Renewable Energy Session - Global Manufacturing · PDF fileWhy Does the UK need Renewable...

Renewable Energy Sessionsponsored by

Chaired by: Brendan Moffett, Marketing Sheffield

© Siemens 2012. All rights reserved.

A route to growing UK

Supply Chains in Offshore Windpower ?

UK Industrial Strategy

Juergen Maier, Managing Director – Siemens UK Industry Sectorr


Agenda


UK Offshore Windpower Supply Chain Opportunities & Challenges

Windpower and Steel

Summing Up

Key principles of UK (BIS) Industrial Strategy

4

Long-term, whole of Government approach

Partnership with business at its heart

Building confidence and give greater certainty

Covering sectors, technologies and innovation , R&D,access to finance, procurement and skills

Strategic partnerships – the sectors

5

Early 2013

Aerospace

Nuclear

Offshore wind

Oil and Gas

Automotive

InformationEconomy

Education

Construction

ProfessionalBusiness Services

Spring 2013 Summer 2013

Agri-tech

Life Science Strategy Dec 2011

Life Science Strategy one-year-on Dec 2012

UK Catapults accelerating R&D/Innovation to commercialisation

6

High value manufacturing

Offshore renewable energy

Cell therapies

Satellite applications

Connected digital economy

Future cities

Transport systems


Agenda



Windpower and Steel

Summing Up


Why Does the UK need Renewable Energy?

SUSTAINABILITYClimate Change

COST (?)Ofgem – Oct 2009 (2020 prices to customers rise least in scenarios with most renewables)

GREEN JOBS

ENERGY SECURITY


Lynn / Inner Dowsing, UK

→ 54 x SWT-3.6-107 (2008)

Rhyl Flats, UK→ 25 x SWT-3.6-107 (2009)

Burbo Banks, UK→ 25 x SWT-3.6-107 (2007)

Frederikshavn, DK→ 1 x SWT-2.3-82 (2003)

Rødsand/Nysted, DK→ 72 x SWT-2.3-82 (2003)

Vindeby, DK→ 11 x 0.45 MW (1991)

Middelgrunden, DK→ 20 x SWT-2.0-76 (2000)

Samsø, DK→ 10 x SWT-2.3-82 (2002)

Rønland, DK→ 4 x SWT-2.3-93 (2002)

Horns Rev II, DK→ 91 x SWT-2.3-92 (2009)

Gunfleet Sands, UK→ 48 x SWT-3.6-107 (2009)

Hywind, NO→ 1 x SWT-2.3-82 (2009)

Lillgrund, SE→ 48 x SWT-2.3-93 (2007)

Rødsand II, DK→ 90 x SWT-2.3-93 (2010)

Pori, FIN→ 1 x SWT-2.3-101 (2010)

Source: SWP

Baltic I, DE→ 21 x SWT-2.3-93 (2010)

Walney I & II, UK→ 102 x SWT-3.6-107/120 (2012)

Greater Gabbard, UK → 140 x SWT-3.6-107

Sheringham Shoal, UK→ 88 x SWT-3.6-107

SIEMENS is Market leader in offshorewith 2.0 GW installed


Borkum Riffgat, DE→ 30 x SWT-3.6-107

London Array, UK→ 175 SWT-3.6-120

Lincs, UK→ 69 x SWT-3.6-120

Gwynt Y Mor, UK→ 160 x SWT-3.6-107

Baltic 2, DE→ 80 x SWT-3.6-120

Anholt, DK→ 111 x SWT-3.6-120

Dan-Tysk, DE→ 80 x SWT-3.6-107

Borkum Riffgrund 1, DE→ 77 x SWT-3.6-120

Source: SWP

Rudong Intertidal, CHN → 21 x SWT-2.3-101

West of Duddon Sands, UK→ 108 x SWT-3.6-120

Teesside, UK→ 27 x SWT-2.3-93

Amrumbank West, DE→ 80 x SWT-3.6-120

Many projects in execution phase, also outside Europe…


UK Round 3

40GW to connect by 2030


Agenda



Windpower and Steel

Summing Up

April 2011 Copyright Siemens all rights reservedSteve Aughton

Elements of offshore wind Supply Chain

Medium Voltage Array switch 1%

High Voltage Marine

export cable 5%

Onshoreexport cable 5%

AC Substation&

ReactiveCompensation 5%

HVDC ConverterStations

Collector Substation 5%

Wind Turbinec45% of Capex

Capex % is typical and for guidance only

Foundation20%

Array cables7%


The coming 154 m rotor for the 6.0 MW is a large piece of equipment …Here with an Airbus A380


6MW DD


Supply Chain Challenges


Offshore Supply Chain ChallengesKey Challenges for the Offshore Supply Chain Manager

Offshore turbines and their components continue to grow in size and weight. How will I physically handle these big and heavy components?

Customer demand is always changing. And so are technology designs. How will I keep the offshore facility flexible - being able to scale up or

down as needed - while keeping the investments low?

The pressure to reduce costs is immense. How will I provide components at lowest cost and how will I increase cost

efficiency in pre-assembly and installation?

Reliability of our offshore turbines and equipment is one of SIEMENS' major success factors. How will I answer all questions above and keep our quality at the required

level?


Can our Advanced Manufacturing Catapults help?

Nuclear AMRCRotherham

AMRCRotherham

April 2011 Copyright Siemens all rights reservedSteve Aughton © Siemens 2012. All rights reserved.

Agenda



Windpower and Steel

Summing Up


Scope – for Steel in Offshore Wind

Planned capacity not yet built = 40 GW

Typically 300t/MW (Germanische Lloyd

estimate)

= 12 million tonnes of steel

This is just the UK’s planned development.

Germany, France, Norway etc are also

developing big offshore projects (approximately

doubling the amount of steel)

Germanische Lloyd project a European volume

of 1.5 Mtpa, mostly in plate, lasting till

approximately 2025


The Manufacturing Operational Challenge:

With the largest machines today around 6MW

40 GW is 6500 turbines

6,500 sets of jackets or piles

The Engineering Challenge:

Every turbine represents:

>300t of rotating machinery

120m in the air

In 50-60m of water

Up to 300km from the shore

Scope – for Steel in Offshore Wind

Images: 6 MW DD prototype in Denmark (onshore testbed, operational since 2011)


Monopile

– simple rolled tube foundation piled into seabed

– can be up to 50m 5m diameter

– up to 600-700 tonnes

“In 50-60m of Water”


Top unit

2 main castings

- Rotor hub (shown)

- Nacelle bedplate

SG iron usually

6 MW unit rotor hub will be 60t+ cast weight


Infrastructure – Offshore Substations

Several thousand tonnes topside

Large Steel Jacket required

Floating structure

Already in Round 2


!

Infrastructure – Offshore Substations

Round 3 subs will be even bigger (or multiple units, so more steel either way)

Topsides may be ~10-12 kt- Same height as the Tower of Pisa- Footprint of a football pitch- Weight of the Eiffel tower

So: very large jackets required…as big as anything in Oil and Gas


Summary

Massive opportunity for UK Supply Chains

Around 12 million tonnes of steel yet to be ordered for UK Offshore wind farms

Most of it in offshore structures and towers (ie plate), that all need fabricating and machining.

The last big chance for large scale plate & fabrication in the UK?

- Right location

- Right technical pedigree (North Sea Oil)

- Right Skills, Innovation and levels of investment?


6 MW DD nacelle in delivery to testbed, June 2011

THANKS FOR LISTENING

Renewable Energy Sessionsponsored by

Case Study

David OswinOffshore & Renewables Sales

Manager

MTL Group Limited

Journey Into Renewables

Who Is MTL Group ?

MTL Group is a contract engineering & manufacturing company operating in

the defence, construction, rail & renewable energy sectors

Established: 1995

Based: Rotherham, UK

Turnover: £50m

Employees: 330

Manufacturing space: 28,000 m2.

MTL Group HQ is a modern 18,000 m2. manufacturing facility based on a 28 hectare secure site.

MTL Group Limited - Rotherham Facility

.

Investment In Facilities - Port of Blyth

From this site we are able to handle fabrications in excess

of 300t in weight

2011 MTL Group Limited invest in a new dockside

Facility

From South Harbour

MTL Group Limited

What Does MTL Group Do ?

Cutting Facility

8 Laser Cutting Machines Bevel cutting facility to 50 deg Up to 30mm laser cut 3 large format machines up to 20m x 3.5m

CNC Profi ling Machine 10m x 4m cutting area 4 head cutting

2 High Defi nition Plasmas Twin head cutting Large format 25m x 5m x 40mm Latest technology in plasma cutting High speed cutting Bevel cutting facility to 40 deg

Robotic Plasma Pipe Cutting 1m Dia x 40mm wall thick Holes, Chamfers & Preps cut

Facilities - Cutting

• 12m x 3m cutting area

• 4 cutting heads

• Bevel cutting option up to 50 degrees

• Any material processed up to 200mm thick

• Cold cutting process no HAZ

Facilities – Water Jet Cutting

Bending and Machining Facility

• 1 Ursviken CNC 7.2m x 640t Robotic handling system. Angle checking device 0.5 degree accuracy.

• 1 Ursviken CNC Press 7.2m x 640t

• 2 Ursviken CNC Presses 4m x 200t

• 1 Euromac CNC DIGIBEND

• 1 CMZ Pyramid Rolls.

Facilities – Press Braking

• Mazatech CNC Twin Pallet machining centre

• Awea VMC

• 4 Hartford Blockbuster VMC

• Wadkins CNC Router

Facilities – CNC Machining

Facilities - Welding Assembly

• 6 No Fanuc Robotic Welding Systems

• BS EN ISO 3834 – Part 2

• 32 manual welding cells

• 100+ qualifi ed welders

• PCN Level 2 NDT

Facilities - Fabrication

Accreditations

• BS EN ISO 9001: 2008• ISO 3834-2• FPAL• EEMUA 158• DIN 18800• Norsok M101• DNV

Approvals• Aker Solutions• Weserwind• Ambau• BiFab• OpenHydro• Soil Machine Dynamics• BAE Systems• Lockheed Martin• General Dynamics• Rolls Royce• Aker Solutions

Accreditations & Approvals

Sales by market sector

Green sector manufacturing represents a quarter of our business

Construction 18%

Defence 26%

Quarrying 19%

Other 6%

Rail 7%

Recycling 9%

Renewables 15%

Diversified markets reduce effects of cyclical swings

•Laser cut and machined parts from mild steel and Hardox material.

•Large pressed chassis components from high strength steels

•Robotic and manually welded chassis components

•Laser cut and robotically formed Components

Market Sector - Construction

http://www.google.co.uk/imgres?imgurl=http://www.robertcole.co.uk/JCB%20LOGO%20COLOUR.jpg&imgrefurl=http://www.robertcole.co.uk/&h=1063&w=1063&sz=333&tbnid=jX8HZw8Kjx8LDM:&tbnh=150&tbnw=150&prev=/images?q=jcb+logo&zoom=1&q=jcb+logo&hl=en&usg=__BMu23_RggYxsBQeHVSMDHVGURgQ=&sa=X&ei=GLkATfCdKMmt8gPdvfGbCA&ved=0CBoQ9QEwAA

• Robot welded vibrating grids manufactured from Hardox steel

• Laser cut, pressed and machined assemblies

• Hopper / Chute fabrications

• Large chassis related fabrications

• Hydraulic & Fuel tank fabrications

Market Sector - Quarrying

•IED Protection

•Mine roller assemblies

• Robot welded fabrications

• Assembly of wheel and hydraulic system

Market Sector - Defence

http://2.bp.blogspot.com/_MoYCAxYkHxA/TTqScdKkN_I/AAAAAAAAAd4/iSYNIDkg4wg/s1600/20110104mineroller-garibay.jpg

Foxhound Vehicle

•Replacement to the Snatch Land Rover

•High strength blast armour

•Fully fabricated at Rotherham

•High volume manufacturing


Armoured Vehicle Hulls

•Laser cut and pressed high strength ballistic steel

•High strength blast armour

•Complete hull/pod manufactured in Rotherham


• Fabricated Truck bodies

• Wear resistant & high strength steel fabrications

• Side Body panels

• High yield strength, low weight components

Market Sector - Recycling

• Sub Surface Line (London)

• Competitive tender (UK /Overseas)

• CNC Water jet & Laser cutting

• CNC Bending & Machining

• Safety critical fabrications

• Final Bolster assembly

Market Sector - Rail

MTL Group Limited

Investing in the latest state of the art machinery

Robot Press

Journey

Into

Renewables

Overview

“Today offshore wind contributed 1.5% of the UK’s electricity supply and that figure will significantly increase in order to achieve the 2020 renewables target”

The Crown Estate, UK Offshore Wind, P3, 2012

The Opportunity

“DECC has predicted that as much as 18GW of offshore wind could be deployed by 2020, with the possibility to reach 40GW by 2030”

EIC, offshore wind supply change challenges, P6, May 2012

The Opportunity

This is a estimated offshore wind market potential of

•8,000 Wind Turbines

•12,000 Boatlanding systems

•120,000 tonnes of processed steel

Ready For Round 3

Rotherham

Blyth

Renewables Sales (£m)

1 23

7

9

2008 2009 2010 2011 2012 2013

Nil

0 To £7m In 5 YearsF

orec

ast

2006

2012 Renewables Export Sales Growth

Offshore Wind Projects

• Ormonde - UK• Nord Sea Ost - Germany • Borkum West - Germany• Meerwind - Germany• Humber Gateway – UK

• Cable Reels - Worldwide

Offshore Wind - Ormonde Operational

• Ormonde Wind Farm - 30 Jackets

• 60 Boat Landing Systems• Beams for Working Platform

Offshore Wind – Ormonde

• Customer: Aker Verdal• 97 Boat Landing Systems• Completed 2013

Offshore Wind – Nord Sea Ost Wind Farm

Nord See Ost– Offshore Fabrications

Platform for high voltage substation

Offshore Wind – Borkum West

Borkum West - 40 Tripods

•40 Boatlanding systems

•Transitional Platforms

•Installed in Germany

Offshore Wind – Humber Gateway

Humber Gateway - 16 Monopiles

•16 Boatlanding Systems

Offshore Cable Reel Fabrication

Offshore Reel Fabrication in our Blyth Facility

Strategy for Growth

1. Understanding the sector

2. Investment in facilities

3. State of the art machinery

4. Investment in people

.

Investment In Facilities - Port of Blyth

From this site we are able to handle fabrications in excess

of 300t in weight

2011 MTL Group Limited invest in a new dockside

Facility

South Harbour

State of the Art Machinery

Six Sigma

• Deployed since 2007

• 3 Black Belts

• Training carried out by Caterpillar Six Sigma team

• Roll out programme to train all employees as Yellow / Green belts

• 12 improvement projects on-going

Investment In People

Investment In People

Investing in Young People16 Apprentices are currently training at our Rotherham site

MTL Group Limited In The Community

Brinsworth 10k Charity RunRaising money for Rotherham Hospice, our nominated charity

Investing In People

Investing in international offshore welding qualifi cation training

•FPAL

•DNV

•IIW

•Norsok M101

The Next Phase

• Wave & Tidal• Nuclear• Wind Tower Internals• Subsea• Joint Ventures with Europe

Next Phase – Wave & Tidal

Next Phase - Wave & Tidal

Next Phase - Nuclear

Hinkley Point

Next Phase – Wind Tower Internals

Next Phase - Subsea

Courtesy of SMD – www.smd.co.uk

Summary

•MTL has established itself as the leading supplier of secondary steel work for offshore wind foundations.

•It has a proven track record of meeting demanding offshore requirements

•It has the latest state of the art equipment specifi c to the requirements of renewables

•MTL is ready to play a leading role in the UK meeting its carbon/reduction targets and energy requirements

Your Partner In Renewable Energy

Dave Oswin

Tel: 01142 61 79 79 Fax: 01142 42 51 77 Email: [email protected]

Thank you

Renewable Energy Session - Global Manufacturing · PDF fileWhy Does the UK need Renewable...

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