Precision Measurement during fabrication stages of the Moray West Offshore Transformer Modules

Project Overview:

The Moray West offshore wind farm, located in the outer Moray Firth, is a significant renewable energy project designed to harness offshore wind power. The project features two offshore substation platforms utilizing Siemens Energy’s proven Offshore Transformer Module (OTM®) technology. Siemens Energy, in consortium with Lemants, a subsidiary of Smulders, was tasked with the supply and implementation of these substations. Smulders Projects UK, based in Wallsend, Newcastle, was awarded the fabrication and fit-out contract for the OTMs.

Scope of Work:

Smulders Projects UK selected RSL to provide comprehensive dimensional control survey services throughout the entire project lifecycle. The objective was to ensure precise dimensional accuracy and alignment during the fabrication and installation of the OTMs. The services provided by RSL included:

Pre-weld and post-weld surveys
Setting out for various stages of construction
Determination of lay down positions
Full as-built surveys of final fabricated items and components

Execution:

RSL deployed specialized dimensional control survey teams to work closely with Smulders' fabrication team. The collaboration ensured that every stage of the OTM fabrication was meticulously monitored and controlled for dimensional accuracy. This approach guaranteed that the project maintained 100%-dimensional control coverage, crucial for the high-precision requirements of offshore transformer modules.

Key Activities:

Pre-weld Surveys: RSL conducted initial measurements and assessments to establish baselines before welding operations. This step was critical to anticipate any potential distortions or misalignments that welding could cause.
Post-weld Surveys: Following welding activities, RSL teams performed detailed surveys to verify that the welded structures met the required specifications and tolerances. Any deviations were promptly addressed to ensure structural integrity and accuracy.
Setting Out: Throughout the fabrication process, RSL provided precise setting out services, ensuring that all components were positioned accurately according to the design plans. This service included marking out the locations for equipment, structural elements, and other critical features.
Lay Down Positions: RSL determined optimal lay down positions for various components during different stages of construction. This planning helped streamline the fabrication process and facilitated efficient workflow management.
As-Built Surveys: Upon completion of fabrication, RSL conducted comprehensive as-built surveys to document the final dimensions and configurations of the OTMs. These surveys provided a precise record of the fabricated structures, ensuring they matched the design specifications and were ready for installation.

Outcome:

The Moray West project, with an installed capacity of 860MW, relies on inter-array cables to transfer power from wind turbines to the OTMs. From there, export cables, operating at 220kV, connect each OTM to an onshore substation. The onshore substation, also provided by Siemens Energy, steps up the voltage to 400kV for integration into the National Grid.
The precision and reliability of RSL's dimensional control survey services were instrumental in the successful fabrication and fit-out of the OTMs. By ensuring exact dimensional accuracy at every stage, RSL contributed to the overall efficiency and quality of the Moray West offshore wind farm project, helping to meet stringent industry standards and project timelines.

Conclusion:

RSL's expertise in dimensional control surveying played a crucial role in the Moray West offshore wind farm project. The collaboration with Smulders Projects UK exemplified the importance of precise dimensional control in the fabrication of offshore transformer modules. This case study highlights RSL's commitment to delivering high-quality, reliable survey services that support the successful execution of complex engineering projects.