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
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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
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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
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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
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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
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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
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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
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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
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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
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Partners involved, esp. ABB
 Control over manufacturing
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Flexibility, independence
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Opportunities
Threats
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Market moving towards DD
 Other players developing DD
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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
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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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