Kristal NV aan de hand van een aantal vragen
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Transcript Kristal NV aan de hand van een aantal vragen
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
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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
The LW 750kW
- multi discipline small organisation
- franchise business model
- 30 turbines in the order book
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Zephyros in value chain
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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
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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
permanent performance
4
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
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Installation hoist
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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
permanent performance
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Single line diagram
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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
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The structural design
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The voltage level
Influence of generator type and voltage level on performance
100
98
96
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PMHV
PMLV
WRHV
WRLV
[%]
92
90
88
86
5
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Windspeed
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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
Rated electrical power
Rated air gap torque
Rated voltage
Rated current
Power factor
Frequency
Rotational speed
Pole number
Pole angle
Torque harmonics
Short circuit current
Ambient temperature
Radial pull
1670 kW
1562 kW
862 kNm
3000 V
327 A
0.92
3 - 9.25 Hz (rated)
9 - 18.5 rpm (rated)
60
33.5 deg.
100% fundamental (862 kNm)
< 1% 6th harmonic (55.5 Hz)
< 1% 12th harmonic (111 Hz)
< 1% 24th harmonic (222 Hz)
569 A (sustained)
40 °C
98 kN/mm between stator and
rotor due to excentricity
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Temperature rise class
Insulation class
Standards
Protection by enclosure
Cooling type
Rotor inertia
Total weight
Stator weight
Rotor weight
Bearing support cone
Bearing weight
PT 100 stator
PT 100 generator air
PT 100 bearing
Airgap distance sensors
Bearing greasing unit
Maximum magnetic
force
F
F (H)
IEC34
IP54
IC40
35000 kgm2
47200 kg
25000 kg
12500 kg
5000 kg
4000 kg
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2
2
4
1
45 kN magnetic pulling
force of one pole.
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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
permanent performance
21
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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Full scale B2B test
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Results
Results:
Good dynamic response
Controllable generator
current
Limitations:
Poor dynamic test
conditions
Poor cooling conditions
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Performance
Track record
(dec 2002 – feb 2004)
Capacity factor 28%
4500 MWh produced
Overall availability 2003: 84%
1600
1400
1200
Power [kW]
1000
800
Calculated
Measured
600
400
200
Wind speed [m/s]
0
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
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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
90
80
70
60
50
Tstat-2
Tstat-3
40
Tstat-4
Tstat-5
30
Tstat-6
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Tambient
10
0
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
-10
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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
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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
permanent performance
28
Benefits
Competitive with catalogue price of 1500 k€
Costs of operation during life-time
maintenance costs (-30%)
availability (+1% point)
insurance fee (-25%)
higher electricity yield (+2%)
€
€
€
€
3,000
3,000
2,500
6,000
compared to identical machine but with conventional generator
reservation for repairs (-2,500)
€ 2,500
1 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
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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
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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
permanent performance
31
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
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Zephyros SWOT analysis
Strengths
Weaknesses
The design; ±2 years ahead of
Track record
market with 2MW PMDD design
Financial power
Partners involved, esp. ABB
Control over manufacturing
Flexibility, independence
Opportunities
Threats
Market moving towards DD
Other players developing DD
Offshore gaining importance
Enercon (price reductions)
Worldwide network can be
GE patent (in US only)
patent issue in Europe is solved!
rolled out very quickly
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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
permanent performance
34
Cost distribution
distribution of costing
2%
0%
rotor :
15%
drivetrain:
29%
hydraulic:
nacelle:
cover :
yaw mechanism:
tow er:
generator:
25%
E-system/converter:
10%
transformer :
auxiliary equipment:
12%
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1%
3%
3%0%
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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
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