Optimisation and expansion of Sif’s monopile production plant
Project facts
- ClientSif Group
- LocationNetherlands
- Date2023
- ChallengeOptimisation, integration and expansion of production to realise growth in number, size and power.
- SolutionOptimised production process that increased productivity and throughput by a factor of two in tonnage.
The challenge
Sif is an industrial goods pioneer in offshore wind monopile foundations which are used in more than 80% of wind turbines currently installed in the North Sea. The company has two production sites in the Netherlands and wants to optimise, integrate and expand its activities in response to growth in the number, size and power of offshore wind turbines.
Royal HaskoningDHV empowered us with their expertise and assisted in realising our ambition and growth plan. Together we have achieved 20% revolution and 80% evolution compared to simply upscaling of the current state of art.
The solution
Sif contracted Royal HaskoningDHV to undertake the full scope of the project – from consultancy and engineering to design and permitting. Working in close collaboration with Sif, the integrated team combined expertise from our two organisations and introduced new ways of thinking. The solution secures five important outcomes: safer, more efficient production, larger monopiles, higher quality and increased tonnage.
Integrating expertise and new thinking to speed throughput at lower cost
A combination of welding technologies, efficient logistics and increased automation make a significant difference to the speed, quality, safety and efficiency of the process. It increases the productivity and throughput by a factor of two (in tonnage).
“It was a team effort between SIF and Royal HaskoningDHV,” explained Joris van de Ven, Project Director at Royal HaskoningDHV. “Once the existing process had been optimised, we enlarged it to accommodate the larger monopiles required. We also used tools such as structural modelling to further test our plans and then prepared a full and integrated design of the production and supporting facilities as well as the permit applications.”
The result
Sustainability integral to the project: 10% less steel and 30% reduction in nitrogen emissions
Sif already uses a land-based wind turbine to power many of the activities at the plant. In addition, we looked together at minimising the need for fossil fuels in the new process. We optimised the building structure using parametric design tools, reducing the quantity of steel required compared to existing buildings by about 10%.
Stringent environmental and permitting restrictions are in place, connected with the location of the plant in the Port of Rotterdam. Our permitting team’s experience in gaining approval for other projects in the port proved helpful. Together with Sif they identified mitigations to ensure the extension remained within allowable limits. Mainly by the electrification of operational processes such as pre-heating of cleaning water, electrical special purpose vehicles (AGV) and electrical generators achieved a 30% reduction in nitrogen emissions compared to the original figures.
Construction for the extension started early 2023. The first of the new, larger-diameter monopiles will be coming off the production line half 2024.
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