Galloper Wind Farm

Wind power is a valuable and growing part of the UK’s renewable energy portfolio and Aquaseal Rubber is proud to have worked with a client on one of their wind farms.

We have recently completed the Neoprene rubber lining of 56 off steel J Tube guides. It was a challenging project as we worked to the precise specifications the client had for the material used and alongside an added 20 years life expectancy of the rubber.

Overview

Aquaseal Rubber has helped in the fabricating of the unmanned offshore substation platform for the Galloper Offshore Wind Farm. This is an extension to the Greater Gabbard Wind Farm, but is being developed as an entirely separate entity. The project engineering and procurement are being undertaken by Petrofac as part of the GE Petrofac Consortium.

The Galloper substation platform will connect turbine generators to a single Offshore Substation Platform (OSP) by subsea array cables. The OSP will be linked to the onshore transition joint bay near Sizewell by two subsea export cables. The offshore site is located within the outer Thames Estuary, 27 kilometres off the Suffolk coast with water depths of 27 to 39 metres. This wind project will help contribute to the growing proportion of wind power generated in the UK. The site is projected to generate enough electricity to provide electricity for 336,000 average UK households.

Enquiry

After the client’s initial enquiry, Aquaseal agreed a material specification with the client and proceeded to have the raw material processed and delivered within two weeks. We then carried out some in-house testing of the material, making sure it worked well in our process.  After the testing was successful, we continued on with the manufacturing, making the 12mm thick sheets required for the order. These were 1.9 m long x 700mm wide x 12mm thick.

We worked with the client and their client while they observed us as we carried out the first off and getting the sign off documents done within 48 hours. We then continued to manufacture the rubber sheets and apply them to the free issue steel guides.

Delivery

Aquaseal worked closely with the customer and their specifications. This required some consultation with the raw material manufacturer who is also based in the UK.

Throughout the length of the order, which was 4 months, we were closely monitored in the traceability and production methods used to apply the Neoprene pads to the steel structures. We were able to provide a full paperwork trail covering everything from the steel manufacturing to the welding inspection and salt test of shot blasting to the rubber manufacturing and application. Upon completion of the project, Aquaseal provided an A4 file and digital copy with all the relevant paperwork.

Results

Aquaseal Rubber was able to deliver the client project on time and to all requirements specified to the client.

‘Barrier Ltd employed Aquaseal Ltd as a sub-contractor on the Galloper Wind Farm Project which is currently being fabricated at Heerema Hartlepool Ltd. The works were for the fitment of 12mm Thick Seawater Grade Neoprene to a total of 56No. J-Tube Guides. Barrier Ltd were impressed by the technical knowledge shown by the management, the commitment of the workforce to meet programmed timescales and the quality of the end product.’ – Gavin, project manager

The client is happy with the quality and the customer service while we delivered the project. We are proud to have contributed to the Galloper Wind Farm’s commitment to sustainable energy.