Telestack has supplied two mobile shiploading systems to DEME, one of the world’s leading marine engineering and offshore energy companies, as part of the Coastal Virginia Offshore Wind (CVOW) project —a landmark initiative in the United States’ renewable energy sector.
As the largest offshore wind project in the U.S., CVOW represents a pivotal step toward clean energy and reducing carbon emissions, with Telestack’s innovative shiploading equipment playing a vital part in its success. CVOW, developed by Dominion Energy, is designed to deliver 2.6 GW of renewable energy—enough to power approximately 660,000 homes at peak output. The project involves the construction of 176 wind turbines, three offshore substations, and undersea cables, with onshore infrastructure to channel renewable energy to the grid.
Telestack’s two mobile shiploading systems have seamlessly integrated into the material handling element of the project, ensuring the efficient loading of large grade armour rock to Flexible Fall Pipe Vessels (FFPV).
Telestack’s innovative shiploading equipment is operating in Bayside, Canada, where they have supplied two AP 1500 D3 wheel-mounted apron steel feeders and two TB 52 (170ft) radial telescopic shiploaders for loading rock material onto DEME’s specialised rock installation vessels at a high loading rate.
The Telestack system included a range of technical features and benefits that were vitally important for the long-term handling of these rock grades. The AP 1500 feeders included a heavy-duty steel apron chain, complete with high-grade cast steel flights and bearings, for large rock applications. The feeder allows the wheel loaders to be fed over 3 x sides for the ultimate flexibility and increased tonnages. Also, the integrated variable speed drive on the feeder ensures a ‘controlled’ flow of material to the TB 52 Shiploader, especially important for the large rock. The feeder features a wheel-mounted design, allowing the operator to move the unit via tow hitch around the quayside as required, ensuring the system’s mobility.
The feeder then discharges into the TB 52 Radial Telescopic, which is equally impressive in its innovative features, designed to meet the challenges of handling this material grade effectively. The 52m (170ft) long telescopic boom conveyor can load the largest flexible fall pipe vessels in the world, including the current DEME – Yellowstone Vessel, which is currently the largest FFPV in the world with a 37,000-tonne capacity and over 14m free-board / draft height.
The design of the radial and telescopic features allows the operator to place the material easily within the rock hold while the material flows, minimising the work of the vessel excavator to move the material within the hold, ultimately increasing the tonnage rate of the entire operation.
The TB 52 Shiploaders are both tracked, mounted units, which allows them to easily move off the site when not required, ensuring their use on multi-cargo berths and jetties. The Shiploaders include heavy-duty rollers, belting, and skirting, complete with anti-roll-back features to handle large rocks. Additionally, the rollers are spaced 600mm apart to minimise the ‘bounce’ of the material when the units stop in operation. This material is further controlled by the variable speed drive on the shiploaders, which works in conjunction with the feeder to ensure full operational control in all scenarios.
This contract has once again demonstrated Telestack as a leader in mobile bulk material handling, largely due to their experience and ability to design and manufacture innovative products that meet the high specific demands of this instrumental project.
Telestack’s shiploading solutions are engineered for high throughput, operational efficiency and flexibility achieved through mobility. Telestack’s International Sales Manager, Carl Donnelly, explains: “Telestack has a huge portfolio of international projects that demonstrate our expertise. Our team is experienced in high-profile projects and values the pre-engineering stage, which allows the solution to develop through true collaboration, listening to the needs of the operation, and leveraging decades of experience. This process isn’t just one meeting – it takes time, patience and partnerships, which we pride ourselves on.”
Designed for the toughest applications, Telestack’s heavy-duty equipment is engineered to handle the most demanding materials with unmatched durability and efficiency. Built with reinforced structures and mine-spec componentry, Telestack’s shiploading solutions ensure performance regardless of the application.
The high-capacity loading ability of the Telestack solutions enables the rapid transfer of rock materials, minimising turnaround times for the FFPV. Additionally, they ensure that materials are delivered to vessels accurately and in compliance with environmental regulations.
Mobile shiploading can significantly enhance the operational performance and productivity of a port by offering greater flexibility, efficiency, and cost savings compared to fixed loading systems. These mobile units enable ports to quickly adapt to different vessel sizes and cargo types, thereby reducing vessel turnaround times and increasing throughput. By eliminating the need for extensive infrastructure modifications, mobile shiploaders minimise capital expenditures while still providing high-capacity loading rates.
Rapid deployment ensures that revenue streams begin to flow almost immediately. Unlike traditional systems that experience downtime due to empty return cycles, mobile solutions enable continuous loading, maximising throughput while reducing operating costs. Designed for simplicity, these machines require minimal training, are easy to maintain, and eliminate complex electrical systems, ensuring smooth, uninterrupted operations.
By embracing mobile solutions, companies like DEME and others within the offshore industry can unlock unprecedented efficiency, safety, and environmental benefits in handling their offshore Rock.
The CVOW project highlights the crucial role of partnerships and innovative solutions in advancing renewable energy. Telestack is honoured to have collaborated with DEME to devise this shiploading system for a groundbreaking endeavour, which will not only bolster the nation’s renewable energy capacity but also inspire confidence in offshore wind as a reliable and sustainable energy source.
