Salzgitter Industrial Supply Chain Concept for Offshore Wind Jackets

Transcription

1 Salzgitter Industrial Supply Chain Concept for Offshore Wind Jackets Cost Reduction Potentials in the Fabrication of Offshore Wind Jackets by Standardized Pipes and Pre-fabricated Components

2 The facts Concept: Usage of standardized tubes and automated welded components X-Joint Brace Leg K-Joint Pre-fabricated assembly jacket kit by Salzgitter AG Final assembly by fabricator Premises, objectives, results A high labor cost content and low production quantities are putting jackets at a competitive disadvantage compared to monopiles/-xl. In the interest of a sustainable development of wind farms, an overall cost reduction of 30 to 40 percent is required. Here, foundation structures play a key role. The only way for the jacket to become competitive is via an industrial fabrication process. Salzgitter AG has developed an innovative fabrication strategy, based on the Salzgitter Mannesmann product portfolio and pre-fabricated nodes. Salzgitter AG has developed an advanced simulation program to evaluate cost improvements of various offshore wind jackets to identify cost saving potentials by utilization of its supply chain concept. Only by the use of an industrial fabrication process the competiveness of the jacket compared to the monopile/xxl will be reached. Results of full-scale welding trials have proven that automatic welding of jacket nodes is possible and superior in terms of welding time, welding cost and dimensional accuracy. 2

3 Cost reduction potentials Cost calculation for manufacturing of 3-leg jacket 100% Logistics/ Documentation -20 % Cost reduction ca. -20 % Scaffold/Cranes Coating Welding /NDT Material 0% Optimized assembly strategy State-of-the-art Version A Version B High wall thickness Low wall thickness Application of tailor-made pipes. No pre-fabrication of components. Usage of beveled pipes, beveling for point to point joints and butt joints. Assembling by butt and tubular joints combined by costly handling effort. Application of standardized pipes and pre-fabricated X-, K-nodes. Reduced assembly time due to no tubular joints and reduced number of components. Application of standardized pipes, long braces and pre-fabricated K-nodes. Less assembly time due to reduced butt-, tubular joints and number of components, but slightly higher steel tonnage. Further advantages of Salzgitter industrial supply chain concept Pre-fabrication of nodes enables welding to be executed from both sides (inside/outside) with improvement of fatigue behavior, which enables a reduction in wall thickness with the consequence of lower material and welding costs Lower investment cost for jacket fabricators due to pre-fabricated components Higher capacity utilization in the production with an additional cost saving for the fabricator High reproducibility by automated welding and lower production risk Delivering of certified components Conclusion Fabrication costs of jackets can be reduced by approx. 20% to 30 % by means of different assembly strategies. This implies a reduced number of pipes to be welded and assembled by the fabricator. A pre-fabrication of components supplied by Salzgitter allows a cost optimized industrial jacket fabrication. 3

4 Pre-fabrication of nodes Automatic welding of nodes for offshore wind jackets Goal Identification of technical feasibility and cost saving potential by full-scale welding trials carried out by Salzgitter Mannesmann Forschung in cooperation with partners. Approach Automatic welding of full-scale K-nodes by means of robotic devices and mechanical manipulator. The manipulator allows 3D movement of the node and welding to be carried out continuously in 1G (optimal) position. Determination of advantages in welding cost and time by comparison with manual welding approach. Executing of destructive and non-destructive tests in accordance to DNV recommendations for offshore wind structures, including: 100% Ultrasonic tests of the weld Charpy V-notch test of weld metal and heat affected zone, test temperature: -40 C Hardness test Determination of dimensional accuracy by 3D laser system Technical details Base materials to be joined: Brace-stub: S355, wall thickness 0.79 (20 mm), outside diameter 24 (610 mm) Leg: S355, wall thickness 1.57 (40 mm), outside diameter 44 (1,118 mm) Angle between brace-stub and leg defined to 45 Welding technique: Gas metal arc welding process (GMAW) Heat input for filling passes: ca. 1.5 kj/mm Deposition rate: >10 kg/h Welding wire: CARBOFIL 1a, EN 440: G4Si1, DNV approval up to -40 C Root pass was manually welded, hot and filling passes automatically welded Seam preparation: 3/4 HV joints, 1/4 fillet weld Welding robot Manipulator 4

5 Pre-fabrication of nodes Results Destructive and non destructive test Hardness and Charpy impact energy values fulfill the requirements of DNV considerably Higher safety for fatigue requirements Metallographic and 100 % ultrasonic tests reveal no abnormities 100% automatic ultrasonic testing seems to be possible 3D measurement of dimensional accuracy for all demonstrator components 45 ± 0.1 angle between brace-stub and leg was achieved Deviations in axes trough centre of gravity between brace stub and leg is lower 0.02 mm Potential of automatic welding CAD studies demonstrate that a broad range of node geometries can be automatically welded without accessibility problems. Comparison of manually and automatically welded nodes shows a reduction in welding time by >50 % and a reduction in welding cost by ca. 30 %, including invest into welding/handling equipment

6 Achieving more together The companies listed below are part of the Tubes Division of Salzgitter AG and possess proven expertise in the offshore wind energy segment. In future we will offer specialized complete solutions from a single source: together we can supply all the relevant components for the industrial fabrication of foundation structures. Together with the emerging market for wind energy, our research centers develop solutions for tomorrow s technology today. Salzgitter Mannesmann Forschung GmbH Automated joint production Salzgitter Mannesmann Forschung GmbH is currently developing innovative automated strategies for the production of welded joints within the framework of a concept for industrial jacket fabrication using high-performance cutting and welding processes and state-of-the-art materials handling systems. The objective is to achieve sustainable improvement in both welding productivity and weld quality through an efficient combination of robots, sensor technology and manipulators. In addition, the upstream production of joint structures by automated welding helps reduce both the defect rate and welding work in jacket assembly at the dockyard. Salzgitter Mannesmann Line Pipe GmbH HFI-welded steel pipe Salzgitter Mannesmann Line Pipe GmbH is a leading manufacturer of longitudinally HFI-welded steel pipes, which have been used successfully for many decades in the most demanding projects around the globe. HFI-welded pipes are used for oil and gas pipelines, for water supply lines and sewage systems, in machinery and plant construction, as oilfield tubulars, district heat pipe and structural tubes for offshore wind jackets with wall thicknesses of up to 25.4 mm. Salzgitter Mannesmann Großrohr GmbH Spiral-weld large-diameter pipe Salzgitter Mannesmann Großrohr GmbH sets standards worldwide for the manufacture of spiral-weld pipe. And not just for the oil and gas industry, but in the same quality for offshore wind jackets as well. EUROPIPE GmbH Longitudinally submerged-arc welded and spiral-weld steel pipe The EUROPIPE Group is a leading manufacturer of large-diameter pipe for extreme service conditions, from permafrost temperatures in arctic regions to the searing heat of deserts, or immense pressures in deep-sea environments. Large diameter pipes from EUROPIPE GmbH are used for gas, oil and water pipelines and, particularly, also for offshore wind jackets

7 Salzgitter product portfolio for offshore wind jackets Salzgitter Mannesmann Line Pipe The production programme HFI (high-frequency inductive) welded steel pipes according to national and international standards and individual customer specifications Outside diameter: mm to mm (4.5 to 24 ) Pipe wall thickness: 3.2 mm to 25.4 mm (0.126 to 1 ) Length: Up to 18 m Material grades: S235 S460 We meet the highest requirements and tolerances of straightness, ovality and diameter accuracy. For use in offshore wind energy Outside diameters from mm (14 ) to a maximum pipe wall thickness of 25.4 mm (1 ) in S355 All dimensions available in S355J2H according to EN10219, EN10210 and S355G13+N according to EN10225 Short delivery through the stocking of coils and pipes KOWIND research project Together with specialists, we are developing a new type of technology to protect offshore wind farms against corrosion using a PA12 polymer and a thermosetting post-factory coating system. Key benefits include: Extended life of steel constructions Exceptional impact resistance and toughness, even at low temperatures Excellent resistance to stress cracking Enhanced corrosion and UV protection Significant reduction in maintenance costs Material savings with fewer resources needed Salzgitter Mannesmann Großrohr The production programme Helically welded steel pipes (HTS technology) according to national and international standards and in line with individual customer requirements. Outside diameter: mm up to 1,676 mm (24 up to 66 ) Pipe wall thickness: 8 mm up to 25.4 mm (0.315 up to 1 ) Length: up to 18.3 m Steel grades: up to L555MB or X80M pursuant to API 5L / ISO 3183 Any diameter between 610 and 1,676 mm can be seamlessly produced. We meet the highest requirements and tolerances of straightness, ovality, and diameter accuracy. Corrosion protection To protect against corrosion and mechanical damage, different coatings or coating systems can be applied depending on the intended use and requirements, such as 3-layer outer coating (PE, PP) or Fusion Bonded Epoxy (FBE). EUROPIPE The production programme Welded, large-diameter pipes according to national and international standards as well as project-related customer specifications. Longitudinally submerged-arc welded: Outside diameter: 508 mm 1,524 mm (20 bis 60 ) Wall thickness: 7 mm 50 mm ( ) Helically submerged-arc welded: Outside diameter: 610 mm 1,422 mm (24 bis 56 ) Wall thickness: 8 mm 20 mm ( ) Lengths: up to 18.3 m (LSAW) or 24.4 m (HSAW) Material qualities High-strength pipe: X80 to X100 HIC-resistant pipe: all grades up to X70 Collapse-resistant pipe: optimisation of geometry and grade Arctic grade pipes: up to X80 Corrosion protection Coating 1-layer technology: Fusion Bonded Epoxy (FBE) 3-layer technology: Polyolefins such as Polyethylene (PE) and Polypropylene (PP) Other innovative systems Research and development Our close cooperation with a global network of partners from research institutes (e.g. Salzgitter Mannesmann Forschung), suppliers, universities, the industry and our customers helps to consolidate our technological leadership for the benefit of everyone. Process development We improve our production and quality by constantly enhancing our processes and technology used in production, inspection and information flows. 7

8 Salzgitter AG Eisenhüttenstraße Salzgitter Germany Salzgitter AG, Offshore Wind Georg Michels Phone: SZ / Cost Reduction Potentials / E / 500 / heselsvomberg.de