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Mass Production of Offshore-Wind-Jackets requires new

Industrial Solutions

Nationale Staalbouwdag
October 2nd

G. Michels
Agenda
g

I
I. Market potentials

II. Supply
pp y chain concept
p

III. Supply chain concept partners SZAG / GSS

IV. Cost benefits of supply chain concept

g ber Kopf-/Fuzeile
V. Automatic welding of nodes

Firma, Abteilung
Datum
Folie 2
Salzgitter Supply Chain Concept
Offshore Winden Energie
g market p
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
Overrall-GW

g ber Kopf-/Fuzeile
20

15

Firma, Abteilung
10

Datum
0

Folie 3
2013/2014 2015/16 2017/18 2019/20
Salzgitter Supply Chain Concept
Offshore Winden Energie
g market p
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

200
Fundationss

g ber Kopf-/Fuzeile
150
Jacket F

Firma, Abteilung
100

50

Datum
0

Folie 4
2013/2014 2015/16 2017/18 2019/20 Source: Ramboll
Wind energy
gy market - p
portfolio of p
products Salzgitter
g AG

Activities Salzgitter AG
t bli h d
established in progress
Pod Plate ---

Tower Plate ---

Foundation Plate for Modular design


structure Monopiles principle consisting of
i d t i l manufactured
industrial f t d
pipes and nodes for
Jacket structures

Piles Plate
Salzgitter Supply Chain Concept
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 byy innovative solutions automated welding,
g,
cutting and NDT processes
Challenges
Fabrication of complex, heavy structures (K, X-nodes)
Guarantee of dimensional accuracy and reliability
Salzgitter Supply Chain Concept
Supply
pp y chain concept
p

Modular design principle


I Supplying
I. S l i off standardized
t d di d pipes
i
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
g strategies
g less
welding time
Delivering of already approved
components
Lower assembly time for fabricator
Welding form both sides improved
fatigue
g strength
g p possibility
y to reduce
wall thickness/welding time
Lower failure rate
Salzgitter Supply Chain Concept
Supply
pp y chain concept
p -p
partnership
p

Expertise:
Salzgitter - Cost efficient p
pipe
p manufacturer ((OD 123-1524mm, wt. upp to 50 mm))
group - high competitiveness against JCO pipes at last 30%
- High dimensional accuracy towards roundness / wall thickness variation
- High delivery reliability
ation

- Delivering of standardized and tailor made pipes from one source


- Manufacturing and delivering of X-/K-nodes produced by manual
coopera

and automatic welding (starting 2016)


- Manufacturing and delivering of node to leg/brace components
- Delivering of complete kit ready for jacket assembling

Expertise:
GS - Manufacturing of large diameter tubes and cones, OD > 1600, wt up 80 mm,
Staalwerken ..lifting capacity up to 80 t
- Manufacturing of structural steel members such as X-/K-nodes, node.to leg
..joints.and secondary steel
- Engineering,
E i i planning,
l i assembling,
bli coating
ti off llarge steel
t l structures
t t such
h as
..bridges, jackets and on-/offshore wind towers
- See water location in Netherland
Salzgitter Group
Group
p structure and key
y data FY 2013

Salzgitter AG Group
External Sales cons.: 9.2 billion Employees: 23,164
Internal Sales: 2.7 billion

Steel Tubes Trading Services Technology

Total Sales: Total Sales: Total Sales: Total Sales: Total Sales:
3.6 billion 1.7 billion 3.9 billion 1.2 billion 1.1 billion
External Sales: External Sales: External Sales: External Sales: External Sales:
2.4 billion 1.4 billion 3.9 billion 0.4 billion 1.1 billion
Employees: Employees: Employees: Employees: Employees:
7,091 5,431 2,142 3,600 4,738

Previous structure, new group structure as of January 1, 2014


englisch

9
All data about employees as per 31/12
Tubes Division
Large-diameter
g Pipes
p

EUROPIPE GmbH
Germany; shareholder: SZAG 50%, Dillinger
Httenwerke 50%

Longitudinal and spiral welded large-diameter DN = 24-60 (610 1524 mm)


pipes for transcontinental and underwater WT = 0,406 1,77 (8 50 mm)
pipelines
p p
In-house coating activities
World market leader (7% market share)
4 locations
l ti iin D
D, F
F, USA

2012 2013
Shipments kt 750 626
Sales m 879 709
Nr. 1 im Weltmarkt
Employees 31/12/ 1,288 1,224
englisch

10
Tubes Division
HFI-welded Pipes
p

Salzgitter Mannesmann Line Pipe GmbH


Germany; shareholder: SZAG 100%

HFI-welded medium line p pipes


p incl. DN = 4" 24 (114.3 610.0 mm)
plastic- and cement coatings WT = 0,126 1,00 (3.2 25.4 mm)
Oil field pipes Capacity: 180.000 Tonnen
Structural pipes
pipes, hollow sections Welding speed 86 ft/min (30 m/min)
7% market share in the EU27 Nr. 1 in world market
2 locations in Germany

2012 2013
Shipments kt 293 207
Sales m 325 221
Employees 31/12/ 504 510
englisch

11
Tubes Division
Large-diameter
g Pipes
p

Salzgitter Mannesmann Grorohr GmbH


Germany; shareholder: SZAG 100%

Spiral-welded
p large-diameter
g pipes
p p 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
Sales m 150 103
Nr. 1 im Weltmarkt
Employees 31/12/ 157 155
englisch

12
Cost saving aspects and welding objectives
Salzgitter Supply Chain Concept
Cost saving
g aspects
p

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. 3.0 million


million

Cost includes secondary steel


steel, piles
piles, transition piece
Salzgitter Supply Chain Concept
Potential assembly
y strategies
g

Optimized assembly strategies


Version A: application
pp of standardized p
pipes
p and p
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


Salzgitter Supply Chain Concept
Cost saving
gppotential

Cost saving of optimized assembly strategies


Version A (prefabricated nodes/standardized pipes) offers the highest saving potential of ca.
ca 20%
(600.000 /Jacket)
Reduction in overall production time by 20%-30%

100

3 M
n%

90
2.8 M
Cost / Jacket in

80 2.55 M
2.4 M
70

60

50

State of the art Version A Version B Version C


Salzgitter Supply Chain Concept
Cost saving
gppotential

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:
g -15%,, less components
p / already
y accepted
p assemblies
Crane- / scaffold cost : -22%, faster assembling only butt joints
Improved capacity utilization/higher throughput
fixed
fi d costs:
t -30%
30%
Reduced inspection cost: -35%
Salzgitter Supply Chain Concept
Cost saving
g potential
p

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
Salzgitter Supply Chain Concept
Challenge
g - dimensional accuracy
y

High accuracy needed


Weld distortion can cause dimensional imprecision's
imprecision s
Angle between brace stub and leg
Difference in neutral axis between brace stub and leg
Low
o accu
accuracy
acy causes:
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


Leverr arm
neutral axis of leg
Salzgitter Supply Chain Concept
Automatic welding
g of nodes

Salzgitter Mannesmann Research in Duisburg


has performed a feasibility study (in
cooperation with partners)

Manufacturing
M f t i off 4 demonstrator
d t t assemblies
bli
Brace-stub: S355, wt 20 mm, outside diameter
610 mm (24``)
Leg: S355
S355, wt 40 mm,
mm outside diameter 1118 mm
(44``)

1118
Automatic welding of K-node
K node by means of
manipulator welding continuously in position PA
Salzgitter Supply Chain Concept
Automatic welding
g 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
450
0.1
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


Salzgitter Supply Chain Concept
Automatic welding
g of nodes

Potential of automatic welding


Comparison
C i off manuall and
d automatically
t ti ll welded
ld d nodes
d revealed
l d
Reduction in welding time by >70%
Reduction in cost by ca. 30% (including investment into welding/handling equipment)
Salzgitter Supply Chain Concept
Accessibility
y test

CAD study of different nodes concerning accessibility during automatic welding


Key
K ffactor
t ffor 3
3-leg
l jackets
j k t
Nodes with small gaps (>100mm) between the brace stubs can be automatically welded

610

min. 1400

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