Focus on Wind Energy Technology Onshore

Transcription

1 Focus on Wind Energy Technology Onshore SIAG Schaaf Industrie AG Burgweg Dernbach, Germany Phone: +49 (0) / Fax: +49 (0) / [email protected] Web: EXPERIENCE IN STEEL EXPERIENCE IN STEEL

2 Innovations in line with the market Steel is the core competence of SIAG Group s four business unit. In a total of 13 locations worldwide, over 2,000 employees work each day on producing top notch quality for our customers. Under the leadership of founder Rüdiger Schaaf, SIAG has developed over the last 15 years into a leading, innovative supplier for the energy generation industry. Reliable delivery, innovation, constant process improvement and centralized organisation have all contributed to making SIAG the first choice for its clients. We are therefore constantly committed to meeting ever higher benchmarks. SIAG combines the benefits of an owner-led industrial firm and the effectiveness of a group. Our flat management structure enables us to respond swiftly to new developments in the market and customer requirements. The latest production methods and state of the art machinery, together with a well-organised supply chain, ensure top performance of our products. Our business units meet all the requirements for development and growth, as well as securing and creating jobs and training positions. Our clients benefit from our long-standing expertise in wind energy technology onshore and complex structural steel engineering and, in addition to this, they gain from the combined know-how of the whole group. To us, our customers are partners in the joint design and implementation of projects. We stand by our word, and we are happy to demonstrate our capabilities. Welcome to SIAG! SIAG Business Units Wind Energy Technology Onshore Maritime Systems / Offshore Environmental and Energy Technology Mechanical Engineering 2 3

3 Customer Proximity SIAG s continuous pursuit of our strategy for growth has allowed us over the past few years to become an international group and the market leader among onshore wind energy technology suppliers. Our production sites for tubular steel towers are currently located in Germany, the Czech Republic, France, Egypt and the United States. By structuring our organization in this way, we are able to ensure maximum customer proximity while reducing logistics costs to the minimum. Our step into offshore technology, which was marked by the setting up of Europe s largest offshore production site in Emden, Germany, underpins our commitment to strengthening our strategic position as market leader. Loading of a complete tower segment Tower storage site at SIAG France, Le Creusot, France Our centralized structure helps us to ensure consistent quality and delivery reliability and to develop highly efficient project solutions for our customers at our various locations. We work together with our clients to develop optimum solutions and to adapt products to meet project specifications. To SIAG, prototyping is an important milestone within the development process. Experienced engineers support our customers right through the process from project start up to implementation. Close customer relationships are a top priority for us and a prerequisite for developing projects in line with customers requirements. Constant project control allows us to guarantee that customer orders are correctly handled and that we can develop solutions early on in the event of problems. Customer audit at SIAG Aerisyn LLC, Chattanooga, USA 4 5

4 Tower and Component Construction Holistic solutions all from one single source We are global suppliers of towers, including built-in parts and electrical installations, which comply with all internationally applicable standards and meet our customers specifications. Conservation booth Top class corrosion protection SIAG s products set the benchmark in terms of workmanship and quality. Welding equipment Welding is a key technology in the production process at our operations around the world, we use the very latest in welding methods. Our integrated quality system ensures that our clients get the same high quality from all SIAG factories, wherever they are in the world. We work in close cooperation with proven machine manufacturers, thus ensuring the best possible quality at any point in time. Our technical, personnel and production capacities allow us to produce both units in series and individual products of all dimensions. All group divisions are centralized at our Dernbach headquarters, making sure our clients always have one single go-to person. Onshore segments: Length: up to 32 m Diameter: up to 6 m Weight: up to 100 t Onshore towers: Height: m Steel thickness: 8-70 mm Weight: up to 320 t Annual output: 900 Tubular steel tower construction sites: Leipzig, Germany Finsterwalde, Germany Le Creusot, France Chrudim, Czech Republic Ain Sokhna, Egypt Chattanooga (TN), USA At our production sites we produce tubular towers up to a height of 125 m, a diameter of 6 m and 100 tons in weight. With our effi cient submerged arc welding machines for multiple-wire technology we have the most advanced manufacturing facilities in Europe. Towers are shot-blasted and coated according to customer specifications and to meet first-class corrosion protection requirements. Quality control is the basis of our work and thus an integral part of high quality conservation. UV, ultra-sonic and surface crack examination ensure the quality of our towers and optimise their service life, corrosion resistance and economy. Constant high quality is our claim and we meet it every day. This is true even for routine work, including tower welding at our Leipzig works. 6 7

5 3D illustration of a SIAG main frame Product Range Completion The addition of the Mechanical Engineering Unit has allowed us to expand the range of our wind energy technology products to include main frames, generator frames, and all of the steel and aluminium components required for tubular tower construction, e.g., platforms, handrails, cable ducts, stairs, and other add-on parts. This makes SIAG a one-stop shop for all of the steel and aluminium parts needed for wind energy plants. Main frame for a 2.5 MW eviag plant In 2010, our annual main frame and generator frame production capacity is 1,000 units, thus making us a leading manufacturer of mechanically-processed, dynamically loaded steel and welding constructions. We can apply any type of paint including paints made to meet offshore criteria using our conservation plant technology. All mechanically processed surfaces, threads, and drill holes have effective corrosion protection. Main frame production SIAG CZ s.r.o. at Chrudim, Czech Republic All plates are shot-blasted to SA 2.5 and cut using sophisticated flame cutters, including weld seam preparation. Plate restamping is used to ensure the traceability of each component. We only use welding equipment made by trusted manufacturers so as to ensure quality in each phase. Non-destructive testing, continuously performed by an external approved body, is a matter of course to us. Our place in the industry speaks to the quality of our work: we serve every established wind energy plant manufacturer. Our experience plays a particularly critical role in the prototyping process, and we bring our expertise to our customers already in the planning phase. Our purchasing department has access to all the suppliers of the plates that are required for main frame and generator frame production. We obtain the best possible price while ensuring supplier quality for the benefit of our customers. On request, our products are delivered customs-free and carriage paid across Europe to our clients assembly sites. Top priority is placed on maximum delivery reliability. SIAG Maschinenbau GmbH supplies machine components to suit dynamic loads including, among other items, machine bodies, machine frames, press frames, chassis, and mechanical engineering components for the mining industry. SIAG has a long track record in this sector also. The first main frames were manufactured in Chrudim (CZ) in Before that, the factory s activities were focused on the production of equipment able to handle high dynamic loads as well as mining equipment (i.e. excavator arms weighing up to 200 tons). We hold manufacturer s certification for welding steel constructions to DIN part 7, class E (dynamic range), and we are certified by TÜV to EN ISO

6 Top Notch Quality By continuously checking and monitoring the production processes, we ensure our clients get top quality wherever they are in the world. Customer satisfaction Research and Development Development and expansion Our quality management system influences our entire The onshore wind energy industry can look back on many Our market leadership has been consistently oriented to- production process. Examinations and measurements are years of experience, especially in Germany. Further expan- wards customer benefit, and we have identified the oppor- made and constantly documented by our QM engineers and sion into new areas is often not possible due to lack of space tunities created by globalisation. With immediate effect we an independent organisation. The results are interpreted by and high population densities, and a frequent consequence will supply the offshore wind energy market and make our both internal and external personnel. Every tower under- of this is the need to repower existing plant. Increased plant contribution to repowering. goes final inspection before shipping which may be to anywhere in the world. Our service continues even after the towers have been delivered. Our production sites are certified by several approved inspection bodies. At each subsidiary, local quality managers work with specialist engineers and quality control staff to apply the quality management system, and to control and monitor the production processes. Measurement of flatness and tilt using Easy- LASER equipment Constant checking and monitoring takes place throughout the process chain. Starting with the receipt of incoming goods right through to order picking and product delivery, we verify and document product quality using advanced, controlled measuring instruments. Any faults are dealt with and remedied in line with the directives defined by the quality management documents. Checks and documentation ensure that the quality of the final product is in line with specifications and avoids creating problems at the place of installation. This saves on downtime costs at the construction site, as well as costs arising from the need to carry out service work resulting from poor quality. Customers receive a finished product which meets their specification, including all the documents they need. We strive to continuously improve our quality management system and therefore we implement any changes which arise from legal and other directives or as a result of customers requirements as swiftly as possible. We are also committed to enhancing our management system with a view to environmental and workplace health sizes and thus higher loads require adaptation of the tower structures on and much higher demands on the quality of the materials used and the welded connections. The focus for SIAG is therefore on continuous research and further development of products and process engineering across sites. Work on research projects jointly with renowned research centres and institutes, universities and industrial partners is an important part of this strategy. At all SIAG Group sites, project teams are working on the further development and improvement of production methods, with welding technology playing a key role in the production process. In this way we guarantee our customers innovative project solutions for all framework conditions. Together with the institutes for steel construction and materials science at Leibnitz University in Hannover, and with Kjellberg Finsterwalde Schweißtechnik und Verschleißschutzsysteme GmbH, SIAG is working on the OPTIWELD research project. This project, which is supported by the Federal Ministry for Environment and Nature Protection (BMU), seeks to develop innovative hybrid welding processes which combine plasma jet and arc, protected by welding powder. Setting up our production sites in Europe, North Africa and North America was an important aim for SIAG and has been successfully implemented. Ain Sokhna in Egypt, which was completed and came on stream in November 2009, is our biggest tubular tower plant. This means a reduction in freight costs for our customers on the African continent and in the Mediterranean region. We are facing up to the challenge of a future-oriented market. Headquarters of SIAG in Dernbach, Germany and safety and to integrate these issues as major management components. In order to optimize and harmonize quality management, this function has become centralized within the SIAG Group. Prospects 10 11