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HYDRO DECK
CONTENTS
OVERVIEW 3
DESIGN 4
OVERVIEW OF KEY FEATURES 6
DESIGN BENEFITS 8
Versatile 8
High capacity ballast system 9
High deck strength and space 10
Integrated mooring system 11
Adaptable 12
OPERATIONAL BENEFITS 14
Ability to work in adverse conditions 14
Improved logistics 14
Level playing field 15
Extended reach and self-reliant 16
SAFETY BENEFITS 18
Tide-independence 18
Rapid ballasting 19
Integrated hydraulic Ro-Ro ramps 20
Safety features, the future and engineering 22
ENGINEERING AND FEED SUPPORT 23
SCOPE VERSATILITY 24
CASE STUDY 26
Load-out of 149 modules using the Hydro Deck, Australia 26
ALE has always been distinguished by its engineering capabilities. We are recognised as a world leader in equipment and solution development, and since the establishment of our Research and Development (R&D) department, our innovative product design has dominated industry news and redefined the boundaries of heavylifting capability in a global market.
Our world-beating R&D department works with teams around the world to find a solution for existing challenges and future issues before it is needed. ALE’s innovation series is designed with state-of-the-art technologies using input from industry experts and includes the Hydro Deck, a one-of-its-kind mobile port solution with unrivalled capabilities.
OVERVIEW
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DESIGN
AG&P and ALE identified the need for a multi-purpose loading-in vessel with a range of capabilities most required by clients, such as high deck strength, a rapid and integrated ballast system, flexible mooring arrangements, and a hull rated for beaching. The vessel had to be adaptable and robust.
ALE, together with AG&P, designed and constructed the Hydro Deck in 2014 to serve as a versatile transition pontoon from vessel to quayside for port or load-in locations subject to extreme tidal variations. The Hydro Deck is also suitable for global projects faced with limited or no port facilities or where rapid ballasting and large displacement, such as required for offshore floatovers, are key considerations.
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• Measures 140m x 40m x 12m; 1.7m minimum draft
• Unique buoyancy control system, using water and air ballasting
• 100% system redundancy
• 24,000m3/hr capacity water ballast system
• 12,000m3/hr capacity air ballast system
• Extreme tidal variation handling up to 10m
• 20t/m2 uniform deck load, with heavy bulkheads and strongpoints
• 5,600m2 deck space
• 20,000t combined cargo capacity
• Designed for maximum self-propelled modular trailer (SPMT) loads and skidding in excess of 10,000t
• Integrated mooring and hydraulic roll-on/roll-off (Ro-Ro) ramp system
• On-board crew day facilities, power generation, hydraulics and fire safety systems
• Self-sufficient operations in remote areas
• Beaching capability (under load)
• Adaptable – optional moonpool, x-point mooring, spud pile mooring and mobile dynamic positioning (DP2)
OVERVIEW OF KEY FEATURES
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VERSATILEThe current design allows for flexible deployment on either a temporary or long-term basis, inshore and offshore, and with any type of mooring. It is fully self-sufficient in terms of power and water supply, sanitary systems and day facilities.
The Hydro Deck can be used for:
• Ro-Ro operations in extreme tidal waters where standard heavylift ships cannot compensate for tidal changes fast enough to remain level with the quay
• Load-out operations by SPMTs
• Skidding operations for loads in excess of 10,000t
• Floatover and reversed floatover operations for topside integration or separation, using its high capacity ballast system and mooring winches
• Offshore construction and subsea installation support
• Lift-on / Lift-off (Lo-Lo) operations using a deck-mounted (crawler) crane
• Shallow water work platform (beaching capability, optional spud pile mooring)
• Towed transport operations for oversized and heavy cargo
• Transition pontoon operations (vessel-to-quayside)
• Near-shore transshipment base / operations (vessel-to-vessel)
• Drop-in-place temporary port and quayside solution
HIGH CAPACITY BALLAST SYSTEM
The Hydro Deck uses innovative and fully redundant water ballast and air tank systems to provide buoyancy control during operations (load-in, load-out, floatover, transshipment and beaching). It can handle rapid draft level changes, for example, due to tidal variations or during floatovers. This allows loads to be transported safely across the deck. Buoyancy can be controlled using specific areas of the pontoon, water can be transferred internally and air tank ballasting can be used on a supplementary basis.
DESIGN BENEFITS
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HIGH DECK STRENGTH AND SPACEThe 5,600m2 of deck space and 20t/m2 uniform deck load-rating provides plenty of working area and significantly reduces the need for load spreading and sea fastening measures, whilst also facilitating maximum SPMT loads and skidding operations in excess of 10,000t.
INTEGRATED MOORING SYSTEM
The Hydro Deck is equipped with a range of mooring equipment to enable flexible and reliable mooring of the barge at quaysides or in jacket approaches, as well as when attending vessels during critical operations. Mooring winches, mooring cylinders, bollards, smit brackets, fairleads and panama chocks are integrated in the deck. The system can be extended or upgraded when needed using ALE’s in-house, modular mooring systems or spud pile mooring.
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ADAPTABLEThe Hydro Deck has the ability to work alongside existing operations or can be placed as a ‘turnkey platform’ for a variety of offshore and subsea construction applications. Its unique design features allow for modifications to fit any scope of work, whether it be a moonpool, a deck-mounted (crawler) crane, modular DP2 system, anchor or spud pile mooring, integrated lifting systems, or a combination of these. The Hydro Deck can be adapted to meet a wide range of project needs.
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ABILITY TO WORK IN ADVERSE CONDITIONSThe Hydro Deck excels when operating in harsh, remote and adverse conditions. Whether it is utilised for transport and offloading fabricated modules, for ‘drop-in-place’ mobile port operations or for topside transport and offshore floatover operations, it has the ability to operate in a range of conditions and environments. The temperature-regulated control room and daytime crew facilities also ensure comfortable working conditions on board.
IMPROVED LOGISTICS Most Heavy Lift Vessels (HLVs) are tide dependent, limiting unloading to 5-6 hours per day and sometimes only on certain days of the month. The Hydro Deck has the ability to operate 24 hours per day, 7 days per week, drastically improving overall project schedule. As a result, the Hydro Deck eliminates the risk of costly demurrage costs whilst ALE takes care of staging and offloading of cargo to the project site.
LEVEL PLAYING FIELD
Acting as the critical link between ship to shore activities with superior handling capabilities, the Hydro Deck makes any HLV suitable for the job. No matter the vessel dimensions, mooring provisions or ballast capability, the HLV can dock comfortably on one side of the Hydro Deck. Using the Hydro Deck’s mooring, hydraulic ramps and ballast system, the cargo can be safely transferred. In addition, few HLVs are capable of compensating for extreme tides and their cost to the project, without the Hydro Deck, will be at premium rates.
OPERATIONAL BENEFITS
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EXTENDED REACH AND SELF-RELIANTThe Hydro Deck has been designed to facilitate cargo handling or any other operation from the deck at any location. The on-board power, potable water and crew day facilities allow for self-reliant operations. ALE can also provide a full package for these locations, including design, engineering and supply of temporary structures such as modular bridges, mooring, and heavy transport and lifting solutions. Projects can be executed on an ad hoc, long-term or turnkey basis, making use of ALE’s global network and local support.
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TIDE-INDEPENDENCE The Hydro Deck provides a tide-independent unloading solution. In the event there are delays to the Ro-Ro operations and the SPMTs are partly on the ship or quay, the Hydro Deck can pump through the tide cycle, creating the window during which all operational issues can safely be resolved.
RAPID BALLASTING
The internal ballast system has been designed with 100% redundancy to assure the Hydro Deck’s critical role in the supply chain. The deck of the Hydro Deck is clear of pumps, hoses and piping for flexible SPMT configurations and support stool locations. The integrated ballast system is highly reliable, whilst protected from the elements. Our experienced crew can closely monitor the Hydro Deck’s performance during critical operations and take care of day to day maintenance.
SAFETY BENEFITS
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INTEGRATED HYDRAULIC RO-RO RAMPSThe ramp system has been designed for maximum axle loads of the strongest SPMTs on the market. The hydraulic capability of the Hydro Deck’s ramps eliminates third party crane and forklift work, and creates a safer workplace during installation and removal of the link between the barge and quayside. The ramps can be operated as a whole or in separate sections, and can be removed when needed.
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SAFETY FEATURES, THE FUTURE AND ENGINEERING
SAFETY FEATURESThe Hydro Deck has been designed and constructed under Lloyd’s Register Class certification to the highest safety and quality standards. To gain third party approvals, every stage was checked, witnessed and approved by globally recognised independent surveyors. Using these strict criteria ensures the very highest standards of design. The on-board equipment has been designed with safety in mind. This includes fire detection, a fire hydrant system, a C02 fire extinguishing system, quick-closing valves, ventilation dampers and emergency stops.
BACKUP OPERATING SYSTEMSALE engineers have equipped the Hydro Deck with primary, secondary and emergency backup systems in critical areas.
THE FUTUREALE’s R&D facility continues to focus on improving current equipment and creating new solutions for the industry. Having a dedicated development facility gives our highly skilled engineers a platform from which to push the boundaries of design. With this expertise and a close working relationship with our clients, we have gained a comprehensive understanding of the market to develop equipment to meet both current and future demand. ALE is committed to proactively meeting the needs of our clients. Our foundations are not built as an equipment rental company; rather, we actively develop solutions to challenges faced by clients and solve them through innovation.
ENGINEERING AND FEED SUPPORTOur experience and pedigree in innovative engineering means we are well equipped to support project development in early engineering and FEED stages. ALE has contributed to many high profile projects at the forefront of technological innovation. In the long-term we will continue to meet the industry’s ever-changing demands and naturally exacting expectations as to safety standards. In the short-term we are able to adapt as the scope of each project becomes more defined. We work closely with our clients from the very earliest stages, providing engineering advice to establish exactly what is required.
We believe that working through complex technical and logistical issues at the outset helps to eliminate expensive changes later.
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Due to its unique features, the Hydro Deck is capable of supporting multiple operations and has the potential for a range of nearshore and offshore applications in various industry sectors.
SCOPE VERSATILITY
SHALLOW WATER OPS MARINE TRANSPORTCABLE LAYSUBSEA INSTALLATION
TRANSSHIPMENTLOAD-OUT BY SKIDDING
CONSTRUCTION SUPPORT
TEMPORARY QUAYSIDELOAD-OUT BY SPMT
FLOATOVER
BRIDGING PLATFORMRO-RO EXTREME TIDE
LO-LO
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The AG&P ALE Ventures Pty Ltd joint venture was contracted by JKC Australia LNG Pty Ltd to load-out 149 pre-fabricated modules from a range of heavy lift vessels. This charter scope was part of the Ichthys Onshore LNG Facilities Complex Project in Darwin, Australia, and was the Hydro Deck’s inaugural project.
The modules were loaded-out by the Hydro Deck’s Operations team on a 24 x 7 basis with 100% availability and 100% safety for the duration of the Hydro Deck’s charter to the project.
The modules varied in weight and size. The heaviest cargo the project team transferred was 3,788t, for which 150 axle lines of SPMT in a 10 file 30 configuration were involved. For the longest module, measuring 73m, 92 axle lines of SPMT in a 4 file 46 configuration were used. The combined total weight of the transferred modules was 41,612t.
With a daily 8.3 metre tidal range in Darwin Harbour, the Hydro Deck dramatically widened the otherwise tide-constrained module delivery windows for the project and provided cost-effective and timely module delivery throughout its charter.
The AG&P ALE Ventures Operations Team of Superintendents, Ballast Engineers, Ballast Operators, Engineers, Mechanical and Electrical Technicians, and other team members worked seamlessly to deliver professional, timely and safe operations without any Lost Time Accidents.
In its inaugural charter, the Hydro Deck was instrumental in delivering the modules safely and in a time-effective way that no other piece of equipment could have achieved.
AG&P ALE Ventures (as the subcontractor), as well as a number of individual Hydro Deck team members, received recognition awards from JKC Australia LNG Pty Ltd for Incident and Injury-Free (IIF) operations and safety. Individual Hydro Deck team members also received ALE’s Smarter, Stronger, Safer award for promoting a safe work culture.
Load-out of 149 modules using the Hydro Deck, Australia
CASE STUDY
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