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A Brief Introduction
                  to KCI’s Project Support Capabilities
                              Renewables

                                           2013


Westpoint Building 4 | De Brauwweg 24-30 | 3125 AE Schiedam | The Netherlands | www.kci.nl | info@kci.nl
Who we are

•   History
     – Founded in 1987
     – Originally Oil and Gas engineering services
                                                                  UK
     – Renewables engineering services since 2006

•   Ownership                                                             NL   D
     – Family owned untill 2003
     – Part of Wood Group (UK) till 2008
     – Management buy-out as of 2008, privately owned

•   At a glance
                                                          Hydrodynamics
     – Succesfull engineering company (approx. 160 pax)
     – Innovative solution provider
     – Operates as a partner with the client
Our mission


•   Our Vision; In the high demand for offshore
    energy KCI sets the development standard
    with their team of highly qualified
    professionals in the next 5 years

•   Our Mission; Enable technically and
    economically challenging developments
    through innovation!

•   Our strength is early involvement from first
    concept to execution and commissioning for
    all engineering disciplines. Beyond that we
    give full support in small and large
    maintenance or upgrade projects.

•   Our proof of the high standard of work that
    KCI is used to provide is the long term client   ‘’KCI employees are hardcore engineers. They produce thorough
                                                        work and take ownership of our problems. They are a natural
    relations based on repeat business with them.                      extension of our organization’’
                                                               Arie Berkman – Hertel Defense & Offshore
General approach




OWT Foundations   Cable installation   AC Substation   DC Sub station
                  Equipment & Design
Owners Engineering: GlobalTech 1
Scope:

Owner’s Engineering support / interface support
                                                  Other Owners
- Turbine foundation designer & fabricator        Engineering Projects:

- project engineering support offshore            - Thornton Bank (BE)
                                                  - Nord See Ost (GE)
                                                  -Gwynt-y-Mor (UK)
                                                  -Luchterduinen (NL)
Foundation Design: Hochse, He Dreith II, Hohe See
Hochse & He Dreith II                  Hohe See
Scope: Concept Design                  Scope: Feed, Basic & Detailed Design
WTG substructure & foundation design   WTG substructure & foundation design
- 3 and 4 legged jacket                - 3 legged jacket
- Water depth: 22 – 39 m               - Water depth: 39 – 40 m
- weight reduction: 110 mT
Transportation & Installation Engineering: Gwynt-y-Mor
For the logistics KCI have advised the client
based on our in house developed logistics
tool TILT.                                            For the installation KCI developed an innovative
                                                      monopile guiding tool to position and place the
                                                      monopoles.




Other Installation Engineering Projects:
- BARD Ofsshore I – Complete WTG Installation
- Global Tech1 – Foundation Installation & Analysis
Installation Engineering for Van Oord
                – Time-domain Installation Analysis
Scope
• Tender & Project support                                                                          Case_01 Lifting
                                                                                                                            Tp 0 to 1 1 to 2 2 to 3 3 to 4 4 to 5 5 to 6 6 to 7 7 to 8 8 to 99 to 100 to 11 to 12 to 13 to 14 to 15 to 16
                                                                                                                                                                                                   1
                                                                                                                            [s] 0.5 1.5 2.5 3.5 4.5 5.5 6.5 7.5 8.5 9.5 10.5 11.5 12.5 13.5 14.5 15.5
                                                                                                                                                                                                         11    12     13 14      15

                                                                                                          Hm0 [m]



• Design Loads
                                                                                                  5.00-5.25         5.125          0      0   0    0    0         0      0      3      37    122    195    52  1   7         0       0        417
                                                                                                  4.75-5.00         4.875          0      0   0    0    0         0      0      5      84    194    243    40  0   7         0       0        573
                                                                                                  4.50-4.75         4.625          0      0   0    0    0         0      0      15    152    327    237    30  0   8         0       0        769
                                                                                                  4.25-4.50         4.375          0      0   0    0    0         0      0      37    248    401    234    5   0   5         0       0        930
                                                                                                  4.00-4.25         4.125          0      0   0    0    0         0      0      97    384    618    247    8   0   5         0       0       1359
                                                                                                  3.75-4.00         3.875          0      0   0    0    0         0      15    273    737    761    137    1   0   5         0       0       1929
                                                                                                  3.50-3.75         3.625          0      0   0    0    0         0      41    514    1019   787     91    1   0   12        0       0       2465



• Workability Optimization
                                                                                                  3.25-3.50         3.375          0      0   0    0    0         0      96    1009   1271   779     66    1   0   8         0       0       3230
                                                                                                  3.00-3.25         3.125          0      0   0    0    0         5     366    1448   1617   645     49    5   0   4         0       0       4139
                                                                                                  2.75-3.00         2.875          0      0   0    0    0         36    772    2163   1741   526     31    20  0   5         0       0       5294
                                                                                                  2.50-2.75         2.625          0      0   0    0    1        138    1646   2828   1800   368     28    10  3   9         0       0       6831
                                                                                                  2.25-2.50         2.375          0      0   0    0    1        481    2938   3524   1827   301     38    5   12  6         0       0       9133
                                                                                                  2.00-2.25         2.125          0      0   0    0    16       1495   4312   3900   1733   297     80    19  9   1         0       0      11862




• Stabbing Procedure
                                                                                                  1.75-2.00         1.875          0      0   0    0   205       3423   4896   4125   1648   342    130    49  3   0         0       0      14821
                                                                                                  1.50-1.75         1.625          0      0   0    2 1187        5351   5799   4369   1464   413    185    45  14  0         0       0      18829
                                                                                                  1.25-1.50         1.375          0      0   0    35 3887       6175   6322   4665   1915   737    212    41  4   0         0       0      23993
                                                                                                  1.00-1.25         1.125          0      0   0   541 8074       6828   7725   5291   2125   502     62    10  0   0         0       0      31158
                                                                                                  0.75-1.00         0.875          0      0   9 4233 9479        8767   7526   4533   1301   150     19    6   0   0         0       0      36023
                                                                                                  0.50-0.75         0.625          0      0  456 #### 8867       7472   4691   1799   249     25     18    6   1   0         0       0      35774
                                                                                                  0.25-0.50         0.375          0      81 2299 5964 7332      2948   1303   262     51     6      7     4   1   3         2       2      20265




• Smart Rigging design
                                                                                                  0.00-0.25         0.125          3     146 1436 2109 1435      472    127     46     25     29     17    0   0   0         0       0       5845
                                                                                                  Alle                                 3 227 4200 #### ####      ####   ####   ####   ####   8525   2718   693 102 114           2       2 236688
                                                                                                                                                                                             Total Downtime           55342              23.4%
                                                                                                                                                                                             Total Uptime             181346             76.6%




• Range of supporting activities relating to
   operations
• Modeling of jack-up motions, crane
   motions, lifting wires, spreader etc
                                                                                                                            OrcaFlex 9.5d: BASE_02_LowFullClosedHs 2.5T p7.4Wdir30Vw12Vc0.25Seed2.s im (modified 12:50 AM on 5/23/2012 by OrcaFlex 9.5b) (azimuth=270; elevation=0)
                                                                                                                            Replay T ime: 362.00s
                                                                                                                                                                                                                                                    Z
                                                                                                                                                                                                                           9m
                                                       Orc aFlex 9.5b: Hs2T p5 1Wdir60Vw12Vc0 25Seed1.sim (modified 10:36 PM on 5/8/2012 by OrcaFlex 9.5b) (azimuth=312; elevation=35)
                                                       Replay T ime: 18.95s                                                                                                                                                                             X
                                                                                                                                                       Z
                                                                                                                        8m                                     Y
                                                                                                                                                                X
 Lift Height vs Max Crane Wire Tension
 for Hs =2.0 @ 60 deg - All Tp - All seed
      1300                                       Tp 5.1 / Seed 1
      1200
                                                 Tp 6.6 / Seed 1
      1100
                                                 Tp 7.7 / Seed 1
      1000
                                                 Tp 5.1 / Seed 2
       900

       800                                       Tp 6.6 / Seed 2

       700                                       Tp 7.7 / Seed 2
                                                                                                                                                                                                                                                     Sf            Hs   = 1.5 m        Sf              Hs = 2 m        Sf           Hs = 2.5   m
       600
W




                                                 Tp 5.1 / Seed 3
M




                                                                                                                                                                                                                                                     90       1.00      1.04 1.09      90       0.91     1.05 1.05     90       0.89 1.00      1.06
N
o
n
C
e
T
a
k
x
s
r
]
[
i




       500
                                                 Tp 6.6 / Seed 3
                                                                                                                                                                                                                                                     60       0.97      1.06 1.06      60       0.95     1.03 1.11     60       0.92 0.99      1.05
       400                                                                                                                                                                                                                                           30       1.02      1.09 1.04      30       0.93     1.01   1.1    30       1.00 1.02      1.07
                                                 Tp 7.7 / Seed 3                                                                                                                                                                                      0       1.01      1.05 1.10       0       0.96     1.05   1.1     0       0.89 1.03      1.07
       300
                                                                                                                                                                                                                                                    Wdir/Tp    4.4       5.7    6.7   Wdir/Tp    5.1      6.6   7.7   Wdir/Tp    5.7   7.4      8.7
-10          0      10        20       30   40
                 Submerged depth [m]
                                                                                                                                                                                                                                                              Tp1       Tp2     Tp3             Tp1      Tp2    Tp3             Tp1 Tp2         Tp3
Cable Lay Analysis: Northern North See Project


Scope:
•   Deck Lay out Design
•   Cable Lay Analysis - all stages
•   Green water Analysis
•   (patented) Heave Compensated
         Overboarding Chute Design
     – Hydraulic Specs
     – Structural Design
     – Capability Report
     – Workability Optimization
Deck layout Design: Cable One, Gjoa, Brittned...
Subsea Cable Design and Installation



•   Hardware/equipment design
     – Vessel lay-outs & modifications

•   Cables
     – Cable lay analyses
     – Cable lay procedures

•   Installation engineering and management
      – Field engineering / site rep’s

•   Permit support
Offshore Substations: Riffgat & Dan Tysk Projects
Scope:
Concept, Basic & Detailed Design

- Process, Piping, Structural,
  Mechanical
- MV & LV E&I
Metmasts: RWE - Tromp Binnen and Nord See Ost


Scope:
Owner’s Engineering Support:
- Design Review
- Prequalification / Bid Review
- Fabrication
- Installation
- Commissioning
Dan Tysk, Germany


Scope: Concept Design

- WTG substructure & foundation design

- Water depth: 21 – 29 m

- 3.6 / 5 MW turbines
Undisclosed


Scope: Concept Design

- WTG substructure & foundation design

- Water depth: 60 m

- 6 MW turbines
BARD - Wind Farm Rotor Installation Engineering
Scope
• Floating Stability Analysis
• Marine Engineering
• Hydrodynamic Response (RAO)
• Rotor Tip Wave contact Analysis
• Workability Optimization Analysis
• Site Specific Assessments
• Dynamic Lifting Analysis Rotor
• Deck Lay-out and Deck strength
• Operational procedures
• Rotor offloading and deck fixation
Thornton Bank

Scope:

Owner’s Engineering support / interface management

- Certifying Authority (DNV)

- Turbine foundation designer

- Turbine supplier
NordSee Ost

Scope:

Owner’s Engineering support / interface management

- Certifying Authority (GL)

- Turbine foundation designer/fabricator

- Turbine supplier
Project Services


Projects are supported with specialists in:
  – Procurement & expediting
       •   Vendor Document control


  – Project planning

  – Fabricator management & support

  – Installation management & support

  – Permit support

  – Owner’s engineering support
Kci presentation renewables

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Kci presentation renewables

  • 1. A Brief Introduction to KCI’s Project Support Capabilities Renewables 2013 Westpoint Building 4 | De Brauwweg 24-30 | 3125 AE Schiedam | The Netherlands | www.kci.nl | info@kci.nl
  • 2. Who we are • History – Founded in 1987 – Originally Oil and Gas engineering services UK – Renewables engineering services since 2006 • Ownership NL D – Family owned untill 2003 – Part of Wood Group (UK) till 2008 – Management buy-out as of 2008, privately owned • At a glance Hydrodynamics – Succesfull engineering company (approx. 160 pax) – Innovative solution provider – Operates as a partner with the client
  • 3. Our mission • Our Vision; In the high demand for offshore energy KCI sets the development standard with their team of highly qualified professionals in the next 5 years • Our Mission; Enable technically and economically challenging developments through innovation! • Our strength is early involvement from first concept to execution and commissioning for all engineering disciplines. Beyond that we give full support in small and large maintenance or upgrade projects. • Our proof of the high standard of work that KCI is used to provide is the long term client ‘’KCI employees are hardcore engineers. They produce thorough work and take ownership of our problems. They are a natural relations based on repeat business with them. extension of our organization’’ Arie Berkman – Hertel Defense & Offshore
  • 4. General approach OWT Foundations Cable installation AC Substation DC Sub station Equipment & Design
  • 5. Owners Engineering: GlobalTech 1 Scope: Owner’s Engineering support / interface support Other Owners - Turbine foundation designer & fabricator Engineering Projects: - project engineering support offshore - Thornton Bank (BE) - Nord See Ost (GE) -Gwynt-y-Mor (UK) -Luchterduinen (NL)
  • 6. Foundation Design: Hochse, He Dreith II, Hohe See Hochse & He Dreith II Hohe See Scope: Concept Design Scope: Feed, Basic & Detailed Design WTG substructure & foundation design WTG substructure & foundation design - 3 and 4 legged jacket - 3 legged jacket - Water depth: 22 – 39 m - Water depth: 39 – 40 m - weight reduction: 110 mT
  • 7. Transportation & Installation Engineering: Gwynt-y-Mor For the logistics KCI have advised the client based on our in house developed logistics tool TILT. For the installation KCI developed an innovative monopile guiding tool to position and place the monopoles. Other Installation Engineering Projects: - BARD Ofsshore I – Complete WTG Installation - Global Tech1 – Foundation Installation & Analysis
  • 8. Installation Engineering for Van Oord – Time-domain Installation Analysis Scope • Tender & Project support Case_01 Lifting Tp 0 to 1 1 to 2 2 to 3 3 to 4 4 to 5 5 to 6 6 to 7 7 to 8 8 to 99 to 100 to 11 to 12 to 13 to 14 to 15 to 16 1 [s] 0.5 1.5 2.5 3.5 4.5 5.5 6.5 7.5 8.5 9.5 10.5 11.5 12.5 13.5 14.5 15.5 11 12 13 14 15 Hm0 [m] • Design Loads 5.00-5.25 5.125 0 0 0 0 0 0 0 3 37 122 195 52 1 7 0 0 417 4.75-5.00 4.875 0 0 0 0 0 0 0 5 84 194 243 40 0 7 0 0 573 4.50-4.75 4.625 0 0 0 0 0 0 0 15 152 327 237 30 0 8 0 0 769 4.25-4.50 4.375 0 0 0 0 0 0 0 37 248 401 234 5 0 5 0 0 930 4.00-4.25 4.125 0 0 0 0 0 0 0 97 384 618 247 8 0 5 0 0 1359 3.75-4.00 3.875 0 0 0 0 0 0 15 273 737 761 137 1 0 5 0 0 1929 3.50-3.75 3.625 0 0 0 0 0 0 41 514 1019 787 91 1 0 12 0 0 2465 • Workability Optimization 3.25-3.50 3.375 0 0 0 0 0 0 96 1009 1271 779 66 1 0 8 0 0 3230 3.00-3.25 3.125 0 0 0 0 0 5 366 1448 1617 645 49 5 0 4 0 0 4139 2.75-3.00 2.875 0 0 0 0 0 36 772 2163 1741 526 31 20 0 5 0 0 5294 2.50-2.75 2.625 0 0 0 0 1 138 1646 2828 1800 368 28 10 3 9 0 0 6831 2.25-2.50 2.375 0 0 0 0 1 481 2938 3524 1827 301 38 5 12 6 0 0 9133 2.00-2.25 2.125 0 0 0 0 16 1495 4312 3900 1733 297 80 19 9 1 0 0 11862 • Stabbing Procedure 1.75-2.00 1.875 0 0 0 0 205 3423 4896 4125 1648 342 130 49 3 0 0 0 14821 1.50-1.75 1.625 0 0 0 2 1187 5351 5799 4369 1464 413 185 45 14 0 0 0 18829 1.25-1.50 1.375 0 0 0 35 3887 6175 6322 4665 1915 737 212 41 4 0 0 0 23993 1.00-1.25 1.125 0 0 0 541 8074 6828 7725 5291 2125 502 62 10 0 0 0 0 31158 0.75-1.00 0.875 0 0 9 4233 9479 8767 7526 4533 1301 150 19 6 0 0 0 0 36023 0.50-0.75 0.625 0 0 456 #### 8867 7472 4691 1799 249 25 18 6 1 0 0 0 35774 0.25-0.50 0.375 0 81 2299 5964 7332 2948 1303 262 51 6 7 4 1 3 2 2 20265 • Smart Rigging design 0.00-0.25 0.125 3 146 1436 2109 1435 472 127 46 25 29 17 0 0 0 0 0 5845 Alle 3 227 4200 #### #### #### #### #### #### 8525 2718 693 102 114 2 2 236688 Total Downtime 55342 23.4% Total Uptime 181346 76.6% • Range of supporting activities relating to operations • Modeling of jack-up motions, crane motions, lifting wires, spreader etc OrcaFlex 9.5d: BASE_02_LowFullClosedHs 2.5T p7.4Wdir30Vw12Vc0.25Seed2.s im (modified 12:50 AM on 5/23/2012 by OrcaFlex 9.5b) (azimuth=270; elevation=0) Replay T ime: 362.00s Z 9m Orc aFlex 9.5b: Hs2T p5 1Wdir60Vw12Vc0 25Seed1.sim (modified 10:36 PM on 5/8/2012 by OrcaFlex 9.5b) (azimuth=312; elevation=35) Replay T ime: 18.95s X Z 8m Y X Lift Height vs Max Crane Wire Tension for Hs =2.0 @ 60 deg - All Tp - All seed 1300 Tp 5.1 / Seed 1 1200 Tp 6.6 / Seed 1 1100 Tp 7.7 / Seed 1 1000 Tp 5.1 / Seed 2 900 800 Tp 6.6 / Seed 2 700 Tp 7.7 / Seed 2 Sf Hs = 1.5 m Sf Hs = 2 m Sf Hs = 2.5 m 600 W Tp 5.1 / Seed 3 M 90 1.00 1.04 1.09 90 0.91 1.05 1.05 90 0.89 1.00 1.06 N o n C e T a k x s r ] [ i 500 Tp 6.6 / Seed 3 60 0.97 1.06 1.06 60 0.95 1.03 1.11 60 0.92 0.99 1.05 400 30 1.02 1.09 1.04 30 0.93 1.01 1.1 30 1.00 1.02 1.07 Tp 7.7 / Seed 3 0 1.01 1.05 1.10 0 0.96 1.05 1.1 0 0.89 1.03 1.07 300 Wdir/Tp 4.4 5.7 6.7 Wdir/Tp 5.1 6.6 7.7 Wdir/Tp 5.7 7.4 8.7 -10 0 10 20 30 40 Submerged depth [m] Tp1 Tp2 Tp3 Tp1 Tp2 Tp3 Tp1 Tp2 Tp3
  • 9. Cable Lay Analysis: Northern North See Project Scope: • Deck Lay out Design • Cable Lay Analysis - all stages • Green water Analysis • (patented) Heave Compensated Overboarding Chute Design – Hydraulic Specs – Structural Design – Capability Report – Workability Optimization
  • 10. Deck layout Design: Cable One, Gjoa, Brittned...
  • 11. Subsea Cable Design and Installation • Hardware/equipment design – Vessel lay-outs & modifications • Cables – Cable lay analyses – Cable lay procedures • Installation engineering and management – Field engineering / site rep’s • Permit support
  • 12. Offshore Substations: Riffgat & Dan Tysk Projects Scope: Concept, Basic & Detailed Design - Process, Piping, Structural, Mechanical - MV & LV E&I
  • 13. Metmasts: RWE - Tromp Binnen and Nord See Ost Scope: Owner’s Engineering Support: - Design Review - Prequalification / Bid Review - Fabrication - Installation - Commissioning
  • 14. Dan Tysk, Germany Scope: Concept Design - WTG substructure & foundation design - Water depth: 21 – 29 m - 3.6 / 5 MW turbines
  • 15. Undisclosed Scope: Concept Design - WTG substructure & foundation design - Water depth: 60 m - 6 MW turbines
  • 16. BARD - Wind Farm Rotor Installation Engineering Scope • Floating Stability Analysis • Marine Engineering • Hydrodynamic Response (RAO) • Rotor Tip Wave contact Analysis • Workability Optimization Analysis • Site Specific Assessments • Dynamic Lifting Analysis Rotor • Deck Lay-out and Deck strength • Operational procedures • Rotor offloading and deck fixation
  • 17. Thornton Bank Scope: Owner’s Engineering support / interface management - Certifying Authority (DNV) - Turbine foundation designer - Turbine supplier
  • 18. NordSee Ost Scope: Owner’s Engineering support / interface management - Certifying Authority (GL) - Turbine foundation designer/fabricator - Turbine supplier
  • 19. Project Services Projects are supported with specialists in: – Procurement & expediting • Vendor Document control – Project planning – Fabricator management & support – Installation management & support – Permit support – Owner’s engineering support