Floating Power Plant A/S “POSEIDON” project · Floating Power Plant A/S “POSEIDON” project...

This project has received funding from the European Union’s Horizon 2020 research and innovation

programme under grant agreement No 673976

Floating Power Plant A/S

“POSEIDON” project

Report: D.2.2 – Report on Potential Value Chain

WP: WP2

Sub task: Task 2.2 & 2.3

Date: 29/09/2016

Revision: 1

Internal/External

Public

Lead: Chris McConville

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Contents

1 Backgroud ....................................................................................................................... 3

2 System Breakdown ........................................................................................................... 4

2.1 Overview ................................................................................................................ 4

2.2 Modules .................................................................................................................. 5

2.2.1 Cross bridge module ............................................................................................. 5

2.2.2 Main hull module .................................................................................................. 6

2.2.3 Bottom main module ............................................................................................. 7

2.2.4 Turret system....................................................................................................... 8

2.2.5 PTO module ......................................................................................................... 9

2.2.6 Wind turbine ...................................................................................................... 10

3 Supply Chain Categories ................................................................................................. 11

3.1 Overview .............................................................................................................. 11

3.2 Description of Categories ........................................................................................ 11

4 Supplier Management ..................................................................................................... 13

4.1 Supplier Database .................................................................................................. 13

4.2 Supplier Identification and Initial Assessment ............................................................ 15

4.3 Selection Process ................................................................................................... 15

5 Potential Value Chain ...................................................................................................... 16

5.1 Summary .............................................................................................................. 16

5.2 Preferred Suppliers ................................................................................................. 17

5.2.1 Current Agreements ............................................................................................ 17

5.2.2 Potential Preferred Suppliers ................................................................................ 17

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1 Backgroud

As Floating Power Plant develop their commercial system and offering it is necessary to ensure that

the value chain (suppliers) that are essential for successful project delivery are identified and man-

aged appropriately. The approach to this has been to carefully examine FPP’s product, the P80, and

provide and determine the categories of supplier and specific components and services required to

deliver this. Potential suppliers for these services are then identified and assessed, with relationships

being formed to prepare the value chain for delivery of the commercial projects.

In identifying and assessing suppliers it was identified that a system of managing the relationships

and information collected was required, which led to the development of a supplier database.

This report outlines the process of developing the value chain through the breakdown of FPP’s sys-

tem, categorization of suppliers and management of supplier information.

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2 System Breakdown

2.1 Overview

The FPP floating hybrid platforms are designed to be built in a module based production flow. In this

process main modules can be constructed at different construction facilities, where they are coated

and outfitted with various subsystems. The main modules are shipped to an assembly site, prefera-

bly close to the installation site. At the assembly site main modules are assembled into the finished

platform, subsystems such as cables and pipes in different modules are joined or installed. The goal

of this modular design is to make the construction sites less dependent on installation sites. This will

enable a cost effective (factory) production of modules at existing production facilities of the subcon-

tractors. The modular concept also gives the possibility to have multiple preferred suppliers for dif-

ferent modules and subsystems. This will make project less susceptible to delays due to missing

production capacity at a single supplier, and maintain competition between suppliers.

The modular concept has the flowing system levels.

• Platform – The finished hybrid platform ready for deployment from the assembly site

• Main module – A finished module, coated and with installed subsystems, ready for shipment

to assembly site.

• Sub module – A module constructed and possibly fitted with subsystems at one supplier,

which will be shipped to another supplier or site for integration with other sub modules to

form a main module. E.g. A PTO house that will later be joined with an absorber to form a

PTO module

• Sub system – A functionally coherent system, serving a particular function. A subsystem is

installed in one or more main modules or in the platform. E.g. ballast or HVAC system

• Components – Raw materials or sub-assemblies used for the construction of the above men-

tioned levels. E.g. steel plates, bearings and cables.

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2.2 Modules

2.2.1 Cross bridge module

The cross bridge is a steel plate box construction, with internal frames. The purpose of the cross

bridge is to provide transverse stiffness for the platform, and to provide access between the main

hull and the four side hulls / PTO modules. The cross bridge provides access for both fixed installa-

tions such as Cables, HVAC, and pipe systems, as well as service personnel and materials.

Figure 1 - Principle drawing of cross bridge module

Main Specifications Main Features / Systems

Length: ~7,5 m Transverse gangway

Height: 3,15 m Transverse crane track / beam, with manual crane

Width: 49,5 m Cable ways, with cables installed where practical

Weight: ~105 tonnes Aux power sockets and lighting

Pipe system for PTO module cooling

HVAC ducts

Access openings towards main module (sealed for

transport)

Access hatches for access to bottom module towers

Watertight doors towards PTO modules

Anti-corrosion coating inside and outside

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2.2.2 Main hull module

The main hull module is the central module of the platform, serving multiple purposes. The main hull

is constructed as a box construction / ship hull, with internal frames, webbing and decks for stiffness

and strength. The module consists of a low aft section with an open deck, serving as boat landing

and access area. A taller reinforced mid-section acting as foundation for the WTG, as interface for

the cross bridge and bottom modules and furthermore houses power and control systems etc. The

wave piercing front section is designed to reduce the wave impact forces and funnel the wave en-

ergy towards the wave absorbers and to accommodate the turret mooring system. Below the aft

deck height is a longitudinal pipe and installation tunnel in the full length of the hull. Beneath this

tunnel the hull is divided into individual ballast compartments. In the middle of the hull is a shaft

leading to the ballast and cooling pump room placed low in the hull. The aft most section is ex-

tended downward to a heave plate.

Figure 2 - Principle drawing of main hull module


Length: 96 m WTG foundation with access to tower

Height: 37 m Boat landing

Width: 6m (heave plate 15.6m) Water tight entry door to aft deck

Weight: ~900 tonnes Access openings towards cross bridge (sealed for transport)

Internal rooms and stairwells as illustrated above

Ballast system with pipes, pumps, valves and sea filters

Water based cooling system for wave PTO (heat dissipated

to ballast water

Switch board room and cableways / cable installations

Power distribution and control switchboard incl. wave PTO

inverter

Export transformer and export cable incl. export slip ring

and subsea cable connector

Emergency power generator and emergency lighting

Cable ways, with cables installed where practical

Aux power sockets and lighting

Pipe system for PTO module cooling

HVAC ducts

Turret mooring system

Watertight emergency escape hatch on foredeck

Anti-corrosion coating inside and outside

Anti-fouling coating on submerged parts

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Figure 3 - Drawing showing various functions and subsystems

2.2.3 Bottom main module

The bottom main module is the transverse submerged part of the platform structure. The main mod-

ule consists of the following sub modules.

One, bottom plate module. The bottom plate module consists of steel plate box constructions with

internal frames and webbing (pink in illustration below). The box constructions form a horizontal

transverse bottom plate; a sloping back wall / spoiler; and two endplates / winglets. The bottom

plate module can be ballasted with sea water and will be fully filled during normal operation.

Two, inner side hulls. The inner side hulls connects the bottom plate and the cross bridge. The ta-

pered forward end splits the wave and funnels it towards the wave absorber. The lower part of the

backside is tapered, whereas the upper part is flat and acts as a bay to which the PTO module can

be latched. The side hulls can be ballasted with sea water using the ballast system in the main hull,

and will be partial filled during normal operation.

Two, outer side hulls. The outer side hulls have a similar function and construction as the inner side

hulls. However the outer hulls is longer and is extended downward below the bottom plate to a

heave plate.

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Length: 43.4 m Ballast pipe system connecting to ballast pumps in main hull

Height: 32.4 m Ballast tank vents

Width: 82.8 m Anti-corrosion coating inside

Weight: ~1100 tonnes Anti-fouling coating on submerged parts outside

Bottom plate module

Length: 24.2 m

Height: 15.4 m

Width: 82.8 m

Inner side hulls

Length: 18 m

Height: 19.8 m

Width: 4.2 m

Outer side hulls

Length: 25.2 m (heave plate

34.8 m)

Height: 32.4 m

Width: 4.4 m (heave plate

13.8 m)

2.2.4 Turret system

The turret system is responsible for connecting the mooring lines and the subsea export cable with

the platform, and ensuring that the platform can turn freely (weather vane). Several different design

options for the turret system exist, and a specific design has not yet been selected.

The general idea is that the part of the system connecting to the mooring lines and export cable is

installed at the site prior to the deployment of the platform. And the turning part of the system is

installed in the front of the main hull. When the platform is deployed and towed to the site the two

parts are joined and the export cable is connected to the platform export cable with dry mate con-

nectors.

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Main Specifications (est) Main Features / Systems

Diameter: ~5 / 12 m Detachable / mooring part

Height: ~15-20 m o Connection to mooring lines

Weight: ~140 tonnes o Integrated with subsea cable system incl. bend stiffener

o Subsea cable terminated in dry mate connector with

dummy plug

o System for hoisting / joining with platform part

o Buoyancy system for maintaining correct floating height

before connection to platform

o Equipment for measuring the force on the individual

mooring lines

o Anti-corrosion and anti-fouling coating (long life)

Fixed / Platform part

o System for fixing and releasing the detachable part

o Rotating mechanism / bearing system

o Equipment / solution for hoisting detachable part

o Matching dry mate connector for export cable.

o Slipring for export cable 33kV and fibbers for communi-

cation

2.2.5 PTO module

The PTO modules consist of the two sub modules wave absorber and PTO house. The purpose of the

PTO modules is to capture the incoming wave energy and convert it into electrical energy. The ab-

sorber is constructed as a steel plate construction with internal frames. The interior of the absorber

is divided into several individual ballast tanks. Several horizontal decks in the tanks provide addi-

tional stiffness and reduce ballast sloshing. The wave absorber is suspended in the PTO module in a

pivot point, and is floating in the sea due to its buoyancy. The absorber is set in motion around the

pivot point. The oscillating motion in the pivot point is transferred via a shaft system / hollow axel to

a yoke in the PTO house. Inside the PTO house pistons connected to the yoke converts the motion to

a flow of hydraulic fluid. This flow drives a hydraulic motor and an electric generator. The PTO house

is constructed as a steel plate construction with internal frames and decks. The PTO house is me-

chanically latched to the main platform structure (Side hull and cross bridge). The PTO module can

be released from the main platform to be docked out and towed to harbour for maintenance.

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Wave absorber Cable ways, with cables installed where practical

Length: 17.2 m Aux power sockets and lighting

Height: 8 m Pipe system for PTO module cooling

Width: 18.3 m HVAC ducts

Weight: ~150 tonnes Watertight door towards cross bridge

PTO module Anti-corrosion coating inside and outside

Length: 10.8 m Anti-fouling coating on submerged parts

Height: 15 m System for latching an releasing from main platform

Width: 4.2 m Hydraulic system for PTO

Weight: ~100 tonnes Generator and control system 1000VDC output power to

main switchboard

Shaft and bearing system for the wave absorber

Shaft sealing system towards ambient sea and splash zone

Ballast system for ballasting individual ballast compartments

in the wave absorber

2.2.6 Wind turbine

The wind turbine is to be based on a standard offshore turbine. The turbine capacity can be between

2 and 5 MW. In order to be able to operate on a floating foundation, special design changes must be

made by the wind turbine manufacturer. The changes will among other be Strength of individual

components, especially the tower and the control system. The special changes must be made in

close dialogue with FPP based on model tests and numerical simulations.

Main Specifications (est) Main Features / Systems

Power capacity: 3 – 8 MW 3 Blade upwind turbine

Hub height: 80 m 33kV AC output power

Rotor diameter: 125 m Automatic nacelle yaw system

Weight: 700 tonnes Automatic blade pitching system

Accessible from tower base

Marinised for offshore use

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3 Supply Chain Categories

3.1 Overview

When considering the construct of FPP’s potential supply chain it was decided to categorise suppliers

according to the services they are capable of providing. This allows for a more efficient assessment

process and recording of potential suppliers suitability as there are distinct requirements within each

category.

This approach is commonly referred to as procurement category management and allows FPP to fo-

cus procurement activities in a way that reflects the supply markets. As such FPP should be able to

identify similar procurement activities that cross organizational functions, enabling procurement effi-

ciencies and optimization.

At this stage, the categories are focused on the delivery of FPP’s product, the P80, and as such it

does not allow for professional business services such as legal, financial and marketing services. The

system can however be easily expanded in the future, or these services could simply be included in

the “Vendor” category.

3.2 Description of Categories

The categories used for FPP’s value chain are described below with an example of the types of work

package fulfilled by each.

Category Description Example Work

Packages

Environmental

Consultancy

This category covers the provision of consul-

tancy services with respect to conducting envi-

ronmental survey, monitoring and reporting.

This is primarily a project specific package re-

lating to the provision of services such as site

surveys, EIA and HRA reporting and mitigation

strategies. As a project specific service this may

have little relevance to FPP in the longer term,

but is important in the first commercial project,

in which FPP must take a more active developer

position, and is of relevance as any data col-

lected may inform FPP’s system and array de-

sign work. Companies which provide these ser-

vices may also be required by FPP in the future

to provide impact assessment and monitoring

services specific to the technology.

• EIA preparation

• Bird monitoring

• Sea mammal monitoring

• Seabed investigations

• Metocean data

Engineering

Consultancy

Covering providers of technical engineering ser-

vices related to FPP’s technology or associated

systems. This includes FEED and basic design

engineering services as well as technical valida-

tion, certification and review services. This cate-

gory may be served by both specialist engineer-

ing consultants and fabricators who have an in

house engineering team.

• Semi-sub design

• Mooring design

• CFD modelling

• Design certification

• Marine systems design

HSE and Risk

Consultancy

Consultancy services which are specific to HSE

and risk issues are considered a specific cate-

gory due to their importance in meeting legisla-

tive requirements and the nature in which they

will be employed, in both technical design and

projects. These services may also be required in

a market specific basis as different countries

will have different requirements which must be

satisfied

• Safety case production

• Design safety review

• Emergency plans

• HSE Liaison

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Detailed De-

sign

This is distinct from Engineering Consultancy

due to the nature of the service and type of

providers. This category is most likely served by

a fabricator providing a major fabrication pack-

age or an engineering consultant who provides

yard management services for such a package.

This category is critical in delivery of the system

as it provides the detailed specifications re-

quired to fabricate, assemble and outfit the fin-

ished system (e.g. weld details, pump make

and models, cable schedules etc.). The category

can be further sub categorized into Structural,

Mechanical and Electrical design

• Structural Detail Design

o Weld/fixing detail

o Sections

• Electrical Detail Design

o Equipment layout

o Cable routing diagrams

o Cables schedules

o Cabinet detail

• Mechanical Detail Design

o Equipment layout

o PID’s

o Equipment schedules

Fabrication

Fabrication of major modules of the P80 struc-

ture, as detailed in section 2 of this report. This

category is specifically focused on the fabrica-

tion of structural elements, although preferred

fabricators will also have capabilities in System

Integration and Assembly in order to outfit and

(at least part) assemble the P80.

• Hull fabrication

• Cross bridge fabrication

• Absorber fabrication

• PTO housing fabrication

• Bottom module fabrication

• Turret fabrication

Global Assem-

bly

Final assembly of the complete P80 device, re-

quiring facilities with a large, high load bearing

quayside with unrestricted access to open sea,

and at least 7m draft. Preferably served by ma-

jor fabricators however there may be suppliers

who have suitable facilities close to project

sites, allowing for efficient transport of multiple

modules for final assembly.

• Full assembly

System Inte-

gration

The integration of multiple systems within the

P80, particularly in modules such as the PTO, is

a critical service. This is expected to be fulfilled

by fabricators however it is important to con-

sider it separately as may fabricators have little

or no electrical and mechanical service offering,

which will limit the modules they are qualified to

build.

• PTO outfitting

• Cable outfitting

• Piping outfitting

• WTG integration

Commissioning

Support

This will cover both in harbour and on site com-

missioning. Much of this work will be overseen

by FPP staff but will require support from vari-

ous OEMs and specialists.

• WTG commissioning

• PTO commissioning

• Systems commissioning

O&M Support

This is a wide category covering many aspects

of O&M. FPP will ideally seek to work with sup-

pliers who can cover a large number of pack-

ages within O&M and provide an fully managed

service, such suppliers shall rank highly on criti-

cality. This category will also cover vessel pro-

viders and port facilities, a database of which

will be useful in establishing future project via-

bility.

• O&M management

• WTG O&M

• PTO O&M

• Structural O&M

• Turret O&M

• Aux systems O&M

• Vessel provision

• Harbour provision

OEM / Vendor

This includes all OEMs and vendors of equip-

ment and services which are utilized within, or

are associated with the operation of, the P80

with no/minimal adaptation (i.e. off the shelf).

• WTG provision

• Export cable provision

• Mooring provision

• Nav aids provision

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4 Supplier Management

4.1 Supplier Database

Due to the number of potential suppliers and variety of categories for which they can supply, com-

bined with the expansion of FPP, it was decided to establish a supplier database. This database

serves two main purposes:

• Recording and storing relevant information on a range of suppliers across all FPP’s procure-

ment categories, which can be easily accessed by all relevant FPP staff. By assigning a FPP

staff member as the main point of contact it also provides consistency in the relationship

and will help identify potential efficiencies through the grouping of contracts

• Efficiently providing a list of potential tenderers for work packages, which can be filtered by

their specific skills and suitability. This will help ensure that contracted work packages un-

dergo a proper competitive tender process by illustrating suppliers suitability and providing a

wider range of suppliers

These points are particularly important as FPP grows as a company and knowledge of suppliers is

spread among a number of staff. The database also helps ensure that FPP comply with the require-

ments of the data protection act by housing all data held on a company in a single location and en-

suring that data is reviewed regularly and stored only as required.

As FPP do not currently have a dedicated procurement manager the database will be ultimately

managed by senior management, however it is expected that the FPP account manager for each

supplier will manage their records. This will be easily managed by filtering the list to identify the rec-

ords due to be updated for each member of staff.

A copy of the template used for each supplier is shown below.

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4.2 Supplier Identification and Initial Assessment

Suppliers are identified in a number of ways including:

• Industry organisation (RUK and SR) directories

• Industry conferences and networking events

• Industry experience

• Direct contact from suppliers

The suitability of suppliers is assessed directly by FPP staff based on the categories illustrated within

the supplier database. The level of investigation into each supplier varies depending on the criticality

of the service in terms of contract value, HSE impact, delivery time and availability of supply. Exam-

ples of the assessment process are provided below for the level of criticality.

Action

Criticality Score

Low

(<2)

Medium

(2 - 3.5)

High

(>3.5)

In person meeting(s) with supplier O O X

Phone meetings O X X

Email correspondence X X X

Facility tour (if applicable) - O X

NDA completion O O X

Sharing of FPP info prior to tender issue - O X

Certification review O O X

Project experience review X X X

Discussion of partnering strategies - O X

Collection of relevant information O X X

Key: X = Required, O = Optional, - = Not required

A supplier registration form, which is derived from the supplier database template, will also be made

available on the website for completion by the supplier. This can then be sent to FPP for assessment

by staff who will decide how best to follow up.

The initial assessment process will only identify the key facts of the organization, workforce and fa-

cilities and whether it is feasible that they could provide suitable services. Suppliers should not be

excluded at this stage unless there is a significant lack in their suitability to provide services required

by FPP. This may, for example, include a wind turbine manufacturer who only provides onshore tur-

bines or a supplier for global assembly whose facility has less than 5m clear draft to quayside.

4.3 Selection Process

All discrete work packages will be awarded through a competitive tender process, with at least three

suppliers (where possible) requested to provide a tender. An assessment of the tenders will be made

on a range of weighted criteria specified internally at the outset of the tender process, with the most

economically advantageous tender (according to the relevant criteria selected) being awarded the

contract.

Although an initial assessment of the suppliers is made at identification and prior to tender, as de-

scribed previously, further assessment of the supplier’s suitability to the specific work package will

be made during the tender process. The level of this assessment will vary depending on the scope of

the contract but may include:

• Investigating HSE stats for high risk work packages

• Reviewing specific staff CV’s

• Requesting that Risk assessments ad method statements (RAMS) are prepared for review

• Reviewing full technical specifications of equipment to be supplied

• Review of warranty and guarantee provision

• Task specific experience and performance review

For certain scopes, such as major fabrication, it may be preferable to work with preferred suppliers

in a partnering approach, however extensive assessment will still be carried out prior to entering

into such agreements.

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5 Potential Value Chain

5.1 Summary

The identification and assessment of potential suppliers is an ongoing business operation, with sup-

pliers being continually added, assessed and reviewed.

An outline of the number of suppliers identified in each procurement category is given below with a

sample of the leading suppliers referenced. Please note that the list of suppliers in each category is

not exhaustive.

Category Current Number Example Suppliers

Environmental Consultancy

• Aquatera • Xodus • RES

• RPS Group • ERM Group • Royal Haskoning DHV

Engineering Consultancy

• CEFRONT Technology • IT Power • Frazer Nash Consultancy • Sgurr Energy • Babcock E&MT • BMT Group

HSE and Risk Consultancy • Risktec • Sgurr Energy • Marex

Detailed Design

• CEFRONT technology • Atkins • Babcock E&MT • Ramboll

Fabrication

• A&P Tyne • Global Energy • BiFab • Babcock E&MS • Cammell Laird • OSB (Bladt)

Global Assembly

• A&P Tyne • BiFab • Global Energy • Cammell Laird

System Integration

• A&P Tyne • Global Energy • Cammell Laird • Babcock E&MS

Commissioning Support

• A&P Tyne • Global Energy • Babcock E&MS • Wood Group

O&M Support

• Semco Maritime • Wood Group • Billfinger Salamis • Babcock

OEM / Vendor

• Siemens Wind • MHI Vestas • ABB • Prysmian

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5.2 Preferred Suppliers

5.2.1 Current Agreements

FPP has several existing agreements with suppliers for specific services and equipment. It is im-

portant to note that these agreements are not exclusive and, although they are intended to enable

development of the value chain and value, FPP are not bound to these suppliers.

Existing agreements include:

• OPES (CEFRONT Technology) – this is an agreement to deliver naval architecture and

marine engineering services for the global design of the P80 system

• Siemens Industry – an agreement for the provision of electrical control equipment related

to FPP’s wave energy Power Take Off (PTO) system

• Fritz Schur Energy – an agreement for the provision of hydraulic components and control

systems related to FPP’s wave energy Power Take Off (PTO) system

5.2.2 Potential Preferred Suppliers

FPP recognize the significance and importance of certain major contracts, particularly major fabrica-

tion and assembly and operation and maintenance contracts. As such, FPP have spent significant ef-

fort in identifying suppliers of these services (which are served by a limited number of suppliers) and

intend to develop these relationships to achieve a partnering or preferred supplier agreement prior

to contract award.

Companies identified as being potential preferred suppliers for major fabrication and assembly con-

tracts include:

• A&P Tyne – A&P have a facility in Hebburn in north east England which includes a modern

panel line system, well suited to constructing the P80. The facility also has suitable access to

the North Sea so could provide complete assembly of the P80 or could transport multiple

modules to an assembly site. A&P could then provide personnel to conduct and oversee the

final assembly and commissioning activities.

• Global Energy – Global Energy have several significant facilities throughout Scotland, in

particular the Nigg site, which was designed for the construction and repair of offshore O&G

rigs, including a 300x150m dry dock. Global Energy have a growing range of experience in

offshore wind and would be well suited to projects in Scotland.

• Babcock – Babcock have expressed an interest in working with FPP and have suitable facili-

ties in Eastern Scotland for major fabrication packages. Babcock’s strength would lie in their

ability to provide detailed engineering services and manage fabrication and assembly at any

facility, whether it is their own or 3rd party.

Companies identified as being potential preferred suppliers for O&M services include:

• Semco Maritime – Semco Maritime are a Danish headquartered offshore service provider

who are capable of providing a range of relevant offshore maintenance services.

• Wood Group – Wood group are a major provider of O&M services to the offshore O&G mar-

ket with skills relevant to FPP’s requirements. Wood Group may be able to provide a com-

plete management service covering all required O&M services and working with OEM’s

providing maintenance services.

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