Mass Production of Offshore-Wind-Jackets requires new Industrial Solutions Nationale Staalbouwdag October 2 nd G. Michels
Agenda I. Market potentials II. Supply chain concept III. Supply chain concept partners SZAG / GSS IV. Cost benefits of supply chain concept V. Automatic welding of nodes Folie 2 g über Kopf-/Fußzeile Datum Firma, Abteilung
Offshore Winden Energie market potentials Assessment of offshore wind market situation 2014-2020 (within EU) 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 30 25 Over rall-gw 20 15 10 5 g über Kopf-/Fußzeile m Firma, Abteilung 0 2013/2014 2015/16 2017/18 2019/20 Datu Folie 3
Offshore Winden Energie market potentials Assessment of offshore wind market situation 2014-2020 (within EU) 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 250 Jacket Fundations 200 150 100 50 g über Kopf-/Fußzeile m Firma, Abteilung Datu 0 2013/2014 2015/16 2017/18 2019/20 Source: Ramboll Folie 4
Wind energy market - portfolio of products Salzgitter AG Activities Salzgitter AG Pod established in progress Plate --- Tower Plate --- Foundation structure Piles Plate for Monopiles Plate Modular design principle consisting of industrial i manufactured pipes and nodes for Jacket structures
Introduction High production costs / low production quantities put jackets at a competitive disadvantage 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, cutting and NDT processes Challenges Fabrication of complex, heavy structures (K, X-nodes) Guarantee of dimensional accuracy and reliability
Supply chain concept Modular design principle I. Supplying of standardized di d 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 welding time Delivering of already approved components Lower assembly time for fabricator Welding form both sides improved fatigue strength possibility to reduce wall thickness/welding time Lower failure rate
Supply chain concept - partnership p Salzgitter group Expertise: - Cost efficient pipe pp manufacturer (OD 123-1524mm, wt. up to 50 mm) - high competitiveness against JCO pipes at last 30% - High dimensional accuracy towards roundness / wall thickness variation - High delivery reliability coopera ation - Delivering of standardized and tailor made pipes from one source - Manufacturing and delivering of X-/K-nodes produced by manual and automatic welding (starting 2016) - Manufacturing and delivering of node to leg/brace components - Delivering of complete kit ready for jacket assembling GS Staalwerken Expertise: - Manufacturing 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 - Engineering, i planning, assembling, coating of large steel structures t such as..bridges, jackets and on-/offshore wind towers - See water location in Netherland
Salzgitter Group Group structure and key data FY 2013 Salzgitter AG Group External Sales cons.: 9.2 billion Internal Sales: 2.7 billion Employees: 23,164 Steel Tubes Trading Services Technology Total Sales: 3.6 billion Total Sales: Total Sales: Total Sales: Total Sales: 1.7 billion 3.9 billion 1.2 billion 1.1 billion External Sales: 2.4 billion External Sales: 1.4 billion External Sales: 3.9 billion External Sales: 0.4 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 englisch All data about employees as per 31/12 9
Tubes Division Large-diameter Pipes EUROPIPE GmbH Germany; shareholder: SZAG 50%, Dillinger Hüttenwerke 50% Longitudinal and spiral welded large-diameter pipes for transcontinental and underwater pipelines pp In-house coating activities World market leader (7% market share) 4 locations in D, F, USA DN = 24-60 (610 1524 mm) WT = 0,406 1,77 (8 50 mm) 2012 2013 Shipments kt 750 626 englisch Sales m 879 709 Employees 31/12/ 1,288 1,224 Nr. 1 im Weltmarkt 10
Tubes Division HFI-welded Pipes p Salzgitter Mannesmann Line Pipe GmbH Germany; shareholder: SZAG 100% DN = 4½" 24 (114.3 610.0 mm) HFI-welded medium line p pipes p incl. plastic- and cement coatings Oil field pipes Structural pipes pipes, hollow sections 7% market share in the EU27 2 locations in Germany englisch Sales Employees Capacity: 180.000 Tonnen Welding speed 86 ft/min (30 m/min) Nr. 1 in world market 2012 2013 kt 293 207 m 325 221 31/12/ 504 510 11 Shipments WT = 0,126 1,00 (3.2 25.4 mm)
Tubes Division Large-diameter Pipes Salzgitter Mannesmann Großrohr GmbH Germany; shareholder: SZAG 100% Spiral-welded large-diameter pipes pp Diameter: 610 1,676 mm (24-66 ) made of hot-rolled coil Wall thickness: 9 25.4 mm (X70) Pipe length: 9 18.3 m Top-modern plants and processes Steel Grade: Grade B X80 Technology leader Mill capacity: up to 220,000 t/a Logistical advantage due to the supply of hot-rolled coil by the Salzgitter HRC mill 2012 2013 Shipments kt 139 90 englisch Sales m 150 103 Employees 31/12/ 157 155 Nr. 1 im Weltmarkt 12
Cost saving aspects and welding objectives
Cost saving aspects Structure of costs following state of the art manufacturing and assembly strategies Application 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 ca. 3 ca. million 3.0 million Cost includes secondary steel, piles, transition piece
Potential assembly strategies Optimized assembly strategies Version A: application of standardized pipes p and pre-fabricated X-,K-nodes 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 State of the art Version A Version B Version C
Cost saving potential Cost saving of optimized assembly strategies 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% 100 Jacket in % Cost / 90 80 70 60 3 M 2.4 M 2.8 M 2.55 M 50 State of the artversion A Version B Version C
Cost saving potential 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 assemblies Crane- / scaffold cost : Improved capacity utilization/higher throughput fixed costs: -30% Reduced inspection cost: -35% -22%, faster assembling only butt joints
Cost saving potential 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 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 cost
Automatic welding of nodes
Challenge - dimensional accuracy High accuracy needed Weld distortion can cause dimensional imprecision's s Angle between brace stub and leg Difference in neutral axis between brace stub and leg Low accuracy acy causes: Higher final assembly costs and time or Impossibility of assembly Impact on static and fatigue performance due to additional bending moments Main goal: high dimensional accuracy neutral axis of brace neutral axis of leg Lever arm
Automatic welding of nodes Salzgitter Mannesmann Research in Duisburg has performed a feasibility study (in cooperation with partners) Manufacturing of f4d demonstrator t assemblies Brace-stub: S355, wt 20 mm, outside diameter 610 mm (24``) Leg: S355, wt 40 mm, outside diameter 1118 mm (44``) Automatic welding of K-node by means of manipulator welding continuously in position PA 1118
Automatic welding of nodes Non destructive tests Ultrasonic tests in accordance to DNV OS F101 and metallographic tests reveal no abnormities 3D measurement of dimensional accuracy 45 ±0 ±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
Automatic welding of nodes Potential of automatic welding Comparison of manual and automatically ti welded d nodes revealed Reduction in welding time by >70% Reduction in cost by ca. 30% (including investment into welding/handling equipment)
Accessibility test CAD study of different nodes concerning accessibility during automatic welding Key factor for 3-leg jackets Nodes with small gaps (>100mm) between the brace stubs can be automatically welded Ø610 min. Ø1400