Enabling Array Cable Cost Reduction All Energy 2015 Glasgow 6 th May 2015 Jeremy Featherstone Product Development Director JDR Cable Systems Ltd 1
Topics Background Aluminium vs. copper conductors Reducing Rating Conservatism 33 kv to 66 kv Rethinking Lifecycle support 2
JDR Cable Systems Ltd Subsea Power Cables including Offshore Renewable Energy Cables Subsea Production Umbilicals Intervention Workover Control Systems (IWOCS) 3
Umbilicals & Power Cables
JDR Hartlepool Vertical Lay-up Machine
JDR Hartlepool Factory Equipment
JDR Hartlepool 2 x 4000t load out carousels 7
JDR EXPERIENCE IN RENEWABLE ENERGY London Array On construction largest ever offshore wind farm Over 200km 33kV inter-array cables Greater Gabbard UK s first offshore wind farm outside territorial waters Over 200km 33kV inter-array cables Meerwind Sud Ost Germany s first privately-financed offshore wind farm Over 110km inter-array cables & terminations Wavehub World s largest wave energy test centre Located offshore South-West UK 25km 33kV 6 core export cable Zero cable failure rate in service 8
Cost Reduction and Aluminium Conductors The biggest cost reduction opportunity available comes from using Aluminium Conductors rather than Copper Aluminium raw material is approx third the cost by weight, and a third the density of copper, so significant cost saving Aluminium raw material price also less volatile than copper Aluminium has 60% the conductivity of copper, so larger conductors required to carry same current, so slightly more material for insulation and larger overall cable Field experience has shown that Aluminium cables can be too light to successfully jet bury may require additional ballast, e.g,. Use of heavier armour wires 9
Cost Reduction and Ratings Historically Offshore Wind has used steady state continuous ratings IEC60287 is considered to overstate armour wire losses and needs revision Dynamic rating take advantage of cyclic loading and environmental conditions, to reduce the required conductor size of a cable Meanwhile, there is a huge data gathering exercise with Distributed Temperature Sensing (DTS) Fibre optic Systems especially for export cables This can feed back into optimising cable design This is now starting to happen (e.g. a real life example is enabling potential use of 500mm2 rather than 630mm2 132kV wind farm export cable) 10
Cost Reduction and 66kV Array Cables Currently almost all array cables are standardised at 33kV the top end voltage for Medium Voltage standards As turbines and wind farm fields get larger, 66kV inter array cables can become viable 66kV cables, accessories and switchgear are more expensive than 33kV, but more power carrying capacity per of investment Ring rather tha radial layout become more viable, and critical cost saving is in reducing the numbers of offshore substations Wet design 66kV array cables now under development at JDR 11
Rethinking lifecycle support to reduce overall cost Current working practice typically sees cable provider hand off at dockside A better connection between interarray cable manufacture and subsequent offshore cable handling, termination and commissioning will: Better support operators through most vulnerable stage of cable lifecycle Utilise design and manufacturing knowledge to optimise service & support programme Contribute to industry cost reduction targets Offshore wind can benefit from specialist field service support 12
JDR Global Services A natural progression for JDR - leveraging 20+ years commissioning of subsea power cables and umbilicals in the offshore O&G sector Pre-installation analysis, planning and testing Offshore installation support and hook-up on vessel (cable end preparation, pull-ins), on WTGs/Substation pull-in, cable stripping, routeing and termination Pre- and Post- Installation testing Service now offered both for JDR and other cable suppliers products 13
Summary Aluminium vs. copper conductors Reducing Rating Conservatism 33 kv to 66 kv Rethinking Lifecycle support 14
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