development and operating experience of the wec winwind wwd-1 g.böhmeke, winwind oy
DESCRIPTION
Development and operating experience of the WEC Winwind WWD-1 G.Böhmeke, WINWIND OY. Concept origin. Direct drives appeared on the market 1994-’95 Comparative study on direct drives, including slow-speed drives with single-stage gearing at aerodyn GmbH in 1996-’97 - PowerPoint PPT PresentationTRANSCRIPT
Development and operating experience of
the WEC Winwind WWD-1
G.Böhmeke, WINWIND OY
Concept origin
Direct drives appeared on the market 1994-’95
Comparative study on direct drives, including slow-speed drives with single-stage gearing at aerodyn GmbH in 1996-’97
First publication EWEC ’97 Dublin
Study results, facts...
Direct drive leads to very high generator mass and cost , the machine is not competitive if bought from ready-made components
The situation becomes worse with increasing size
This can only be partially neutralized by making the generator and inverter in large series in the own workshop
A newcomer can not start on this basis
... Facts
Large-scale gearbox failures from 1999 to 2002
Investigations partially confidential. Published results leave many questions open
Damages seem to concentrate on high-speed parts
A newcomer should not take the risk of using a conventional gearbox
Aim
Reliable and competitive wind turbine, suitable also for arctic and remote locations
Concept scaleable up to several MW
Components bought from well-known component deliverers, but own test and assembly
Avoiding all gearbox problems known today
Avoiding the cost and mass problems of direct drives
Solution
Low-speed drive train, planetary gearbox with comparatively slow generator
Gearbox and generator risk analysis and measures against possible problems
Further measures to increase overall reliability
Patents, co-operation, funding
Slow-speed integrated drive train concept called MULTIBRID and patented by aerodyn GmbH
WinWinD and its cooperation partner Pfleiderer Wind Energy GmbH hold the utilisation rights.
Pfleiderers 5MW-MULTIBRID is in parallel under development
TEKES subsidy to WINWIND for the development of the 1MW wind energy converter WWD-1
Founded in March 2000, share company
Largest share holders
Powest Oy, A subsidiary of biggest Finnish power company, Pohjolan Voima Oy
Head Future Technologies Oy, Venture capital company, member of the Head Team
Presently 20 employees, three locations
WinWinD
Location
Workshop, assembly and testIi-Raasakka
Machine design and development Helsinki
Main office and administrationOulu
WWD-1 Main component deliverers
Hub and mainframe casting METSO FOUNDRY
Tower steel RAUTARUUKKI
Inverter ABB
Main bearing HRE
Blades EUROS
Gearbox METSO DRIVES
Generator ABB
WWD-1 drive train
WWD-1 drive train (simplified)
WWD-1 Basic data
Rated power 1 000 kWRotor diameter 56 (60) mClassification IEC 2-A (3-B)Tower height 56 - 70 mCut-in wind speed 3 m/sCut-out wind speed 25 (20)m/sRated wind speed 12.5 m/sTop mass 53 to
Rated rotor speed 25.6 rpmRated gen. speed 146 rpmGear ratio 5.71
Temperature rangeFirst machine (Oulu) -30C to +25CSeries site-specific
WWD-1 Basic dataDiagram from
aerodyn GmbH
0
5
10
15
20
25
30
35
40
45
50
25 35 45 55 65 75 85 95 105 115 125
Durchmesser [m]
rel.
Tu
rmko
pfm
ass
e [k
g/m
²]
GE 3.6 » 268 t
E 30
E 40
E 66
NTK 1500
NTK 300 V 47
V 66
bwu 750
MD 70
leichte WEA
schwere WEA
mk = a * D2.75
Technologie Faktor a = 0.7 to 1.1
N 80
Aeolus II
MOD 5b
M 5000 » 300 t
WWD1
WWD3
E112 ca. 500t
Design rules gearboxBearings and gears
Own crosscheck and neutral expert approvalNo high-speed partsFEM analysis of bearing influence on gearing
Load peaksVariable speed and pitch concept, defined torqueSlip clutch against short circuit torque peaks
Brake dynamics torque peaksBrake acts with only rated torque
Reaction forces and casing deformationsConcentric structure and FEM analysis
Spherical roller bearing problemsOnly cylindrical roller bearings
Oil quality and temperatureAmple cooling and fine filtering
Design rules generatorWinding temperature level
Inherently large surface per kW of lossWater jacket coolingPermanent excitation saves losses and heat
Dielectric winding stress dU/dtAdequate filter
Salt, water, erosionPreformed coil winding, no round-wireNo ambient air through generator
Air gap collisionConventional length/diameter ratio, stiff casingNo direct influence of rotor loads on air gapSensor and supervision
Magnet degradingQuality controlThick glassfibre sleeveCurrent limiting
WWD-1 assembly
WWD-1 back-to-back test
WWD-1 test and running-in
WWD-1 site assembly
WWD-1
August 2001First machine erected in Oulu
April 2003 two units to Kokkola
June 2003 three units To Oulunsalo
September 2003 three units to Kristiinankaupunki
1Q 2004 two units to France
Operational experience...Power curve
As predicted, pitch control needed parameter refinementsNoise
First results Lpa= 103 dBANo measured single tone contentGearbox silent Dominant machine noise is generator slot frequencyNo elastic suspension/insulation needed anywhere
Grid interferenceAs designed and predicted by inverter manufacturerEN-SFS 50160 limits are fulfilled
DynamicsAs designed
... operational experienceSite
Some days of downtime due to rime iceBlade heating system not justifiedGenerator air cooling => water jacket for series machinePreheating procedure needed optimization
Temperature level during operationGearbox oil max. 60C so far, est. 80C with 25C ambientGenerator winding max. 85C so far, est. 100 C
Conclusion No problems related to the drive train concept
Low temperature levels, no unexpected loads,high reliability and long lifetime can be expected.
From WWD-1 to WWD-3
Same drive train concept, but increased gear ratio to cancel the lower rotor speed
Still more compact structure and special measures against structure-born noise
Machine development is under work, prototype scheduled for spring 2004
First machine to be sited near Oulu
WWD-3 preliminary base data
Rated power 3 000 kWRotor diameter 90 mTower height 85-90 mCut-in wind speed 4 m/sCut-out wind speed 25 m/sRated rotor speed 15.9 rpm
Aim: MULTIBRID 1, 3 and 5 MW product family