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© 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
© Siemens 2012. All rights reserved.
Agenda
UK Industrial Strategy
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
© Siemens 2012. All rights reserved.
Agenda
UK Industrial Strategy
UK Offshore Windpower Supply Chain Opportunities & Challenges
Windpower and Steel
Summing Up
© Siemens 2012. All rights reserved.
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
© Siemens 2012. All rights reserved.
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
© Siemens 2012. All rights reserved.
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…
© Siemens 2012. All rights reserved.
Agenda
UK Industrial Strategy
UK Offshore Windpower Supply Chain Opportunities & Challenges
Windpower and Steel
Summing Up
Page 14 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%
Page 15 April 2011 Copyright Siemens all rights reservedSteve Aughton
The coming 154 m rotor for the 6.0 MW is a large piece of equipment …Here with an Airbus A380
Page 18 April 2011 Copyright Siemens all rights reservedSteve Aughton
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?
Page 19 April 2011 Copyright Siemens all rights reservedSteve Aughton
Can our Advanced Manufacturing Catapults help?
Nuclear AMRCRotherham
AMRCRotherham
Page 20 April 2011 Copyright Siemens all rights reservedSteve Aughton © Siemens 2012. All rights reserved.
Agenda
UK Industrial Strategy
UK Offshore Windpower Supply Chain Opportunities & Challenges
Windpower and Steel
Summing Up
© Siemens 2012. All rights reserved.
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
© Siemens 2012. All rights reserved.
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)
© Siemens 2012. All rights reserved.
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”
© Siemens 2012. All rights reserved.
Top unit
2 main castings
- Rotor hub (shown)
- Nacelle bedplate
SG iron usually
6 MW unit rotor hub will be 60t+ cast weight
© Siemens 2012. All rights reserved.
Infrastructure – Offshore Substations
Several thousand tonnes topside
Large Steel Jacket required
Floating structure
Already in Round 2
© Siemens 2012. All rights reserved.
!
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
© Siemens 2012. All rights reserved.
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?
© Siemens 2012. All rights reserved.
6 MW DD nacelle in delivery to testbed, June 2011
THANKS FOR LISTENING
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
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
• 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
• 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
• 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
Foxhound Vehicle
•Replacement to the Snatch Land Rover
•High strength blast armour
•Fully fabricated at Rotherham
•High volume manufacturing
Market Sector - Defence
Armoured Vehicle Hulls
•Laser cut and pressed high strength ballistic steel
•High strength blast armour
•Complete hull/pod manufactured in Rotherham
Market Sector - Defence
• 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
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
Offshore Wind Projects
• Ormonde - UK• Nord Sea Ost - Germany • Borkum West - Germany• Meerwind - Germany• Humber Gateway – UK
• Cable Reels - Worldwide
• 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
Offshore Wind – Borkum West
Borkum West - 40 Tripods
•40 Boatlanding systems
•Transitional Platforms
•Installed in Germany
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
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
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