Mass Production of Offshore-Wind-Jackets requires … · and automatic welding (starting 2016) - Manufacturing and delivering of node to leg/brace components cooper - Delivering of

Mass Production of Offshore-Wind-Jackets requires new Industrial Solutions

Nationale StaalbouwdagOctober 2nd

G. Michels

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

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• 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)

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• 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

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Source: Ramboll

Wind energy market - portfolio of products Salzgitter AGgy p p g

Activities Salzgitter AG

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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

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

Supply chain conceptSalzgitter Supply Chain Concept

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• 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

Supply chain concept - partnershipSalzgitter Supply Chain Concept

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Salzgitter Expertise:- Cost efficient pipe manufacturer (OD 123-1524mm, wt. up to 50 mm)

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- 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

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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

Group structure and key data FY 2013Salzgitter Group

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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

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All data about employees as per 31/12engl

isch

Large-diameter PipesTubes Division

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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

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Nr. 1 im WeltmarktSales €m 879 709

Employees 31/12/ 1,288 1,224

engl

isch

HFI-welded PipesTubes Division

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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

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Sales €m 325 221

Employees 31/12/ 504 510

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isch

Large-diameter PipesTubes Division

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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

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Nr. 1 im WeltmarktSales €m 150 103

Employees 31/12/ 157 155

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isch

Cost saving aspects and welding objectivesCost saving aspects and welding objectives

Cost saving aspectsSalzgitter Supply Chain Concept

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• 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

Potential assembly strategiesSalzgitter Supply Chain Concept

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• 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

Cost saving potential Salzgitter Supply Chain Concept

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• 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%

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Version A Version B Version CState of the art

Cost saving potentialSalzgitter Supply Chain Concept

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• 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%

Cost saving potentialSalzgitter Supply Chain Concept

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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

Automatic welding of nodes

Challenge - dimensional accuracy Salzgitter Supply Chain Concept

• High accuracy needed • Weld distortion can cause dimensional imprecision's

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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

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neutral axis of leg

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Automatic welding of nodes Salzgitter Supply Chain Concept

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• 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

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Automatic welding of K node by means of manipulator welding continuously in position PA

Automatic welding of nodes Salzgitter Supply Chain Concept

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• 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

Automatic welding of nodes Salzgitter Supply Chain Concept

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• 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)

Accessibility testSalzgitter Supply Chain Concept

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• 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