Case Study: Full Dimensional Control Survey Services for the Galloper Wind Farm Project
Client: Heerema Hartlepool
Project Start Date: 04/04/2016
Heerema Fabrication Group (HFG) was awarded a contract by Petrofac to fabricate the substation platform for Galloper Wind Farm Limited (GWFL). The engineering and procurement activities were carried out by Petrofac as part of the GE Petrofac Consortium.
Background:
The Galloper Offshore Wind Farm, located in the outer Thames Estuary, 27 kilometers off the Suffolk coast, is an extension to the Greater Gabbard Wind Farm but is being developed as a separate entity. Heerema Hartlepool fabricated the unmanned offshore substation platform (OSP) which connects turbine generators to a single OSP via subsea array cables. This platform is linked to the onshore transition joint bay near Sizewell through two subsea export cables. In 2008, Heerema Hartlepool completed its first EPC project in the offshore wind energy sector by delivering the topsides transformer platform for the Greater Gabbard Wind Farm. Building on this experience, Heerema Hartlepool embarked on the Galloper substation platform project with a clear vision and robust capabilities.
RSL’s Role in the Project:
To ensure the precision and quality of the fabrication process, Heerema Hartlepool chose RSL to provide comprehensive dimensional control and survey services throughout the project. RSL's involvement was crucial in maintaining the high standards required for such a complex and critical infrastructure project.
Role of RSL:
RSL provided a full range of dimensional control survey services, which included:
Initial Survey and Setup:
• Establishing control networks and baselines to ensure all components were fabricated to precise specifications.
Ongoing Dimensional Control:
• Continuous monitoring and verification of the fabrication process to detect and correct any deviations in real-time.
• Working across all shifts to provide 24/7 dimensional control cover, ensuring seamless support for Heerema’s project and fabrication teams.
Final Verificiation and Validation:
• Conducting final dimensional surveys to verify that all components met the stringent tolerances and specifications before assembly and installation.
Challenges and Solutions:
Coordination Across Multiple Teams:
• Challenge: Coordinating between Heerema's fabrication teams and RSL’s survey teams to maintain uninterrupted workflow.
• Solution: RSL deployed multiple survey teams working in shifts to provide continuous support and immediate response to any issues.
Accuracy in Harsh Offshore Conditions:
• Challenge: Ensuring dimensional accuracy in the challenging offshore environment of the Thames Estuary.
• Solution: Utilizing advanced surveying equipment and techniques tailored for the offshore setting to maintain high precision.
Adherence to Tight Schedules:
• Challenge: Meeting the project timelines without compromising on quality.
• Solution: Implementing a proactive survey approach with regular checks and immediate corrective actions to keep the project on track.
Outcome
The collaboration between Heerema Hartlepool and RSL resulted in the successful fabrication of the Galloper substation platform. RSL's meticulous dimensional control and survey services ensured that the platform was constructed to the highest standards, contributing to the seamless connection of turbine generators to the offshore substation platform.
The Galloper Offshore Wind Farm now stands as a testament to the effective partnership between Heerema Hartlepool and RSL, showcasing the importance of precision and collaboration in large-scale offshore projects.
Conclusion:
RSL’s full dimensional control survey services were instrumental in the successful completion of the Galloper Wind Farm substation platform. This case study highlights the critical role of accurate dimensional control in the fabrication of offshore wind farm infrastructure, demonstrating how strategic partnerships and expert services can lead to outstanding project outcomes.
