OFFSHORE GRID NL

Document Title:
Standard Offshore Substation
Cable Pulling Methodology

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04 30-03-2017 Issued for OWF MRU MRU MRU

03 01-02-2016 Issued for OWF TenneT TenneT TenneT

02 15-01-2016 Issued for ITT MTNP/FESA STJA MVJ

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Project no.: 1100015665

Site code: Page: 1 of 29

TenneT Document No.:

ONL-TTB-00188
Intended for
TenneT

Document type
Report

Date
February 2016

Ramboll ref.
1100015665/ROGE-Z-RA-000420, Rev. 1

OFFSHORE GRID NL

STANDARD 700 MW AC OFFSHORE SUBSTATION

CABLE PULLING METHODOLOGY

STANDARD OFFSHORE SUBSTATION

Revision Date Made by Checked by Approved by Description

A 18-12-2015 MTNP/FESA - - Issued for comments

0 15-01-2016 MTNP/FESA STJA MVJ Issued for ITT
1 01-02-2016 TenneT TenneT TenneT Issued for OWF

Ramboll
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Standard offshore substation
Cable Pulling Plan

CONTENTS

1. Introduction 1
1.1 Final deck configuration 1
2. Regulations, Codes and Standards 2
3. Basis of Design 2
4. Cable Pulling methods 3
4.1 General 3
4.1.1 Cable pulling layout 3
4.1.2 The cable ‘sledge’ method 3
4.1.3 The Samson post method 4
4.1.4 The cable pulling frame 5
4.2 Cable pulling winch 5
4.3 Sequence of cable pulling 5
4.4 Rigging equipment 6
4.5 Escape routes 6
4.6 Jacket structure 6
4.7 Screenshots from the 3D model 7
5. Field layouts 9
Standard offshore substation 1 of 9
Cable Pulling Plan

1. INTRODUCTION
This document outlines the general methodology regarding the pulling of HV sea cables on the
standard 700MW AC offshore substation. It’s main purpose is to prove the feasibility of the HV
sea cable pull-in.

This methodology will be the basis for the detailed cable pulling methods which will be
established by the various cable contractors in close cooperation with the platform contractor
during the detailed design phase of the project.

This document does not outline the scope demarcation between TenneT and the Offshore Wind
Farm (OWF).

The scope demarcation is described in:

• ONL-TTB-03024-MA--T13 Installation Interface Management PP v2

Both documents are the result of the consultation process between TenneT and Offshore Wind
farm developers. The consultation process and the documents could be found at:

http://www.tennet.eu/nl/grid-projects/projects-in-the-netherlands/grid-at-sea/consultation-process.html

1.1 Final deck configuration

The basic design of the standard 700MW AC offshore substation is shown in
• ONL-TTB-00206-MA-EN_01--Plotplans
• ONL-TTB-00216-MA-EN_00--Plotplan, Layout WPO Control Room
• ONL-TTB-00109-MA-EN_03--Jacket Structure - Primary Steel Drawings

The basic design of the standard 700MW AC offshore substation is based on the following deck
designations and elevations:

Cable deck EL. +20.000 T.O.S

Main deck EL. +26.500 T.O.S
Utility deck EL. +34.000 T.O.S
Control deck EL. +38.000 T.O.S
Roof deck EL. +42.000 / 44.000 Top of steel

Figure 1-1: Basic design deck configuration

However, the effective cable deck height to be considered during detail design follows from the
preliminary drawings, which shows the current foreseen height of the cable deck so far:
• ONL-TTB-03556_01-MA--Cable Deck 66kV Infield Cable Routing

During detailed design, construction and installation, the following deck designations and
elevations shall be used as basis:

Cable deck EL. +20.000 T.O.S

Main deck EL. +27.500 T.O.S
Utility deck 1 EL. +35.000 T.O.S
Utility deck 2 EL. +39.000 T.O.S
Roof deck EL. +43.000 / 45.000 Top of steel

Figure 1-2: Final deck configuration

Standard offshore substation 2 of 9
Cable Pulling Plan

During detail design the Offshore Wind Farm(s), the export cable contractor and the platform
contractor shall optimize the cable deck height. The following requirements shall be taken into
account when detailing the cable routing:
• Bending radius for all cables during pulling and permanent installation
• It shall be possible to pull sea cables both before and after placement of the topside on
the jacket.
• Crossing of cables
• Sufficient space for repair of cables
• Storage of cables on the cable deck before the installation of the topside

2. REGULATIONS, CODES AND STANDARDS

The governing codes and standards applicable to the cable pulling methodology are:
• DNV-OS-J201
• DNVGL-OS-D201
• GL Noble Denton 0027/ND

Offshore Wind Farms shall follow these codes when establishing their detailed cable pulling
method.

3. BASIS OF DESIGN
This chapter states the relevant parameters used and the number of cables to be pulled:
• No. 2 off 220kV export cables
• No. 18 off 66kV array cables

The following cable specifications have been used for the basic cable pulling methodology and
determination of the deck height and cable routes:

220kV sea cable (hang-off – 220kV GIS):

- Minimum bending radius (3 core cable) = 4200 mm
- Diameter of 3 core cable = 300 mm
- Minimum bending radius (1 core cable) = 2000 mm
- Diameter of (1 core cable) = 120 mm

66kV sea cable (hang off – 66kV GIS):

- Minimum bending radius (3 core cable) = 3000 mm
- Diameter of 3 core cable = 175 mm
- Minimum bending radius (1 core cable) = 1500 mm
- Diameter of (1 core cable) = 65 mm

For the detailed design, Offshore Wind Farms shall use the specifications of their intended cable
supplier, which shall be above (bending radius) or below (diameter) the specifications given
above.
Standard offshore substation 3 of 9
Cable Pulling Plan

4. CABLE PULLING METHODS

4.1 General
Three different methods are preferred to be used for pulling of the sea cables through the J-
tubes: the cable ‘sledge’ method, the Samson post method and the ‘cable pulling A-frame’
method. If cable pulling is done when the topsides has not yet been installed, no structure will be
present above the J-tubes, and therefore these three methods are preferred as no structure
above the J-tubes is required. Below two installation sequences are mentioned, where one of
them shall be followed; if cable pulling is performed before installation of topside, sequence 1.
shall be used and if the topside has been installed, sequence 2. shall be used instead. Storage
area for cables shall be defined in detail design phase, but the maximum height allowed is 3
meter in order not to intervene with cable ways installed on the topside.

1. Cable pull-in Storage of cable Topside installation Cable routing to GIS

2. Topside installation Cable pull-in Cable routing to GIS

4.1.1 Cable pulling layout

A preliminary overall 220/66kV cableway layout on the cable deck has been made to indicate a
feasible solution on routing the 220kV and 66kV sea- and internal platform cables, see:

• ONL-TTB-00135-MA-EN_01--Overall 220 66kV Cableway Layout Cable Deck

The preliminary layout drawing only indicates one placement of a cable pulling winch, but the
detailed design phase shall determine two locations on the cable deck (one for each OWF), see
chapter 4.2 for further information.
Furthermore the cable pits area has been shown with a dotted line, to indicate where the cable
pits will be located underneath the 66kV GIS areas.
All cable ways sizes and deck penetrations are estimated and shall be detailed designed in the
next phase.

4.1.2 The cable ‘sledge’ method

As seen in the figure below, this method consists of a sledge guiding system, which securely
guides the sea cable from the J-tube onto the cable deck. The placement of the winch and the
pulling pad eyes on the jacket structure allows for all sea cables to be pulled in one pull without
the need of moving the pull-in head for further pulling. For this method the winch can be situated
at one place and angled in three or more different positions in order to reach and pull all the
array and export cables.

The sledge guiding system shall be sized and designed by the (OWF's) cable contractor(s)
according to the minimum bending radius of their cable(s), having in mind the maximum height
and other requirements to be fulfilled.

Figure 3-1: The cable ‘sledge’ method

Standard offshore substation 4 of 9
Cable Pulling Plan

The T.O.S. (Top Of Steel) elevation of the J-tubes will be positioned at a suitable elevation for
using the sledge. A clearance of 300 mm between the Top of Grating (T.O.G.) and the flange is
reserved for the installation of the cable clamp upon the flange. It assumed the flange will fit with
standard type of hang-off clamps, which are compliant with DIN 2642. Nevertheless, the (OWF's)
cable contractor(s) shall review and design the flange detail for fitting with the cable clamp
chosen during detail design.

The structure of the cable deck is sized in order to carry the lifting equipment and its related
design loads.

The structure supports a sledge guide, which may be oriented around the required directions; a
pad eye, which is used for the installation of the snatch block and a winch. The sledge guide is
bolted to the structure. If it is deemed necessary, due to local loads, the grating has to be
replaced with plating.

4.1.3 The Samson post method

The cable is lifted vertically through a jack-up positioned on top of the post (see Figure 3-2). The
structure is sized in order to provide the concentrated design reaction forces to the column. The
Samson post is bolted to a flange located in correspondence with each J-tube.

Jack-up

cable

Post

Figure 3-2: The Samson post method.

Standard offshore substation 5 of 9
Cable Pulling Plan

4.1.4 The cable pulling frame

The cable is lifted vertically through a mobile gantry crane (see the Figure 3-3). The deck
structure is sized in order to provide the design reaction forces to the basement of the A-frame.
The specific structural requirements for supporting the basement during lift operations and
movement around the cable deck will be taken into account in detail design.

Figure 3-3: The pulling A-frame.

4.2 Cable pulling winch

The cable pulling winch shall be provided by the Offshore Wind Farm(s). Proposal is to mount the
winch on a turn plate for easy rotation of the winch so the pulling wire can be directed through
the snatch blocks, further over the chosen pulling method and down the J-tube. TenneT will
provide two locations on the cable deck for the winch and the turn plates. The location and
interface shall be determined during detailed design in consultation with the Offshore Wind
Farm(s).

Design factors
The pulling force is multiplied by the following design factors:
• Weight contingency 1.05
• Dynamic effect 1.1
• Consequence factor 1.3
• ULS load factor 1.3

The dynamic effect makes reference to cable pull-in operation in other similar platforms. The
weight contingency and consequence factor refer to Noble Denton guidelines for marine lifting &
lowering operations, 0027/ND.

4.3 Sequence of cable pulling

A preferred sequence could be to start pulling sea cables from the south or north end, and
afterwards follow the sequence one by one to the centre of the platform in order to gain the most
possible working space for each pull, but this is not obligatory. The cable length has been
estimated for the array to be between 19-25 metres and between 12-17 metres for export cables
at the present J-tube placement.
Standard offshore substation 6 of 9
Cable Pulling Plan

4.4 Rigging equipment

The area between the boat landing cages and behind the boat landing cage towards south can be
used for cable pulling rigging equipment and for placement of a small diesel generator providing
the necessary power for the cable pulling winch, lighting fixtures and various other small
consumers required during this phase. The Offshore Wind Farm(s) shall arrange power for their
cable pulling operation.

4.5 Escape routes

If the permanent primary escape routes are blocked for some reason during the cable pulling
phase, new alternative routes shall be determined in these periods.

4.6 Jacket structure

Inner diameter of J-tube shall be more than 2.5 times cable outer diameter. Therefore, based on
the sizes of the cables, defined in the section “Basis of Design”, the inner diameter of 66 kV J-
tube is chosen 450 mm and of the 220 kV J-tube is 700 mm.

J-tubes shall be located in such a way that one side of the Substation is kept free of cables, to
allow a Jack-up vessel at that side. Furthermore the J-tubes shall be located so that the cables
can be separated as much as possible on the seabed close to the Substation. Due to Remote
Operating Vehicle “ROV” cable pull-in operations, the distance between J-tubes and seabed
during cable pulling operation has to be coordinated with ROV supplier to ensure that the ROV
can manoeuvre freely also with dynamic sand banks in mind. 2.5 meters between J-tubes and
sea bed is a conservative approach and can be used as a guideline.

J-tubes will have minimum bending radius required for the cables, with single curvature and will
be able to withstand the cable pulling forces with no jamming.

The J-tube inner surface shall be smooth, free of obstructions, sharp and cutting edges. The J-
tube shall be checked by pigging or other suitable operation.

J-tube entrance shall be characterized by the presence of suitable smooth bell-mouth opening.
The bell-mouth shall be suitably sealed allowing for an easy opening at the time of the pulling by
means of a ROV. A simple example of a possible solution is shown in below sketch.

Figure 3-4: Typical bell-mouth arrangement

Standard offshore substation 7 of 9
Cable Pulling Plan

Design and construction of the bell-mouth shall include the following requirements:

• Bell-mouth elevation above seabed: 2.5 m, bell-mouth angle (from horizontal): 15°
• Bell-mouth exit angle: +/- 30° (see Figure 3-4)
• Bell-mouth exit angle shall guarantee the minimum bending radius of 3.4 m in the 66 kV
J-tube and 5.6 m in the 220 kV J-tube.
• Bell-mouth shall be aligned with the exit direction of cable (route of the cable
approaching the Platform)
• Bell-mouth exit point shall be outside the platform footprint for the ROV access
• Area in front of J-tube entrance shall be free of obstacles and shall allow safe approach
of the cable laying vessel and ROV and ease pulling of the cable.

4.7 Screenshots from the 3D model

In this chapter four screenshots are shown which have been taken from the 3D model of the
substation to give an impression of the cable deck size and available space. All four screenshot
are taken before installation of the topside and therefore no cable ways will be shown in the
screenshots.

1. Screenshot in Figure 3.5 shows an overview of the entire cable deck including the two
placement of cable pulling winches, the two sledges and the Samson post pulling method.
The pulling A-frame has not been inserted in the 3D model
2. Screenshot in Figure 3.6 shows the large sledge suitable for pulling of export cables
3. Screenshot in Figure 3.7 shows the small sledge suitable for pulling of array cables
4. Screenshot in Figure 3.8 shows the Samson post mounted on one of the array J-tubes

Figure 3-5: Overview of the entire cable deck.

Standard offshore substation 8 of 9
Cable Pulling Plan

Figure 3-6: Shows the large sledge.

Figure 3-7: Shows the small sledge.

Figure 3-8: Shows the Samson post.

Standard offshore substation 9 of 9
Cable Pulling Plan

5. FIELD LAYOUTS
In the principle field layout the platform is located such that it is surrounded by the two wind
park areas. The array cables enter the platform from three sides (north, west and south). The
export cables to shore can optimally be connected to the platform on the north side, but
connection on the south side will be kept open. The east side shall be kept free from cables on
the seabed to secure future accessibility for a jack-up-based heavy lifting crane vessel for
potential replacement of a main transformer, GIS or shunt reactor.

The principle field layout of Hollandse Kust Zuid is shown in:

• ONL-TTB-04016-MA-EN_00--Field_Lay_Out_HKZ_Alpha_(1-10)
• ONL-TTB-04017-MA-EN_00--Field_Lay_Out_HKZ_Beta_(1-10)
• ONL-TTB-04018-MA-EN_00--Field_Lay_Out_HKZ_Alpha_(1-20)
• ONL-TTB-04019-MA-EN_00--Field_Lay_Out_HKZ_Beta_(1-20)

These drawings show a preliminary lay-out. The lay-out shall be the basis for further optimization
during detailed design between TenneT, Offshore Wind Farm, Platform Contractor and Cable
Contractors.