Design and Development in Offshore Branch

Transcription

1 Bilfinger Mars Offshore sp. z o.o. Design and Development in Offshore Branch Szczecin, PONP Speaker: Dr Marek Los, Proxy, Head of Engineering, Design & Development Bilfinger Mars Offshore

2 Agenda 1. Offshore Foundation for Wind Turbines Producing of Offshore Wind Energy Jacket - Offshore Foundation Monopile with TP - Offshore Foundation 2. Cost distribution and potential savings Saving potential Innovation demand 3. Design and Optimization by BMO Innovation demand BMO s standardised Jacket concept Total Costs Comparison Jacket vs MP BMO Optimizied TP BMO Standarized Secondary Steel BMO Automated Welding Page 2

3 1. Offshore Foundation for Wind Turbines Overview

4 Producing of Offshore Wind Energy Source: Roland Berger Page 4

5 Jacket - Offshore Foundation Source: Ramboll Designs Foundations for Cape Wind Offshore Wind Farm Page 5

6 Monopile with TP - Offshore Foundation Source: Ramboll Designs Foundations for Cape Wind Offshore Wind Farm Page 6

7 2. Cost distribution and potential savings

8 Offshore Wind Park Cost distribution Source: BNFE, Levelised cost of Energy update, Q2 2011, Research Note, February, London Page 8

9 Saving potential 40% cost reduction = 10 EUR Ct / kwh demand 5-7 % fabrication 3-5 % installation 2-5 % lower risks Demand: Cheaper foundation fabrication & installation at more robust & reliable implementation! Page 9

10 Innovation demand Innovation demand: DESIGN: Integrated design of WTG & FOU! DESIGN: Standardization of (jacket) design! FAB: Cheaper scour protection systems! FAB: More competition, new serial production methods & plants! INS: More & new (floating) installation vessels with larger deck space & crane for jackets! INS: Flexible sea-fastening (for jackets)! INS: Reliable & cheaper noise mitigation! Page 10

11 3. Design and Optimization by BMO

12 Engineering, Research and Development Department Team Offshore Engineering and Consulting Highly specialized in-house design department, with focus on cost efficient serial production, especially on jackets Specialists for automated production and advanced welding technologies Development of standardized offshore foundation designs including certification Own R&D department for development of future innovations, improving the products (offshore foundations) and the production line Bilfinger Offshore Systems can provide holistic services for : Design Production Logistics page 12

13 ENGINEERING Engineering / R&D Department Tasks Design Calculation Research Development Innovation Production Support 3D Models and Workshop Drawings Product optimization Hydrotechnical Structures R & D page 13

14 BMO s standardised Jacket concept as an answer to cost-down pressure Concept Enabling industrialised fabrication. Systemisation by module & pile stick-up step-by-step design! Initial separation of upper & lower part (later fusion)! Usage > 65-85% standard tubes! High repetition factor of equal components ( clones )! All geometry, material qualities, steel thicknesses, component weights etc. acc. BMO s design guidelines = plant requirements. Robotic pre-fabrication of K- and X- nodes and other components (overcoming point-to-point )! Page 14

15 Up to 30% cost reductions possible 100% costs 0% point to-point fabricated Jacket Material Welding / NDT Coating -30% Cost reductions industrial fabricated Jacket Scaffold / cranes Logistics / documentation Efficient industrial assembly assured by standardised pipes and pre-fabricated X- and K-nodes Supply chain secured through cooperation with partners Design adapted to serial manufacturing approach of BMO Fabrication Cost efficient mass production of standard components through: - industrial tube production, - automated processes for welding, cutting and assembling Cost reduction of up to 30% Page 15

16 Total Costs Comparison Jacket vs 40m water depth w/ 80x 6MW WTG Jacket beats Monopile, in terms of foundation total installed cost. Today s Developments: Serial Fabrication at Bilfinger Mars Offshore: New plant with layout for serial fabrication Design of Standard Jacket: Standard tube utilisation (cooperation w/ Salzgitter AG) Optimized design including modularisation WTG-Tower: Optimisation of WTG Tower Cost Comparison Today 100 % 95 % Future Prediction Future 100 % 85 % Future Developments Future: Further optimisation: Serial fabrication processes and jacket design Transports (load-out) improvements: Optimized sea-fastening & faster (barge) transports New transport & installation concept: Feeder technology combined w/ floating installation MP Jacket MP Jacket Source: Detailed comparison designs & estimations by Bilfinger Offshore Systems / EPCI scope current North Sea OWF w/ 80x 6 MW 40m water depth Page 16

17 BMO Optimizied TP Transition Piece Objectives: Based on manufacturer requirements Allows automated welding for work-intensive parts Using of standard profiles, connectors, work sequence Optimizing of primery steel Minimazing of scrap Page 17

18 BMO standarized secondary steel for TP and Jackets Objectives: Based on manufacturer requirements Allows automated welding for work-intensive parts Using of standard profiles, connectors, work sequence Using the same construction types for most TP-projects Speeding up of production processes Increasing of quality Page 18

19 BMO Automated Welding and improving of Fatigue characteristics Objectives: Decreasing of production costs Speeding up the production processes Increasing the quality of welds Improving the S/N-Curves to save material Page 19

20 Bilfinger Mars Offshore sp. z o.o. ul. Brdowska Szczecin Poland P: F: E: info.bmo@bilfinger.com W: