4 - v112-3.0mw_vestas
TRANSCRIPT
Harnessing low and medium onshore winds for you.
V112-3.0 MW
Gianfranco Leoni - Vestas Italia
Agenda
1 The V112-3.0 MW – harnessing low and medium onshore winds for you
2The V112-3.0 MW is designed to optimize your energy production and reduce
energy costs
3 The V112-3.0 MW delivers business case certainty
2
4 Vestas wind turbines also benefit from advanced monitoring solutions
Vestas’ new wind turbine: The V112-3.0 MW
DESIGNED FOR IECIIA and IECIIIA ...
IEC IIEC IIIEC III
V80-2.0 MW
V90-1.8 MW
V100-1.8 MW
IEC IIIEC III IEC IIEC IIIEC III
Existing WTGs
3
6 6.5 7 7.5 8 8.5 9 9.5 10
Wind Speed [m/s]
�112 m rotor
�3.0 MW rated power
V90-3.0 MW
V112-3.0 MWNew WTG
The V112-3.0 MW covers almost three wind classes
500
1000
1500
2000
2500
3000
3500
Pow
er [k
w]
2
4
6
8
10
12
Fre
quency [%
]
V112-3.0 MW Power Curve Probability @7.5 m/s
AEP [MWh]V112-3.0 MW
V112-3.0 MW AEP Benchmarking
Optimized for onshore locations with low and medium wind speed
12.000
15.000
4
00 1 2 3 4 5 6 7 8 9 10111213141516171819202122232425
Wind Speed [m/s]
0
Annual Average Wind Speed [m/s]
�Approved for IECIIa and IECIIIa
�Optimized for wind speed 8,5 m/s
�Nominal rating 3.0 MW
Standard Air Density 1.225 kg/m3
High productivity
0
3.000
6.000
9.000
5,0 5,5 6,0 6,5 7,0 7,5 8,0 8,5
Industry Range
Agenda
1 The V112-3.0 MW – harnessing low and medium onshore winds for you
2The V112-3.0 MW is designed to optimize your energy production and reduce
energy costs
3 The V112-3.0 MW delivers business case certainty
5
4 Vestas wind turbines also benefit from advanced monitoring solutions
Pitch System�Double feeding pump system ensuring
redundancy and reliability�Solutions for safe work in hub integrated in
design
Blade55% larger swept area over V90-
Vestas CoolerTopTM
�Operation up to 2,000 m
altitude without derating
Permanent magnet generator & Full scale converter �Excellent grid support capability
�Reduced maintenance cost�Highly adaptable for future requirements
�HCCBA bearings (High Capacity Bearing)
Unprecedented energy production and reliable performance
6
Drive train� Integrated rotor lock system to improve
maintenance ability
• Best performing gear solutions (proven from VPDC data) implemented.
�55% larger swept area over V90-3.0 MW
�Large root diameter (Φ2.6 m) ensures blade bearing longevity
�Lightning receptors and internal grounding cable integrated
�Robust performing profiles less sensitive to dirt
�Reduced noise level
altitude without derating�No power consumption for
fans�No noise emission from
cooling system
Yaw System:�8 yaw gears�Robust plain bearing with build
in frictions
Robust DesignHigh Reliability
Lower energy costs
Reducing noise impacts power production minimally
90
95
100
105
110
3 4 5 6 7 8 9 10 11 12 13 14
Mode 2
Mode 1
Mode 0
Power reduction of various noise modes
�Site specific operation modes possible
�High production during low noise operation due to
� Low noise blade profiles
�The full-scale converter
�Permanent magnet generator
Sound power
Annual Average Wind Speed [m/s]
Power (KW)
7
4.3%MODE 2: MAXIMUM SOUND EMISSION 104.5 DB(A)
0.3%MODE 1: REDUCED SOUND EMISSION AT LOW WIND SPEED
AEP REDUCTION @ 8 M/S
STANDARD MODES 105.0 DB(A)*
Power Reduction of Various Noise Modes
Higher yield
0
1.000
2.000
3.000
3 4 5 6 7 8 9 10 11 12 13
Mode 2
Mode 1
Mode 0
Annual Average Wind Speed [m/s]
Power (KW)
V112-3.0 MW platform – the new power system
� Permanent magnet generator
�Synchronous
�No slip rings/brushes needed for operation
�Internal ventilation and water jacket cooled
�Compact design
�Low weight
�Hybrid bearings (ceramic)
8
�Hybrid bearings (ceramic)
�Full scale converter
�Water cooled
�Modular layout
�Transformer
� 650 V – 10-35 kV, air cooled
� High voltage cable
�Switchgear
Simple and effective power system with high efficiency and excellent fault ride
through capabilities
The new power system
FeaturesFull grid compliance
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Features� Designed for superior grid support� Power factor range: ± 0.9� Zero Voltage Ride Through: 0.5 s� Fast run back to 20%, spinning reserve 20% to 100%
Full grid compliance� Voltage range 0,8 – 1,2� Frequency 45-65 Hz � FRT Yes� Reactive current injection Yes
� Power Recovery Yes� Short-circuit contribution 1.5 pu� Max short-circuit level 23 kA� Fast ramp up Yes
Excellent grid support capabilityReduced Maintenance Cost
Highly adaptable for future requirements
Reactive power capability
P (pu)
0.5
0.3
0.4
Q (pu)
0.2
0.1
0.0
Power Factor = +/- 0.90
10
P (pu)
0.90.80.70.60.50.40.30.2 1.00.0-0.1
-0.2
-0.3
-0.4
-0.5
0.0
0.1
Under-excited Lagging Inductive
Over-excited Leading Capacitive Improved Grid CapabilityHigher Power Efficiency
Low voltage ride through
Voltage FRT-profile (WTG)
0,00; 1,10
0,00; 0,90
10,00; 0,80
10,00; 0,90
2,60; 0,80
0,45; 0,00
0,00; 0,00
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
1,1
1,2
-0,5 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 6,0 6,5 7,0 7,5 8,0 8,5 9,0 9,5 10,0 10,5 11,0
Time (s)
U (
pu
)
� Designed for FERC 661A regulations
11
� Tested for FERC 661A regulations
Designed AND tested
Reduced BOP cost
Lower foundation costs� Advanced control algorithms (Load Management System)
reduce the loads� Low top head mass reduce the dynamic loads
Reduced substation cost� Full converter reduces the substation size and cost by
eliminating need for StatComs and switched capacitors
12
Reduced BOP cost
eliminating need for StatComs and switched capacitors
Reduced road and crane pad stand cost� No components weigh more than 70 tones'� Replacement of components can be done by tower crane
Designed for uncomplicated transport
Turbine split in modules
�“Easy” transport: In terms of weight, height and width, all of its components comply with local and international limits for standard transportation
�Standard trailers useable for main components
�Easy to use jacking system
13
Easy to transport
Designed for easy service
�Work area in nacelle increased by 60% over previous Vestas turbines
�Nacelle designed with technicians in the Virtual Reality Centre to ensure good working environment (easy access to tools, enough space to do service, etc)
�Service conditions improved by direct crane access to converter modules for quick and safe maintenance.
�Switch gear is controlled via internet connection
14
Designed for serviceability
�Switch gear is controlled via internet connection
�Serviceability build into design. Easy-to-understand storyboards describe exchange of all critical components
�Modular design allows easy access and fast component replacement
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First of its kind – Vestas’ virtual technology improves the arrangement in the hub
� Virtual Reality helps you make sure that service technicians can perform their jobs safely
� Visualisation and simulation technique allows Vestas to communicate and move knowledge much faster to you
15
Easy training of staff
Agenda
1 The V112-3.0 MW – harnessing low and medium onshore winds for you
2The V112-3.0 MW is designed to optimize your energy production and reduce
energy costs
3 The V112-3.0 MW delivers business case certainty
16
4 Vestas wind turbines also benefit from advanced monitoring solutions
Pitch System�Design based on V90-3.0 MW�Double feeding pump system ensuring
reliability
Blade
Permanent magnet generator & Full scale converter �PM generator: Designed by key employees Vestas acquired
from ePower LLC, which has 3 decades of experience in motor and generator technology
�VND The full-scale converter in the V112 is based on 10(+) years experience from design, operation and manufacture of converters for DFIG system
V112-3.0 MW design based on proven technology
Control system�Design based on V90-3.0
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Drive train�Based on V90-2.0 MW gear technology�Best performing gear solutions (proven from
VPDC data) implemented
Blade�Design based on V90-3.0 MW�Red
Yaw System:�Design based on V90-3.0 MW
and V90-2.0 MW�Robust plain bearing with build
in frictions
Robust DesignHigh Reliability
Towers:�Designed based on V90-3.0
MW technology
�Design based on V90-3.0 MW
For the new gearbox MONITORING OF 20+ FAILURE MODES IN 12 SEVERE USER SEQUENCE TESTS has been conducted to identify known and unknown potential failure modes
RIGOROUS TESTING OF NEW COMPONENTS
GENERATOR
GEARBOX
GeneratorR = 90.0%
L10 @ 20 years
Vestas Test Center ensures V112-3.0 MW platform reliability
18
Comprehensive testing has been applied to ALL CRITICAL COMPONENTS
Stressors causing failure modes have been identified and TESTED IN SPECIALIZED RIGS to ensure reliability of each component
ENCODER
L10 @ 20 years
CI = 50%
Encoder, ground brushes
and lubrication systemR = 99.0%
L1 @ 5/20 yearsMTBR = 5 years
CI = 50%
HousingR = 99.8%
L0.1 @ 20 years CI = 50%
StatorR = 94.0%
L6 @ 20 years CI = 50%
BearingsR = 99.1%
L0.9 @ 20 yearsL10mh @ 400 khMTBR = 10.7 y
CI = 50%
Bearing
hardwareR = 99.9%
L0.1 @ 20 years
CI = 50%
RotorR = 99.0%
L10 @ 20 years CI = 50%
Stator coreR = 99.9%
L0.1 @ 20 years CI = 50%
WindingsR = 99.8%
L0.2 @ 20 years CI = 50%
Insulation
systemR = 99.0%
L1 @ 20 years CI = 50%
Electrical
connectionsR = 98.5%
L1.5 @ 20 years CI = 50%
Temperature
sensorsR = 96.7%
L3.3 @ 20 years CI = 50%
Rotor coreR = 99.9%
L0.1 @ 20 years CI = 50%
MagnetsR = 99.4%
L0.6 @ 20 years CI = 50%
Magnet
retention systemR = 99.9%
L0.1 @ 20 years CI = 50%
Fan and hubR = 99.8%
L0.2 @ 20 years CI = 50%
ShaftR = 99.99%
L0.01 @ 20 years CI = 50%
IDENTIFY FAILURE MODES & MECHANISMS DESIGN THE TEST
Specific procedures are in place for severe testing of new design elements
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M10 Bolt
SCHOCK TEST
Y
M10 Bolt
Encoder
Vertical Table
Z
X
Slip Table
Encoder
Direction of vibration
Direction of vibration
CONDUCT THE TEST & EXTRAPOLATE SETUP THE TEST
Vestas has identified all critical processes for both in-house and sub-supplier production and is systematically installing and monitoring quality controls
QUALITY CONTROLS ACROSS PRODUCTION
Span of Control
Nacelles46%
5 SIGMA PRODUCTION PERFORMANCE
DESIGN
SPECIFICATIONS
• …………
•………….
•………….
•………….
5 sigma performance target to ensure EACH COMPONENT IS IDENTICAL to the validated design specifications
20
VESTAS HAS A CLEAR OVERVIEWof span of control and sigma performance levels at component, platform, factory and process level
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Skag
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Span of Control 50% 55% % 55% 45% 45% 0% 0% 35% 41% 35% 56% 56% 77%
Main Processes w ith Control 10 11 0 11 5 5 0 0 6 7 6 5 5 10
Count of Main Processes 20 20 0 20 11 11 11 11 17 17 17 9 9 13
Low est Sigma Level 4,01 2,04 1,51 4,06 3,67 4,5 3,94 4,5
Span of Control
Main Processes w ith Control
Count of Main Processes
3MW Hub
Span of Control 35%
Main Processes w ith Control 6
Count of Main Processes 17
Low est Sigma Level 3,944,06
77%
20
26
4,041,51 3,67 0
13
34
10
1860
10
44
2MW Nacelle 3MW V52
46%
99
2MW Hub 1.65MW
53%
32
38%
213
56%23%
Quality Assurance
Agenda
1 The V112-3.0 MW – harnessing low and medium onshore winds for you
2The V112-3.0 MW is designed to optimize your energy production and reduce
energy costs
3 The V112-3.0 MW delivers business case certainty
21
4 Vestas wind turbines also benefit from advanced monitoring solutions
Global 24/7/365 COVERAGE OF 16,227 TURBINES with more than 50,000 high speed data tracks per month
Identify performance deviation and issues in the fleet based on predictive models and INITIATE PREVENTIVE MAINTENANCE though conditioning monitoring system & Vestas Turbine monitor
MONITORIDENTIFY
& INITIATE
Vestas performance & diagnostic center offers prevention through prediction
22
Planning of maintenance based on weather forecast & making repairs to MINIMIZE LOST PRODUCTION FACTOR
Findings are used to improve predictive models to provide RELIABLE PERFORMANCE AND YIELD MANAGEMENT
INITIATE
PLAN & REPAIR
LEARN & IMPROVE
Vestas condition monitoring (CMS) - predicting costly mechanical failures
Vibration level
Functional loss
Inspect damage Order spare parts Repair work
Production loss
Corrective service
Predictive service
Using condition monitoring
Damage detected
WITHOUT condition monitoring
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Time
Inspect component Order spare parts Repair work
monitoring
Cost reductionOptimization of maintenance efficiencyMaximized availability and production
�Assessment of the "health" of a machine by analysis of measured signals
�Estimation of time of failure�optimised planning of maintenance activities
VestasOnline® – Vestas’ SCADA solutions
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This SCADA system turns a group of wind turbines into a
wind power plant
Grid meter
Standard features � Plant Layout view� Event notification� Basic Statistics� Online Production View� Event View� 24/7 surveillance� Standard Production Reports
VestasOnline® is the most advanced system on the market today
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Add-on features� Production Control� Grid Control� 3rd Party grid integration� Plant Customization� Maximized production at PCC� Customized Reports
Allows monitoring of complete park including
substation
THANK YOU FOR YOUR ATTENTION
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