The subject of this month’s feature once again throws the spotlight on the UK shipbuilding industry and is the result of a collaboration between 3 South Coast experts in their maritime fields, namely BAR Technologies (Portsmouth), Chartwell Marine (Southampton) and Seacat Services (Cowes) with the entire design and build process remaining in the UK. We start with Land Rover BAR’s modern headquarters that opened on the Camber in Old Portsmouth in the summer of 2015 for the Ben Ainslie Racing team. Designed by HGP Architects, responsible for Portsmouth’s Spinnaker Tower, the building was opened as a base for Sir Ben Ainslie and his racing team prior to launching their bid to bring the America’s Cup home to the UK in 2017. With a carbon neutral theme, the building was constructed using cutting-edge methods, fabric and technologies optimising sustainability to BREEAM Excellent standard. Powered by 432 solar photovoltaic panels, it generates 130MWh a year providing all electricity required. The sail-like façade, created from transparent PTFE fabric stretched around a polished concrete base, is designed to be backlit at night and assists the building’s efficiency. Another aim for the location was to support the growth of the marine sector in the Solent area to match the UK’s Formula 1 Racing innovation hub. In November 2021 the BAR team moved out of the site and relocated to Brackley but remaining in situ was the Applied Technology business, BAR Technologies, and the official BAR charity the 1851 Trust, with over 100 personnel working on-site. The loss of the racing team caused huge disappointment to the city. Before the BAR team’s final departure, the British advanced maritime technology business, SubSea Craft Ltd. and BAR Technologies, signed a new 5-year contract to further reinforce their partnership, which saw SubSea Craft move its operations from Havant into the Camber, Portsmouth, alongside BAR Technologies. The intention with this set up was to create a hub for innovative and advanced maritime technology in the heart of Portsmouth. BAR Technologies (BARTech) was formed in 2016 as the culmination of decades of experience at the very highest levels of competition on both land and water. The team specialises in technically challenging multidisciplinary design, evaluation and optimisation engineering challenges. BARTech’s expertise encompasses Naval Architecture, Design Optimisation, Computational Fluid Dynamics, Performance Simulation and Analysis, Control System Software Design, Structural Analysis, Mechanical, Composite and Detail Design and Project Supply and Supply Chain Management. This expertise is employed within the following maritime sectors, Workboats and Commercial Vessels, Shipping, Leisure Marine and Yachts and Special Projects. Ultimately, the day-to-day work of BAR Technologies draws upon the highest level of engineering expertise and understanding of hydrodynamics from the fields of Formula 1 racing and the America’s Cup respectively, to take on some of the biggest challenges in vessel efficiency and maritime decarbonisation.

Reinventing the CTV

BAR Technologies challenged themselves to incorporate a broad knowledge of naval architecture, simulation, CFD and patented IP into a superior Crew Transfer Vessel (CTV) for taking technicians to work on Wind Turbines (amongst other uses). The aim was to improve seakeeping and help make a green energy sector even greener by dramatically reducing fuel requirements and CO2 emissions.

Windfarm Technicians transit to wind turbines in sea states up to a wave height of 2 metres and they must arrive fit for work. If any of these personnel become seasick then all passengers (up to 24) aboard the vessel must return to port immediately. These abortive trips cost the offshore energy companies large amounts of money, so superior seakeeping is an essential part of the vessel’s key requirements. Technicians must also be able to safely transfer from the vessel onto the wind turbines so the CTV should create a stable platform from which to climb onto the turbine structure, by pushing against it whilst the engines provide thrust. The location and nature of the turbine, and docking with it, also requires the CTV to have excellent manoeuvring capability at slow speeds. BARTech’s design team came up with a truly novel craft that takes its patented form from extensive simulations and incorporates a foiling system. The latter corrects pitch and roll and the narrow hull form, with the swath style outrigger, helps to minimise motion and fuel use to ensures the most comfortable and economic journey. The all-new CTV design is the BARTech 30 ProA, a 33.29m long vessel that reduces vertical accelerations by between 35% and 70%, is between 30% and 50% more fuel efficient and therefore produces far less greenhouse gases compared to similar propulsion methods. (Precise figures are subject to the drivetrain installed). With the BARTech 30 being able to operate in higher sea states than a catamaran, the turbines can be serviced and maintained on more days per annum, thus saving the companies downtime and considerable expense. The new design, achieved in partnership with Chartwell Marine, is also comparable in terms of build cost to a catamaran, but offers superior usage for the minor increment in investment. The first BARTech 30 order was announced on 21st September 2020 with a contract for two craft being signed by class-leading offshore energy support vessel (OESV) operator, Seacat Services.

Game Changer

Seacat Services is based in Cowes, Isle of Wight, and was formed in 2010. In November 2022 their website did not reference the BARTech 30 order but did show a catamaran fleet totalling 15, ranging from 21m to 27m varieties and dating from 2012-2022. The youngest vessels were the 111gt/2020-built Seacat Weatherly, the 110gt/2020-built and Seacat Rainbow and the 110gt/2022-built newbuild Seacat Sceptre, all 24m long Chartwell Marine C24 catamarans. A fourth C24 was underway with this and the Seacat Sceptre being new hydrofoil-optimised Offshore Energy Support Vessels (OESV). Developed by Chartwell Marine, the ‘Sceptre is the first of two OESVs ordered by Seacat Services equipped with the new Foil Optimisation and Stability System (FOSS) technology, designed by BAR Technologies, to enhance the stability, crew comfort, and efficiency gains of OESVs. The vessel and her stability system exceeded expectations for performance, improving passenger comfort and directional stability, as well as demonstrating 10% fuel savings at a cruising speed of 28 knots, a higher top speed, and increased cruising speeds through higher sea states. The Seacat Sceptre is now working for Seagreen, a £3 billion, 114-turbine Scottish wind farm development venture between SSE Renewables and TotalEnergies located in the North Sea Firth. FOSS also forms part of the BARTech 30s list of innovations and combines the latest in active hydrofoil technology with advanced hull hydrodynamic optimisation. The resulting system achieves significant efficiency gains whilst actively improving handling and sea keeping. The use of active, differential foil actuation has demonstrated the following handling and comfort advantages, general motion damping (the vessel feels larger and more stable), active roll and trim response (counters sea state, loading conditions and the effects of speed and acceleration on trim, also negates the need for stabiliser fins when underway), roll response in turns (the amount of banking in a turn can be reduced or exaggerated to suit personal preference), decoupling the effect of roll and yaw in quartering seas (significantly reduces broaching behaviour and increases control), ability to select vessel response, providing the most appropriate passenger experience for those onboard. Hydrofoil technology is increasingly present in new vessel designs due to the ride, speed, economic and environmental benefits. Ultimately FOSS will cut CO2 emissions by up to 600 tonnes per annum for a craft if working on a 12-hour shift operation. So, these initial BARTech 30 newbuilds are among the first true Low Emission Vehicles (LEVs) servicing the offshore wind market, with total emissions 30% lower than conventional CTV designs. Perhaps the phrase gets overused but the new BARTech 30 truly is a game changer in green vessel design and within the offshore industry. The very first example was given the name Seacat Columbia and was launched on 13th June 2022 from Diverse Marine Ltd’s Medina Yard in Cowes on the River Medina, Isle of Wight. The second vessel of the twin order will be named Seacat Cambria. Fellow UK-based CTV operator, High Speed Transfers, has since ordered two BARTech 30s. Diverse Marine Ltd was established in 2018 by Ben Colman, Matt Floyd and Matt Chessell and offers a range of newbuild vessels, together with refit, repair and maintenance from the company’s base at Medina Yard in Cowes. A plethora of fast offshore vessels have been built here with Cowes being no stranger to shipbuilding with past names including J. Samuel White, Souter, FBM Marine and South Boats. Another positive step for the area came on 10th October 2022 when Diverse Marine announced that it had completed the purchase of the freehold of Medina Yard and Medina Village from the Peter Harrison Trust. This site represents 12 acres of waterfront at Cowes, part of which is the current base of the UK’s leading workboat builder. This acquisition not only protects the future of Diverse Marine, its staff and contractors but also gives security to other tenants on the site that support the company in day-to-day activities.

Racing Pedigree

The profile of the BARTech 30 is quite unique but, from the starboard side, could be mistaken for a more standard Crew Transfer Vessel. However, the craft consists of that narrow hull form and a swath style outrigger, which gives a very different look from every other angle. Considering BARTech’s racing pedigree, it is perhaps no surprise that this sleek, capable design was arrived at. The 163gt and 33.29m vessel has an overall beam of 10.9m, a hull depth amidships of 3.79m, an operational draught of 1.50m and a fully laden displacement of 95 tonnes. There are three deck levels aboard, namely Wheelhouse, Main Deck and Below Main Deck. The wheelhouse has 360 degree visibility and full height windows facing forward for maximum visibility over the foredeck, docking area and for general navigation from the Skipper’s position. The trio of navigation team seats are supplemented by a crew lounge/mess area (starboard side aft) and a crew galley (port side aft). The crew can vary 3-6 persons. The lower level of the deckhouse features a passenger saloon (forward) with three rows of seating (6, 8 and 10 seats from port to starboard, 24 in total). The aft section of this area features a wet room, toilets and lockers. There is also a Technician Galley and a mess area at the back of the saloon, port side. Aft of the deckhouse on the starboard side is an area for a 10ft container. A further two 10ft containers can be carried on the forward deck. The total cargo area is 62m2 and the deck load capacity is 1.75T/m2. Sited forward on the starboard side is a 2,000kg capacity TMP 900XL Knuckle Boom Crane for cargo purposes. Manufactured by TMP Hydraulik A/S of Denmark, this hydraulic crane has a maximum outreach of 7.9m and the brand is a popular choice among offshore craft Designers/Operators. The bow features a collision void space and heavy duty fendering for docking at wind turbines. Behind this void is the forward void space and aft again is the accommodation space that consists of 4 crew bunks and shared facilities. This area is designed for use whilst in port overnight. Adjoining this area is a small utility room with washing machine and tumble dryer. The fuel and fresh water tanks are located beneath this accommodation, midships. Aft of the accommodation space is the machinery space, which is home to a pair of MTU 2000 12V M72 engines (2,160kW total output/2,250rpm). These engines have a 135mm bore, a 156mm stroke and a displacement of 26.76 litres. The engines are each linked to a ZF3050 gearbox and each drive a Kamewa S56-3/CA direct drive waterjet.

The maximum speed is 31 knots, the service speed is 25 knots, the economy speed is 20 knots and the tower bollard push for docking/crew transfer at a wind turbine is 12t. There is also a retractable Ocean Marine Systems (OMS) E-0500-V Series manoeuvring thruster with a 508mm diameter propeller, a power output of 99kW and a maximum force of 1,188kg. This is located in the outrigger on the port side. Onboard power is provided by a 34kW Nanni generator. The BARTech 30 is designed to be drivetrain agnostic but various options are available that include Volvo IPS, Fixed Pitch Propeller (FPP), Changeable Pitch Propeller (CPP) and Hybrid. The CPP drivetrain us deemed the most expensive whilst the MTU and waterjet drivetrain installed on the Seacat Services craft was an owner choice to match the drivetrain of their existing fleet members. Between the engine room and stern is the jet void space. The waterjets and FOSS system are located beneath the platform situated at the stern of the vessel to enable servicing and maintenance.

Industry Debut

Before the Seacat Columbia was completely finished she was shown off to the industry at Seawork 2022 in Mayflower Park, Southampton 21st-23rd June 2022, just a few days after her launch. The BARTech 30 design has since been awarded approval in principle from the American Bureau of Shipping (ABS), providing another class-certified, Jones Act compliant option for vessel operators looking to enter the US offshore wind market. Once the fitting out and sea trial processes were finished, the Seacat Columbia visited BARTech’s headquarters at Camber Docks, Old Portsmouth, on 25th August where she was handed over to Seacat Services and also christened by Ian Baylis, Founder of Seacat Services and Martin Whitmarsh, Chairman of BARTech. Guests attending the ceremony were given an in-depth tour of the vessel and shown some of the key features that provide the new craft’s superior efficiency and handling. Chartwell Marine and BARTech have also established a partnership to support the delivery of the next generation of offshore wind CTVs, which will drive forward the development of new vessel designs ranging from 30m CTVs to 60m Service Accommodation and Transfer Vessels (SATVs). The Seacat Columbia’s first deployment was at Equinor’s Sheringham Shoal and Dudgeon wind farms off the coast of Norfolk, UK. The charter to the Norway-based company covers service at the 317 megawatt Sheringham Shoal and the 402-megawatt Dudgeon wind farms, whilst based at the operations and maintenance hub in Great Yarmouth. Both offshore wind farms are being developed after selection by the Crown Estate in 2018 to progress to the award of rights together with several other extension projects. The work will double the capacity of the two existing wind farms to around 1.4 GW in total, providing renewable energy to power an additional 785,000 UK homes. It is estimated that the Seacat Columbia’s use will reduce carbon dioxide emissions by up to 1,200 tonnes annually when she is working on the 24-hour charter operation. A larger model, the BARTech 50, was also available at the time of writing.