A tale of two vessels - AAL optimises delivery of Kings Farm Wind Farm components

AAL Shipping has completed the transport of 125,175 revenue tonnes (RT) of wind turbine blades and towers for Western Australia’s King Rocks Wind Farm, using two sailings to move cargo that would typically require three or four voyages.

The operation was carried out by the 32,000 dwt Super B-Class vessel AAL Antwerp and the 31,000 dwt A-Class vessel AAL Shanghai. AAL Shipping said the cargo strategy delivered cost, schedule and environmental benefits through higher cargo intake and vessel utilisation.

Preparing the unloading of wind turbines from AAL Antwerp at Port of Bunbury. Image: AAL Shipping

The final shipment saw AAL Antwerp arrive in Bunbury with 91,739 RT of wind energy cargo, including 51 wind turbine blades measuring up to 80 metres and weighing more than 36 tonnes each. The blades were stowed up to six units wide and five tiers high, reflecting the vessel’s cargo intake capability and the stowage planning used for the shipment.

This final voyage accounted for more than 70% of the project’s total cargo volume. Combined with the earlier sailing by AAL Shanghai, the two vessels moved the full 125,175 RT of wind turbine components for the 17-turbine King Rocks Wind Farm near Hyden, Western Australia.

“Projects such as the 105 MW King Rocks Wind Farm demonstrate the value that AAL Shipping’s engineering expertise and modern vessel design bring to renewable energy logistics,” said AAL Shipping Australia regional operations manager, Renate Poppe.

“Despite the sheer size and volume of the components involved, by optimising cargo stowage and vessel utilisation we were able to consolidate what would traditionally require multiple sailings into just two voyages, delivering tangible financial and schedule benefits for our customer while maintaining the highest standards of safety and cargo care,” Ms Poppe continued.

The King Rocks Wind Farm will generate 105MW of renewable energy, enough to power about 70,000 homes, and is expected to support around 200 jobs during construction and operations over its 30-year lifespan.

“The discharge operation of AAL Antwerp in Bunbury presented its own challenges, particularly the stringent crew and cargo safety measures required when handling upper-tier blades stacked up to five levels high,” said AAL Shipping global head of engineering, Nicola Pacifico.

“Painstaking planning and execution were required to accommodate port crane height and outreach limitations. Despite the complexity, discharge was completed safely and efficiently within nine days.”