Lean møde April Agenda: Siemens intro. Lego workshop London Array projektet Formål, midler og resultater

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1 Lean møde April 2013 Niels Bjært Senior Project Manager Siemens Wind Power Agenda: Siemens intro Lego workshop London Array projektet Formål, midler og resultater Eksempel Esbjerg Havn Formål, midler og resultater Afrunding Arbejdet med: Wind Power: Horns Rev 2, DK London Array, UK Westermeerwind, NL Turn key kraftvarmeværker incl. bygninger Varmeværker Fjernvarme, inkl. ombygning af huse til fjernvarme Gasturbiner Gasmotorer Sandpumpestation mm Firmaer: Siemens Wind Power Fiberline Composites Siemens Industry Kemp&Lauritzen ABB Dansikring (Group4) ER-Electric (YIT) Page 1

2 Lean møde April 2013 Agenda: Siemens intro Lego workshop London Array projektet Formål, midler og resultater Eksempel Esbjerg Havn Formål, midler og resultater Afrunding Page 2

3 Fra 5 MW til 630 MW i løbet af 23 år Verdens første offshore wind power plant Verdens første offshore wind power plant med MW turbiner Verdens største offshore wind power plant i drift Verdens største offshore wind power plant i drift Verdens største offshore wind power plant i drift Verdens største offshore wind power plant i drift Vindeby Middelgrunden Nysted Horns Rev II Greater Gabbard London Array 5 MW 40 MW 166 MW 209MW 504 MW 630 MW Ca medarbejdere i Siemens Wind Power world wide Page 3

4 Focus på 3 områder vil reducere omkostningerne til etablering af vind energi Reduce costs via 3 levers Siemens Wind Power scenario: -40% in less than a decade. < 10 years to reach wholesale parity Innovation LCOE [ct / kwh] Industrialisering Baseload energy price Strategiske Alliancer 2013 Page 4

5 Industrialisering Standardisering af processer! Economies of Scale: Average cost per unit falls as the scale of output increases.! Nacelle line production: production time was reduced by more than 50%.! Standardizing Installation Processes: Processes are isolated and whenever possible moved onshore.! Lean Manufacturing: Implemented in both the production line and during installation processes. London Array: The World's largest offshore wind power plant! Industrialize Offshore value chain: Strategic partnerships and lean BOP design Page 5

6 Lean møde April 2013 Agenda: Siemens intro Lego workshop London Array projektet Formål, midler og resultater Eksempel Esbjerg Havn Formål, midler og resultater Afrunding Page 6

7 Industrialisering London Array eksempler Hvad gjorde vi så på London Array projeket: Reference mølle Analyse af alle processer fra produktion til endelig aflevering til kunden Fjerne alle dobbelte checks Flytte checks fra offshore tilbage til preassembly eller produktion Nyt design for udvendige installationer: belysning, sø navigation, tåge detektor mm for dermed at flytte offshore arbejder tilbage til preassembly- faktor 10 i omkostningsreduktion Installation workshop en leg med Lego Page 7

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9 Industrialisering London Array eksempler Hvad gjorde vi så på London Array projeket: fortsat Tiden for installation af en vindmølle blev reduceret fra xx timer til gns. yy timer Vi påtog os appointed person ansvaret Vi fjernede reload i Harwich for det ene af vores 2 installationsskibe Mr. Fix it Teknisk back up On site På hjemmekontoret for mere langhåret troubleshooting Omgående levering af reservedele Brug af hotelskib Brug af nyudviklede skibe til transfer af mandskab Brug af Tetra kommunikation Page 9

10 Communication offshore standards to be implemented London Array leading the way forward Secure a reliable communication in and between all sites and inside turbine tower via TETRA Localization in all sites and inside turbine tower via TETRA / GPS Condition Monitoring of generators via TETRA Dispatching & Control from Ramsgate, Esbjerg and Vessel Offshore Internet/Intranet access + Crew2Family commmunication (Skype,..) via WiMAX Tailored Emergency Broadcast from TETRA to GSM / People and vessel tracking Page 10

11 Industrialisering London Array eksempler Hvad gjorde vi så på London Array projeket: fortsat Privatfly til skift af mandskab Fuld scala mock up af Transition Piece og tårnbund for derved at fjerne overraskelser offshore Workshops for detaljeret aftale om alle arbejder med kunde og med underleverandører Opfølgningsmøder med kunde og underleverandører for hver ny process Hvis problemer, gentagelse Page 11

12 Slutresultatet på London Array Merværdi til kunden pga kortere installation og hurtigere idriftsættelse Accumulated Actual from W43...W18 equal to 27 weeks in autumn and winter Average 32 % adverse weather Planned for W5...W52 equal to 47 weeks dominantly in the summer Average 19 % adverse weather Grid available one Year after planned 0 Calendar Week Planned Commssioning Planned 240 h test Actual Commissioning Actual 240 h test Page 12

13 Agenda Lego workshop 12/10 (Siemens, LAL, Weldex, ABJV, A2SEA) Presentation of the workshop Presentation of Participants Introduction to Role-play Building of the lego-vessels and cranes Role-play 1; Load out in Esbjerg to Barges Sum-up of Role-play 1 Role-play 2; Re-load in Harwich from Barge to SeaWorker Sum-up of Role-play 2 Role-play 3; Installation on site Seaworker Sum-up of Role-play 3 Closure of today's workshop 13/10 (Siemens, LAL, Weldex, ABJV, MPI) Presentation of the workshop Presentation of Participants Introduction to Role-play Building of the lego-vessels and cranes Role-play 4; Load out in Esbjerg to Discovery Sum-up of Role-play 4 Role-play 5; Installation on site Discovery Sum-up of Role-play 5 Role-play 6; Re-load in Harwich from Barge to Discovery Sum-up of Role-play 6 Closure of the workshop Page 13

14 Introduction to role-play We want to play it Lifting roles and responsibilities All scenarios from loading in Esbjerg until Turbine is installed on site. Each part/person play their own role compared to the LAL scope of work. Page 14

15 Introduction to role-play Today we play 3 scenarios; Role-play 1; Load out in Esbjerg to Barges (Siemens (Weldex), ABJV, LAL) Role-play 2; Re-load in Harwich from Barge to SeaWorker (Siemens, ABJV, A2SEA, LAL) Role-play 3; Installation on site Seaworker (Siemens, ABJV, A2SEA, LAL) - Each session will be video-recorded and Sum-up after the play Page 15

16 Building of the lego-vessels and cranes Siemens; 2 x crawler cranes Containers 10 turbines (+ lifting equipment, tag-lines etc.) Draw map (Esbjerg) ABJV; 4 x Barges 2 x Tugboats A2SEA; 1 x Installation vessel Seaworker 10 x Walkie Talkies (mobile phones) LAL; 10 x Foundations Draw map (Harwich, Site) Page Restricted Siemens AG 20XX All rights reserved.

17 Bare lige nogle fine fotos Page 17

18 Page 18

19 Page 19

20 Page 20

21 Lifting intro Page 21

22 Lift intro index only Re-Loadout Harwich BORA to Seaworker (Tower) INDEX; Re-Loadout Harwich ABJV Barge to Seaworker Loadout Esbjerg Barges (Blade) 1a (Blade) Loadout Esbjerg Barges (Blade) 1b Re-Loadout Harwich ABJV Barge to Seaworker Loadout Esbjerg Barges (Tower) 1a (Blade over a... Loadout Esbjerg Barges (Tower) 1b Re-Loadout Harwich ABJV Barge to Seaworker Loadout Esbjerg Barges (Nacelle) (Nacelle) Re-Loadout Harwich to Seaworker (BORA) Re-Loadout Harwich ABJV Barge to Seaworker Re-Loadout Harwich ABJV Barge to Seaworker (Nacelle) (ABJV) Installation Seaworker - Positioning Re-Loadout Harwich BORA to Seaworker Installation - Seaworker Jacking height (Blade) Installation - Seaworker Tower Re-Loadout Harwich BORA to Seaworker Installation - Seaworker Nacelle (Nacelle) Installation - Seaworker Blades Page 22

23 Role play 1: The LOAD-OUT In Esbjerg to Barges WTG Component responsibility Siemens ABJV Notify arrival of Barge at Esbjerg to Contractor Siemens Toolbox talk Siemens Lifting Nacelle / Blades from Quayside to Barge Siemens Lifting Towers from Quayside to Barge ABJV Secure seafastenings / bolting Handover of WTG Component from Siemens to LAL (ABJV) ABJV Check seafastenings / bolting (Tug Master) ABJV Monitor weather conditions and arrange departure. WTG Component responsibility LAL (ABJV?) ABJV Arrange Pilot & mooring of barge at Harwich HARWICH Siemens Provide to Employer progress report of Assembly progress. LAL Final Inspection of WTG components before load out. Siemens Connect power supply to WTG Components Siemens / LAL Sign Handover certificate ABJV Provide daily progress report to Employer LAL ABJV Arrange MWS review Progress Report Insp Report Provide power supply for preservation of WTG components. MWS Cert Handove r Cert DPR Page 23

24 Role play: løfteoperation offshore Page 24

25 Lego workshop resultater Opdatering af Responsibility matrix fra kontrakt Page 25

26 Lean møde April 2013 Agenda: Siemens intro Lego workshop London Array projektet Formål, midler og resultater Eksempel Esbjerg Havn Formål, midler og resultater Afrunding Page 26

27 Esbjerg Havn et andet eksempel, denne gang møllekomponenter i masonit Page 27

28 Page Restricted Siemens AG 20XX All rights reserved.

29 Esbjerg Havn - resultat Page Restricted Siemens AG 20XX All rights reserved.

30 Lean møde April 2013 Agenda: Siemens intro Lego workshop London Array projektet Formål, midler og resultater Eksempel Esbjerg Havn Formål, midler og resultater Afrunding Page 30

31 Ref: London Array firing on all cylinders 08/04/2013 The 630MW London Array offshore wind farm is now fully commissioned. The final Siemens 3.6MW turbine was powered up at the 175-unit site over the weekend and all machines are exporting power to the grid. Project director Richard Rigg said: This is the final major milestone of the construction phase and the culmination of more than two years offshore construction work, which began in March 2011 with the installation of the first foundation. Turbine installation at the Dong, Eon and Masdar-owned project was completed just before Christmas. The farm will be handed over to the operations and maintenance team when the last shallow array cable is buried this summer. Dong UK wind business country manager Benj Sykes said: As we now look to our pipeline of future projects we are determined to drive down the costs of our offshore wind farms to 100 per megawatt hour for projects we ll be sanctioning in What we have learned at London Array will help us achieve that. Eon UK chief executive Tony Cocker added: It s been a tough time for the team. The recent bad weather and north easterly winds have whipped up the waves, preventing access to the site, so this milestone is true reward for their hard work. London Array lies around 20km off the coasts of Kent and Essex on a site of 245 square kilometres. Phase 1 covers 90 square kilometres. A possible second phase could add enough capacity to bring the total to 870MW. Dong owns 50% of the facility, Eon has 30% and Masdar holds a 20% stake. Image: Turbine E13 was the final unit to be commissioned at the site (London Array) Page 31

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