Most of the electricity we use is produced using fossil fuels. Several countries are investing in renewable energy to work towards a cleaner and greener future. Japan is one of the countries taking steps to achieve a goal of zero greenhouse gas emissions by 2050. Offshore wind power is aimed to be one of the core sources to cover Japan’s future energy demand. MV Lone of SAL Heavy Lift has taken part in kicking off this transition by delivering the first batch of monopiles for the Akita and Noshiro Port Offshore Wind Farm project.

Photo Credit: SAL

Full speed ahead for offshore wind energy in Japan: Japan aims to be world’s third-largest offshore wind power producer in 2040 as part of efforts to achieve net zero carbon dioxide emissions by 2050. Japan has kicked off its offshore wind growth with the arrival of the first nine monopiles for the Akita Noshiro Offshore Wind Farm from Rotterdam, the Netherlands.

The Akita and Noshiro project will install bottom-fixed offshore wind turbines along with an onshore substation and transmission lines – using a total of 33 monopiles and 33 units of steel transition pieces.

Photo Credit: SAL

“SAL had the honourable task of transporting the first nine monopiles from Rotterdam, the Netherlands to Akita Port, Japan. These monopiles included the heaviest units for the project with weights up to 881 metric tons, and dimensions of up to 78.7 by six-by-six metres, in just one shipment – a perfect task for our Type 183 vessel MV Lone,” said Mischa Tchang, Managing Director at SAL Heavy Lift Japan.

The full project scope not only included the transport of nine monopiles, but also the cradle design and supervision of cradle fabrication, fatigue analysis of the monopiles as well as structural integrity calculations for monopiles. The latter three were carried out by SAL’s sister company, SAL Engineering.

“It took us seven days to load all nine monopiles. In various past projects, we were able to gather extensive experience in handling offshore wind equipment such as monopiles and transition pieces,” explained Thomas Schulz, Project Engineer at SAL Engineering. He continued: “Special plug-and-play tween-deck spacers were necessary to increase the clearance below nearly all tween deck covers, so that the covers could rest on a slightly higher level. We also came up with DNVGL-certified sea fastening hooks which were attached to the bottom and top of the monopiles to ensure safe lashing.”

Photo Credit: SAL

A third-party contractor installed motion-monitoring sensors on top. Two monopiles were successfully loaded (and later also discharged) as single-lift, while the remaining ones were all handled as dual-lifts. “In monopile shipments, it is quite typical to optimise the position and number of cradles between the ship’s structure and the load distribution of the monopile. Improving the load situation for the ship’s structure by moving the cradles might lead to higher loads at the monopile and vice versa. Eventually, the cradle arrangement needs to be transferred on board, making the accurate measuring of cradle positions and positioning of monopiles in the cradles essential for a successful shipment,” explained Thomas Schulz. “To keep a bit of planning flexibility, we installed the cradles ‘on-the-fly’ while loading the cargo. In this way, we were also able to match the tight schedule and to keep preparation and mobilisation times to an absolute minimum,” he added.

Eyehooks and fibre slings, much lighter than steel wire, ensured safe and fast loading and discharging operations. This allowed for an easier and faster connection of the rigging.

After safely arriving in Japan, it took another six days to discharge all nine monopiles. At Akita Port, MV Lone needed to discharge the monopiles at a distance of 20 metres from the edge of the quay to meet local restrictions, which was no problem for MV Lone due to her two 1,000 Mton capacity cranes.

“We are very proud to take part in this milestone project and look forward to supporting the offshore wind industry in Japan in the years to come,” concluded Mischa Tchang.

In total, MV Lone transported about 5,848 tons and 20,245.7 cubic metres in this shipment. The foundation installation is scheduled to commence in the first half of 2021 and the turbines are expected to be installed in 2022.

“Despite harsh winter conditions with snow and ice, the discharging operations and cargo handling operations at Akita Port were carried out in a smooth and safe manner. SAL’s crew and all other involved parties worked hard to meet our schedule and to discharge all monopiles on time. We are very pleased with the good cooperation and SAL’s efforts. We are looking forward to welcoming MV Lone and her excellent crew in Japan on many more visits.” - Shigeru Goto, Kamigumi Co., Ltd. SAL Heavy Lift is Project Logistics Alliance’s exclusive project and heavy lift cargo carrier.

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