mass production of offshore-wind-jackets requires new industrial
TRANSCRIPT
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Mass Production of Offshore-Wind-Jackets requires new Industrial Solutions
Nationale StaalbouwdagOctober 2nd
G. Michels
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Agendag
I Market potentialsI. Market potentials
II. Supply chain concept pp y p
III. Supply chain concept partners SZAG / GSS
IV. Cost benefits of supply chain concept
V. Automatic welding of nodes
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Offshore Winden Energie – market potentialsSalzgitter Supply Chain Concept
g p
• Assessment of offshore wind market situation 2014 - 2020 (within EU)• Increasing installation up to 2020 (and beyond)• Increasing installation up to 2020 (and beyond)• Realistic evaluation reveals ca. 450 – 550 foundations p.a. requires ca. 1,471 Mio.
tonnes steel high portion of monopiles
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Salzgitter Supply Chain Concept
Offshore Winden Energie – market potentials
• Assessment of offshore wind market situation 2014 - 2020 (within EU)• Increasing installation up to 2020 (and beyond)
g p
• Increasing installation up to 2020 (and beyond)• Realistic evaluation reveals ca. 450 – 550 foundations p.a. requires ca. 1,471 Mio.
tonnes steel high portion of monopiles• Portion of jacket foundations increases market for industrial fabricated tubes
200
250
s
150
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Source: Ramboll
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Wind energy market - portfolio of products Salzgitter AGgy p p g
Activities Salzgitter AG
t bli h d in progressPod
established in progress
Plate ---
Tower Plate ---
Foundation structure
Plate forMonopiles
Modular design principle consisting of
i d t i l f t dindustrial manufactured pipes and nodes for
Jacket structures
Piles Plate
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IntroductionSalzgitter Supply Chain Concept
• High production costs / low production quantities put jackets at a competitive disadvantage compared to monopiles/XXLdisadvantage compared to monopiles/XXL
• For jackets to be competitive a cost reduction of 30% is required
• One way for the jacket to become competitive is via an industrial fabrication process
• Supply chain concept by Salzgitter AG• Cost saving by supplying pre-fabricated assemblies
and usage of standardized pipes modular design principle• Pre-fabrication by innovative solutions automated welding, y g,
cutting and NDT processes• Challenges
• Fabrication of complex, heavy structures (K, X-nodes)• Guarantee of dimensional accuracy and reliability
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Supply chain conceptSalzgitter Supply Chain Concept
pp y p
• Modular design principleI S l i f t d di d iI. Supplying of standardized pipes • High dimensional accuracy and lower costs
compared to tailor-made pipes
II. Pre-fabrication of assemblies (K, X nodes)• Reduction of cost by:
• Automated welding strategies less g gwelding time
• Delivering of already approved components
• Lower assembly time for fabricator• Welding form both sides improved
fatigue strength possibility to reduce g g p ywall thickness/welding time
• Lower failure rate
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Supply chain concept - partnershipSalzgitter Supply Chain Concept
pp y p p p
Salzgitter Expertise:- Cost efficient pipe manufacturer (OD 123-1524mm, wt. up to 50 mm)
groupp p ( p )
- high competitiveness against JCO pipes at last 30%- High dimensional accuracy towards roundness / wall thickness variation- High delivery reliability
- Delivering of standardized and tailor made pipes from one source- Manufacturing and delivering of X-/K-nodes produced by manual at
ion
and automatic welding (starting 2016)- Manufacturing and delivering of node to leg/brace components- Delivering of complete kit ready for jacket assembling co
oper
a
GS Expertise:- Manufacturing of large diameter tubes and cones, OD > 1600, wt up 80 mm,
StaalwerkenManufacturing of large diameter tubes and cones, OD 1600, wt up 80 mm,
..lifting capacity up to 80 t- Manufacturing of structural steel members such as X-/K-nodes, node.to leg ..joints.and secondary steel
E i i l i bli ti f l t l t t h- Engineering, planning, assembling, coating of large steel structures such as ..bridges, jackets and on-/offshore wind towers- See water location in Netherland
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Group structure and key data FY 2013Salzgitter Group
p y
Salzgitter AG GroupExternal Sales cons.: € 9.2 billionInternal Sales: € 2.7 billion
Employees: 23,164
• Total Sales:
Steel Tubes Trading Services Technology
• Total Sales: • Total Sales: • Total Sales: • Total Sales:€ 3.6 billion
• External Sales:€ 2.4 billion
€ 1.7 billion
• External Sales:€ 1.4 billion
€ 3.9 billion
• External Sales:€ 3.9 billion
€ 1.2 billion
• External Sales:€ 0.4 billion
€ 1.1 billion
• External Sales:€ 1.1 billion
• Employees:7,091
• Employees:5,431
• Employees:2,142
• Employees:3,600
• Employees:4,738
Previous structure, new group structure as of January 1, 2014
9
All data about employees as per 31/12engl
isch
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Large-diameter PipesTubes Division
g p
EUROPIPE GmbH
Germany; shareholder: SZAG 50%, Dillinger Hüttenwerke 50%
• Longitudinal and spiral welded large-diameter pipes for transcontinental and underwater pipelines
DN = 24“-60“ (610 – 1524 mm)
WT = 0,406“ – 1,77“ (8 – 50 mm)p p
• In-house coating activities• World market leader (7% market share)
4 l ti i D F USA• 4 locations in D, F, USA
2012 2013
Shipments kt 750 626
Sales €m 879 709
10
Nr. 1 im WeltmarktSales €m 879 709
Employees 31/12/ 1,288 1,224
engl
isch
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HFI-welded PipesTubes Division
p
Salzgitter Mannesmann Line Pipe GmbH
Germany; shareholder: SZAG 100%
• HFI-welded medium line pipes incl. DN = 4½" – 24“ (114.3 – 610.0 mm) p pplastic- and cement coatings
• Oil field pipes• Structural pipes hollow sections
WT = 0,126“ – 1,00“ (3.2 – 25.4 mm)
Capacity: 180.000 Tonnen
Nr. 1 in world market
• Structural pipes, hollow sections• 7% market share in the EU27• 2 locations in Germany
Welding speed 86 ft/min (30 m/min)
2012 2013
Shipments kt 293 207
Sales €m 325 221
11
Sales €m 325 221
Employees 31/12/ 504 510
engl
isch
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Large-diameter PipesTubes Division
g p
Salzgitter Mannesmann Großrohr GmbH
Germany; shareholder: SZAG 100%
• Spiral-welded large-diameter pipes • Diameter: 610 – 1,676 mm (24” - 66”)p g p pmade of hot-rolled coil
• Top-modern plants and processes• Technology leader
• Wall thickness: 9 – 25.4 mm (X70)• Pipe length: 9 – 18.3 m• Steel Grade: Grade B – X80
• Technology leader• Logistical advantage due to the supply
of hot-rolled coil by the Salzgitter HRC mill
• Mill capacity: up to 220,000 t/a
2012 2013
Shipments kt 139 90
Sales €m 150 103
12
Nr. 1 im WeltmarktSales €m 150 103
Employees 31/12/ 157 155
engl
isch
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Cost saving aspects and welding objectivesCost saving aspects and welding objectives
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Cost saving aspectsSalzgitter Supply Chain Concept
g p
• Structure of costs following state of the art manufacturing and assembly strategies• Application of tailor-made pipesApplication of tailor-made pipes• No pre-fabrication of components in advance • Usage of beveled pipes, beveling for point to point (tubular) joints and butt joints
Cost includes secondary steel piles transition piece
∑ ca. 3 million €∑ ca. 3.0 million €
Cost includes secondary steel, piles, transition piece
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Potential assembly strategiesSalzgitter Supply Chain Concept
y g
• Optimized assembly strategies • Version A: application of standardized pipes and pre-fabricated X-,K-nodespp p p p
• No tubular joints and reduced assembly time due to reduced number of components
• Version B: delivery of long legs and braces made of standardized pipes • Less assembly time due to reduced butt joints and number of components but higher steel tonnage
• Version C: delivery of long braces and pre-fabricated K-nodes made of standardized pipes• Less assembly time due to reduced butt -, tubular joints and number of components but higher steel
tonnage
Version A Version B Version CState of the art
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Cost saving potential Salzgitter Supply Chain Concept
g p
• Cost saving of optimized assembly strategies• Version A (prefabricated nodes/standardized pipes) offers the highest saving potential of ca 20%Version A (prefabricated nodes/standardized pipes) offers the highest saving potential of ca. 20%
(600.000€ /Jacket) • Reduction in overall production time by 20%-30%
90
100
n %
3 M€2.8 M€
70
80
Jack
etin
2.4 M€2.55 M€
60
70
Cos
t/
50
Version A Version B Version CState of the art
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Cost saving potentialSalzgitter Supply Chain Concept
g p
• Cost model developed by SZ and Ramboll Hamburg with input from several fabricators• Cost model developed by SZ and Ramboll Hamburg with input from several fabricators
• Cost saving of optimized assembly strategy A = 600.000 €• Material cost: -20%, UOE, HFI pipes• Welding / NDT cost: -28%, automatic welding / pipe roudness ↑• Logistic/Documentation: -15%, less components / already accepted assembliesg , p y p• Crane- / scaffold cost : -22%, faster assembling only butt joints
• Improved capacity utilization/higher throughput fi d t 30%• fixed costs: -30%
• Reduced inspection cost: -35%
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Cost saving potentialSalzgitter Supply Chain Concept
g p
Further not included cost savings by optimized assembly strategies• Quality improvements by industrial processes / automatic welding of nodes
• High / reliable quality within production • monitoring of welding parameter / less repair lower production risk• monitoring of welding parameter / less repair lower production risk • predictable production• Sustainable manufacturing and assembling time securing of delivery dates
• Welding from both sides (inside/outside) improvement of fatigue behavior• Opportunity to reduce wall thickness optimization of total weight and welding• Opportunity to reduce wall thickness optimization of total weight and welding
cost
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Automatic welding of nodes
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Challenge - dimensional accuracy Salzgitter Supply Chain Concept
• High accuracy needed • Weld distortion can cause dimensional imprecision's
g y
Weld distortion can cause dimensional imprecision s • Angle between brace stub and leg• Difference in neutral axis between brace stub and leg
• Low accuracy causes:o accu acy causes• Higher final assembly costs and time or • Impossibility of assembly• Impact on static and fatigue performance due to additional bending moments• Impact on static and fatigue performance due to additional bending momentsMain goal: high dimensional accuracy
neutral axis of brace
neutral axis of brace
r arm
neutral axis of leg
Leve
r
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Automatic welding of nodes Salzgitter Supply Chain Concept
g
• Salzgitter Mannesmann Research in Duisburg has performed a feasibility study (inhas performed a feasibility study (in cooperation with partners)
M f t i f 4 d t t bli• Manufacturing of 4 demonstrator assemblies• Brace-stub: S355, wt 20 mm, outside diameter
610 mm (24``)• Leg: S355 wt 40 mm outside diameter 1118 mm• Leg: S355, wt 40 mm, outside diameter 1118 mm
(44``)
• Automatic welding of K-node by means of
1118
Automatic welding of K node by means of manipulator welding continuously in position PA
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Automatic welding of nodes Salzgitter Supply Chain Concept
g
• Non destructive tests• Ultrasonic tests in accordance to DNV OS F101 andUltrasonic tests in accordance to DNV OS F101 and
metallographic tests reveal no abnormities• 3D measurement of dimensional accuracy
• 45°±0 1° angle was achieved in all cases• 45 ±0.1 angle was achieved in all cases • Deviations in neutral axis is lower 0.02mm
• Optimal dimensional accuracy can be ensured
Neutral axis of brace
Neutral axis of leg
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Automatic welding of nodes Salzgitter Supply Chain Concept
g
• Potential of automatic weldingC i f l d t ti ll ld d d l d• Comparison of manual and automatically welded nodes revealed
• Reduction in welding time by >70%• Reduction in cost by ca. 30% (including investment into welding/handling equipment)
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Accessibility testSalzgitter Supply Chain Concept
y
• CAD study of different nodes concerning accessibility during automatic weldingK f t f 3 l j k t• Key factor for 3-leg jackets
• Nodes with small gaps (>100mm) between the brace stubs can be automatically welded
Ø610
min. Ø1400