Transporting heavy reels from Newcastle to Takoradi

The Load out in Newcastle

The project started as a standard reel lift out from Baker Hughes’ facility in Newcastle, which is something we have done many times before.

For the lift, we designed a specific rigging solution that was suitable for all of the reels, and complied with DNV-ST-N001.

It worked well, and the load out was carried out safely and efficiently. We prepared stow plans and lift plans, which included rigging design, specification, and procurement. We encountered one small problem at this stage. During the load spreading frame analysis we determined that the frame and stool design were insufficient for the heaviest two reels. To fix this, we helped the manufacturer to adapt the initial design for two of the load-spreading frames so that it could accommodate the reels.

We also designed a storage solution for the MOD500 lifting beam, which was used for lifting the reels throughout the project. This came in the form of two tailor-made grillages with forklift pockets; one for the beam and one for the shackles. Once broken down into its constituent parts, the beam and shackles could be stored easily in the grillages.

This elegant solution made it seamless for us to the store and transport the beam as it continued on its journey to Ghana.

Load out 2 in Le Trait, France

Once loaded with the cargo, the vessel sailed from Newcastle to France. Here, we loaded another five reels for transportation to Ghana. For this stage of the project, we designed stow plans, and prepared lashing and securing calculations and designs. We were on site in Le Trait to act as port captains to ensure the safe loadout of the cargo.

Discharge in Takoradi, Ghana

Finally, the vessel sailed to Takoradi in Ghana where she was discharged, and the cargo was put into storage.

The discharge required additional planning compared to the loading of the reels. For each of the reels we:
• Loaded a trailer with a specific load-spreading grillage
• Marked out the position of the reel on the grillage. This was different for each reel, due to Centre of Gravity positions and reel dimensions
• Positioned the trailers within the vessel crane's working radius
• Discharged the reel and positioned it on the load spreading frame
• Lashed the reel to the trailers and transported it to the storage facility
• Positioned the reel in the pre-marked out position in the storage area
The storage solution for the cargo was a challenge in this project. The area had not been specified before our arrival, so we had to measure, design and implement to the storage solution on site. We were able to think on our feet and carry out the required planning quickly. In order to place the cargo into storage, we used a hydraulic trailer with a tractor unit. Normally, we would use a conventional SPMT for this manoeuvre, but no SPMT was available. Instead, we adapted the initial storage plans on-site, and updated the plans to work within new limitations.

Safety throughout the project

As always, safety is our top consideration on any project. We were on site at every point to make sure that every step of every plan was implemented correctly. Any changes to the plans were recorded in Management Of Changes for example, the topography of the storage area was smaller than we had expected.

The heavier reels should have been stored on eight load-spreading mats, but instead they sat only on four. This was covered in an MOC, and deemed acceptable due to the ground condition of the storage area being much better than expected.

We also took on the role of port captaincy at each of the ports in the UK, France, and Ghana. We had to navigate challenges of different languages, and ways of working. However, with calm and clear instructions, every team co-operated well and co-ordinated the moving parts of the project. Each phase was carried out efficiently, and without interruption.

At one point in the project, we were provided with storage cradles, rather than installation cradles. Storage cradles are weaker, which meant that we could not subject the reels to the same accelerations as we would have, if we had been given installation cradles. To adapt to this, we set limits on sea stakes and wave heights.

We gave the vessel a document which clearly set out adequate safe havens if the state of the sea exceeded these limits at any point.