1 permanent performance design of the z72 wind turbine with direct drive pm generator introduction ...
TRANSCRIPT
1permanent performance
Design of the Z72 wind turbine with direct drive PM generator
Introduction
The turbine design
The conversion system
Testing and operational experience
Commercial advantage of the Z72
Does it sell
How to improve
C.J.A.
Versteegh (R & D manager) Trondheim,
June 15, 2004
2permanent performance
Introduction
In 2000 a consortium has been established to upscale the
Lagerwey DD turbine. Participation of ABB in generator
and converter design
In April 2003 Zephyros has become an independent wind
turbine manufacturers with Triodosbank and Renerco as
shareholders.
Presently: - prototype track record 1.5 year
- multi discipline small organisation
- franchise business model
- 30 turbines in the order book
The LW 750kW
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Zephyros in value chain
1. Wind turbine design (>100 years of experience)
2. Certification (Germanische Lloyd / Det Norske Veritas)
3. Wind turbine sales (direct + franchise)
4. Manufacturing components (suppliers)
5. Wind turbine assembly (in own assembly hall)
6. After sales / service
7. Electricity production
8. Electricity sales
2 3 4 5 6 7 8 1
4permanent performance
Design of the Z72 wind turbine with direct drive PM generator
Introduction
The turbine design
The conversion system
Testing and operational experience
Commercial advantage of the Z72
Does it sell ?
How to improve
5permanent performance
Design requirements
Top of range design (1999) Integrated design Single bearing concept Minimum number of components Full size 4-q converter No transport restrictions; minimum hoisting capacity
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Base design parameters
Rotor diameter 70 m
Nominal rotational speed 18 (<100 dB(A))
Nominal power 1500 kW
Protection IP 54
Maximum transport size 4 m
Maximum transport weight 50 tonnes
Offshore application; no noise restriction
10permanent performance
Design of the Z72 wind turbine with direct drive PM generator
Introduction
The turbine design
The conversion system
Testing and operational experience
Commercial advantage of the Z72
Does it sell ?
How to improve
12permanent performance
The conversion system
Use of voltage source converter Universal 50 - 60 Hz design Good connectivity to grid Electric braking and positioning of rotor Generator loaded with minimum AC current Capable to operate under line dips Sensor less drive
14permanent performance
The voltage level
86
88
90
92
94
96
98
100
[%]
5 7 10Windspeed
Influence of generator type and voltage level on performance
PMHV
PMLV
WRHV
WRLV
15permanent performance
The stator winding
Preformed wire
Advantage : Slot fill factor of 0.7
: High quality insulation
Disadvantage : More connections
: Magnetic slot wedges
Vacuum impregnated stator
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Generator specifications
Rated shaft power 1670 kW Temperature rise class F Rated electrical power 1562 kW Insulation class F (H) Rated air gap torque 862 kNm Standards IEC34 Rated voltage 3000 V Protection by enclosure IP54 Rated current 327 A Cooling type IC40 Power factor 0.92 Rotor inertia 35000 kgm2
Frequency 3 - 9.25 Hz (rated) Total weight 47200 kg Rotational speed 9 - 18.5 rpm (rated) Stator weight 25000 kg Pole number 60 Rotor weight 12500 kg Pole angle 33.5 deg. Bearing support cone 5000 kg Torque harmonics 100% fundamental (862 kNm) Bearing weight 4000 kg < 1% 6th harmonic (55.5 Hz) PT 100 stator 6 < 1% 12th harmonic (111 Hz) PT 100 generator air 2 < 1% 24th harmonic (222 Hz) PT 100 bearing 2 Short circuit current 569 A (sustained) Airgap distance sensors 4 Ambient temperature 40 °C Bearing greasing unit 1 Radial pull 98 kN/mm between stator and
rotor due to excentricity Maximum magnetic force
45 kN magnetic pulling force of one pole.
21permanent performance
Design of the Z72 wind turbine with direct drive PM generator
Introduction
The turbine design
The conversion system
Testing and operational experience
Commercial advantage of the Z72
Does it sell?
How to improve
22permanent performance
Full scale B2B test
1. Light load test 5 Endurance test
2. Overspeed 6 Optimisation grounding concept
3. Short circuit test 7 Optimisation closed loop control
4. Firing through
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Results
Results: Good dynamic response Controllable generator
current
Limitations: Poor dynamic test
conditions Poor cooling conditions
25permanent performance
Performance
Track record (dec 2002 – feb 2004)
Capacity factor 28%
4500 MWh produced
Overall availability 2003: 84%
0
200
400
600
800
1000
1200
1400
1600
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Wind speed [m/s]
Pow
er [k
W]
Calculated
Measured
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Heat run
Maximum Tstator 86 °C, Tbearing 75 °C and Tambient 17 °C
Heat run at full load during 24 hours
-10
0
10
20
30
40
50
60
70
80
90
1 25 49 73 97 121 145 169 193 217 241 265 289 313 337 361 385 409 433 457 481 505 529 553 577 601 625 649 673 697 721 745 769 793
Tstat-2
Tstat-3
Tstat-4
Tstat-5
Tstat-6
Tambient
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Improvements
Prototype modifications Improvement of noise level
Improvement of control algorithm
Safety and control software fine tuning
Modifications ventilation system
Design modifications Double row TRB (option)
State of art PLC and SCADA
Nacelle casted and not welded
Hydraulic yaw brakes
Modifications ventilation system
28permanent performance
Design of the Z72 wind turbine with direct drive PM generator
Introduction
The turbine design
The conversion system
Testing and operational experience
Commercial advantage of the Z72
Does it sell?
How to improve
29permanent performance
Benefits
Competitive with catalogue price of 1500 k€
Costs of operation during life-time maintenance costs (-30%) € 3,000 availability (+1% point) € 3,000 insurance fee (-25%) € 2,500 higher electricity yield (+2%) € 6,000
compared to identical machine but with conventional generator
reservation for repairs (-2,500) € 2,5001 in 5 turbines need to replace gearbox after warranty.
Cost of new gearbox + lost production: € 250,000 €17,000 per year
Capital costs lighter crane needed (- € 25,000 to – € 50,000) Installation on 600kW locations
30permanent performance
1.5 – 2.0 MW
Upgrade to 2 MW
Conversion system designed for 2 MW Make use of 7 kV insulation system Optimum use of variable speed behaviour Noise level increase 3 dB(A) PPV improvement of 8 % (for class 3 wind climate) Minor extra investment cost DNV prototype certificate for both obtained
31permanent performance
Design of the Z72 wind turbine with direct drive PM generator
Introduction
The turbine design
The conversion system
Testing and operational experience
Commercial advantage of the Z72
Does it sell?
How to improve
32permanent performance
The market
Wind market 2002: $7bn
Past 5 years : CAGR >30%
Till 2012: CAGR 10-20%
Trends:
- offshore development
- large scale wind farms
- big multi MW turbines
33permanent performance
Zephyros SWOT analysis
Strengths The design; ±2 years ahead of
market with 2MW PMDD design
Partners involved, esp. ABB
Flexibility, independence
Opportunities
Market moving towards DD
Offshore gaining importance
Worldwide network can be rolled
out very quickly
Weaknesses
Track record
Financial power
Control over manufacturing
Threats
Other players developing DD
Enercon (price reductions)
GE patent (in US only)patent issue in Europe is solved!
34permanent performance
Design of the Z72 wind turbine with direct drive PM generator
Introduction
The turbine design
The conversion system
Testing and operational experience
Commercial advantage of the Z72
Does it sells ?
How to improve
35permanent performance
Cost distribution
distribution of costing
29%
10%
1%3%
0%3%12%
25%
15%
2%0%
rotor :
drivetrain:
hydraulic:
nacelle:
cover :
yaw mechanism:
tow er:
generator:
E-system/converter:
transformer :
auxiliary equipment:
36permanent performance
Future developments
Short term development
Improvement of PPR with 10 % by: Make use of existing structural design
Increase of rotor diameter to 78 m
Development areas: Independent blade pitching (to reduce fatigue loads)
Low solidity blade design (to reduce extreme loads)
Integrated blade pitch and converter control