm sites, making the design of the crane critical to the project.

Together, we are Smarter, Safer, Stronger

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INSTALLATION – MECHANICAL AND ELECTRICAL In addition to the specialist equipment, ALE also has the experienced personnel to complete the mechanical and electrical installation of all components, meaning that ALE can provide the full TCI package. This enables the client to use a single source supplier, from receiving the components off the vessel to handing over the final product for commissioning. In order to provide our clients with an internationally-recognised quality service, we pride ourselves on three values that are fundamental to our performance and success: the technical skills involved in the installation, the project management skills and our experience with various turbine manufactures and models. At ALE, we continually invest in our teams so all of our people have the most up to date technical skills. All ALE operators have to undergo regular training and we run in-house Standard Schemes of Training (SSOTs) featuring 10 pragmatic, vocational training schemes. We actively encourage training and development across all areas of the business, as well as ensuring all of our people have the required industry-recognised qualifications. Within the wind energy sector, these internal training schemes have been designed to complement the external training required to build up the specific knowledge for each and every manufacturer and project.

ALE offers the full service, which includes Project Management. This service is valuable on any project and can ensure the smooth operation and coordination of all aspects. By offering this added service, our clients are assured of the synchronicity of the project and only need one point of contact on site for the full TCI process. We have a wealth of experience working in the wind energy sector, with dozens of successfully completed projects working across various manufacturers with different models. This extensive knowledge and portfolio means we give our clients the confidence to trust our installation capabilities

Together, we are Smarter, Safer, Stronger

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CASE STUDY Amakhala wind energy project, South Africa Project Scope »» Port Handling »» Transport

OVERVIEW: ALE was contracted to provide the handling of 560 wind turbine generator components for the Amakhala project in the Eastern Cape of South Africa. ALE was responsible for receiving the components at the Port of Ngqura, transporting them to a temporary storage and to site, before finally offloading the components on-site.

Throughout the course of the project, ALE received the components and transported them from the finger jetty to a temporary storage facility in the port, before reloading the components for onward transportation. In order to handle the components, ALE supplied two mobile cranes and one telehandler for the port operations.

SERVICES REQUIRED: A total of 56 wind turbine generators needed to be delivered (excluding related accessories and containers). These comprised of 10 components each, namely three blades, one nacelle, one rotor hub, one drivetrain and four tower sections. The components ranged in weight and dimensions, with the longest blades transported to date by ALE at 58.5m.

The components were then transported to the site located in Amakhala, Bedford, approximately 250km from the port. The 58.5m blades were transported by means of 3 x 4 axle lines of nooteboom axle quarto-extendable blade trailers. The nacelle, hub, drivetrain and four tower sections were transported individually on 7 x 8 axle lines of nooteboom single extendable trailers.

The components arrived by means of eight geared vessels in the Port of Ngqura, Port Elizabeth. ALE were the first company in South Africa to make use of a new laydown outside the Port of Ngqura.

On the day of transportation, the components departed from the port of Ngqura under the control of police traffic escorts. The components travelled together in convoy consisting of 10 special abnormal load trailers, 20 ALE light vehicle escorts as well as the presence of the police escort to site. Once on site, ALE offloaded the components using two mobile cranes and one telehandler with a rigging crew and site manager to oversee and coordinate the offloading operations. The feed rate was to deliver two complete turbines per week, consisting of 20 components in total. The project lasted approximately eight months.

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CASE STUDY

CASE STUDY

Chaba wind energy project, South Africa

Noblesfontein wind project, South Africa

Project Scope

Project Scope

»» Port Handling »» Transport »» Cranes

»» Port Handling »» Cranes »» Installation

OVERVIEW: ALE has completed the TCI package for the Chaba wind energy project in the Eastern Cape, South Africa. SERVICES REQUIRED: ALE was contracted to facilitate the lifting, handling and transportation of pre-pop and offloading of seven V112 3MW 84HH wind turbine components. The wind turbine components consisted of blades, nacelles, hubs and a drivetrain, all varying in weight and dimensions. To perform the lifts and handling, ALE supplied a 250t, 130t and 90t mobile crane. ALE also supplied various specialised trailers for the transportation scope of the project, including 4 and 8 axle trailers. ALE successfully completed the required scope of work in two weeks.

OVERVIEW: ALE successfully completed the TCI package of 41 wind turbine generators (WTGs) at the Noblesfontein project site in the Northern Cape, South Africa. SERVICES REQUIRED: The 41 WTGs ranged in weight and size with each consisting of eight components, including three tower sections, one hub, one nacelle and three blades, totalling at 328 abnormal components. The scope involved receiving the wind turbine components from the vessel at Coega Port, offloading and handling them at the port. ALE then transported the components 570km to the site location using 4 axle lines and 8 axle lines of extendable trailers. This was the first time ALE had transported abnormal components this distance. Once onsite, the turbines were offloaded and installed using an LG1750 crane as well as auxiliary cranes. As the final part of ALE’s scope of work, a team of skilled electromechanical technicians completed the installation works for handover to the commissioning team. This site was extremely challenging, as the turbines were positioned at the top of hills. ALE had to also negotiate the difficult terrain when transporting the components as well as ALE’s larger equipment around the site, such as their LG1750 crane.

Together, we are Smarter, Safer, Stronger

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CASE STUDY

CASE STUDY

Dorper wind energy project, South Africa

Greater Gabbard, UK Project Scope

Project Scope »» Port Handling »» Transport

OVERVIEW: ALE was contracted to handle the port operations, offloading and transportation of 40 wind generator turbines (WTGs) to Dorper wind farm. SERVICES REQUIRED: The turbines comprised of three blades, nacelle, drive train, hub and four tower sections, along with the associated equipment for 40 WTGs. The components were delivered to the Port of Ngqura, Port Elizabeth, where they were offloaded and loaded onto ballasted haulers by means of mobile cranes. They were then transported to a laydown area. The components were grouped into different sets: three blades; four towers; a nacelle, hub and drive train. From there, following a strict schedule, the WTG components were transported to Dorper wind farm. All components were successfully delivered within the allocated time schedule.

»» Port Handling »» Transport »» Cranes

OVERVIEW: 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. SERVICES REQUIRED: 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.

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CASE STUDY

CASE STUDY

Hopefield wind energy project, South Africa

Khao Kho wind energy project, Thailand

Project Scope

Project Scope

»» »» »» »»

»» »» »» »»

Port Handling Transport Cranes Installation

OVERVIEW: ALE has completed the lifting and transportation of wind turbine generators (WTGs) for the Hopefield wind energy project in the Western Cape, South Africa. SERVICES REQUIRED: ALE was contracted to render services for the TCI package for 37 WTGs for the Hopefield wind energy project. The wind turbine components consisted of blades, nacelles, tower sections and hubs, all varying in weight and dimensions. ALE received the components at Saldanha Port, where they were offloaded using an LR1250 crawler crane, a LTM 1095 mobile crane, one 5t capacity telehandler and a 7t capacity telehandler. The components were then transported within the Saldanha Bay municipality by 8 axle and 4 axle line extendable trailers. ALE successfully completed the required scope of work in 19 weeks.

Port Handling Transport Cranes Installation

OVERVIEW: ALE successfully completed the TCI package of 24 3MW WTGs at a project site in Khao Kho, Thailand. SERVICES REQUIRED: The scope involved receiving the wind turbine components from the vessel in several shipments over three months, before offloading and transporting them into a temporary storage facility at the Port of Laem Chabang, in the Chonburi province, Thailand. The components ranged in weight and size, with some blades weighing 12.5t and measuring 59m long. ALE then transported the components 620km to the site location. During the challenging route, ALE faced many tight bends and gradients as steep as 15% on the final approach to the site. In order to overcome this, ALE implemented civil works to increase the turning radius in several areas of the road. By making these adjustments, devising precise engineering designs and using specialist tower transporters and extendable trailers, ALE could navigate this challenging route and deliver the components safely to site. Once on-site, the turbines were offloaded and erected. ALE then performed the mechanical and electrical installation of all the components. ALE then handed over to the client for the final commissioning. The project was completed in eight months.

Together, we are Smarter, Safer, Stronger

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CASE STUDY

CASE STUDY

Coega wind farm, South Africa

Noupoort wind energy project, South Africa

Project Scope »» Port Handling »» Transport

OVERVIEW: ALE has completed the handling and transportation of all major components for the Coega wind energy project in Oyster Bay, Eastern Cape, South Africa. SERVICES REQUIRED: ALE was contracted to render services for the handling and transportation of wind turbine 32 N100 R80 wind turbine generators for the Coega wind energy project. The wind turbine components consisted of three blades, a nacelle, hub, drive trains and four tower sections, along with the associated equipment, all varying in weight and dimensions. ALE used a 90t and a 130t mobile crane for offloading/reloading the components. The components were grouped into different sets: three blades; four towers; a nacelle, hub and drive train. They were transported from the port to the Coega wind energy project site using an 8 axle extendable trailer and a 4 axle triple extendable trailer.

Project Scope »» Port Handling »» Transport

OVERVIEW: ALE has successfully carried out the handling and transportation of the components of 35 wind turbine generators from Port Elizabeth in the Eastern Cape province to Noupoort in the Northern Cape province. SERVICES REQUIRED: The project consisted of 35 wind turbine generators in total, each made up of nine abnormal components, including four tower sections, three blades, one nacelle and one hub. The 140 tower sections were fabricated in Atlantis, Western Cape, and were transported 1,033km to the project site. ALE received the remaining 175 abnormal components for the project direct from the vessel at the Port of Ngqura. Here, they were offloaded and stored at the port. From the temporary storage at port, ALE reloaded the components and transported them 401km to the project site, based in Noupoort.

Together, we are Smarter, Safer, Stronger

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CASE STUDY

CASE STUDY

West Coast 1 project, South Africa

Waainek wind energy project, South Africa

Project Scope

Project Scope

»» Port Handling »» Transport »» Cranes

»» Port Handling »» Transport »» Cranes

OVERVIEW: ALE has transported and pre-populated 47 V90 2MW 80m HH wind turbine generators for installation as part of the West Coast 1 project in the Western Cape region of South Africa. SERVICES REQUIRED: ALE were contracted to provide the port operations and full TCI package preparations of 47 wind turbine generators (Vestas machines) on site for the West Coast 1 wind energy project, located approximately 50km from Saldanha Bay Port. For the port operations, ALE utilised one 250t crawler crane, two 90t mobile cranes, one telehandler and three trailers to look after the vessel discharge. To transport the generators, four axle lines of extendable trailers were used for blade transport and eight axle lines used for the towers and nacelle.

OVERVIEW: ALE has completed the port operations and full TCI package for eight V112 3MW 84HH WTGs for the Waainek wind energy project in the Eastern Cape. SERVICES REQUIRED: For this operation, ALE was responsible for the offloading on site, at the turbine foundations, as well as the handling of components on the various crane pad locations. ALE was also responsible for the dismantling, relocation and erection of the LG 1750 main crane on the Waainek wind energy project. One shipment, comprising of eight WTGs was received at the Couga Port. The components were offloaded and handled using a 250t crawler crane, a 90t mobile crane and a 40t mobile crane. These components were then delivered and offloaded at the Waainek wind energy project site.

The generators were offloaded and ALE prepared and positioned the wind turbine components ready for the main installation using a 130t – 250t mobile crane and telehandler. This included the top and tailing of the bottom tower sections to vertical. ALE completed this scope in approximately four months.

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SECTORS

SERVICES

CIVIL

MINERALS & METALS

NUCLEAR

OFFSHORE

OIL, GAS & PETROCHEMICAL

PORTS

POWER GENERATION

RENEWABLES

SHIPYARDS

BALLASTING

CRANE LIFTING

ENGINEERING

JACKING

LIFTING SYSTEMS

LOAD-IN & LOAD-OUT

LOGISTICS

MARINE ENGINEERING

OFFSHORE INSTALLATION

SKIDDING

TRANSPORTATION

TURNKEY OPERATIONS

WEIGHING

Together, we are Smarter, Safer, Stronger

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EQUIPMENT

INNOVATION SERIES

CRANES

SPECIALIST

CRAWLER

TRANSPORTATION

GIRDER FRAME

SPMT

MODULAR TRAILERS

SPT

SKID SYSTEMS

WEIGHING SYSTEMS

BALLAST SYSTEMS

JACKING SYSTEMS

BARGES

AUXILIARY, ANCILLARY & ACCESS EQUIPMENT

MOBILE

MEGA JACK

AL.SK CRANES

HYDRO DECK

MEGA JACK 800

ALL TERRAIN TRANSPORTERS

LIFTING SYSTEMS

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[email protected] WWW.ALE-HEAVYLIFT.COM

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING