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Vestas V90
151© MERVENTO
3.5.2011
Vestas V112
3 MW wind turbineRotor diameter 112 mTraditional geared turbine with one bearing on main shaft
152© MERVENTO
3.5.2011
Vestas V112
153© MERVENTO
3.5.2011
Vestas V112
154© MERVENTO
3.5.2011
Vestas V164
6 MW wind turbineRotor diameter 164 mSemigeared
155© MERVENTO
3.5.2011
WinWinD WWD-3
Semigeared 3 MWRotor diameters 90 and 100 mMultibrid-technologyTwo stage planetary gearPrototype in 2004ypSerial production 2005Annual volume approximately 20pp yComing years volume 50 annuallyyNacelle 127 tTotal weight nacelle + rotor 163 t Total weight nacelle rotor 163 t
156© MERVENTO
3.5.2011
WinWinD WWD-3
157© MERVENTO
3.5.2011
WinWinD WWD-3
158© MERVENTO
3.5.2011
WinWindD 3
3 MWRotor diameters 100, 109 and 120Frequency converter and transformer down to tower bbaseNacelle weight 80 t (without hub?)hub?)
159© MERVENTO
3.5.2011
Market positioningMarket positioning
Established turbines
150m
140m
120
130mRePower 5M
Bard 5.0
ØEnercon E-126
er
110m
120m Siemens SWT 3.6-120
Areva M5000
diam
ete
100m Siemens SWT 2.3-101
Siemens SWT 3.6-107
Alstohm E100Rot
or
90m Vestas V90MWT92
Established turbines mainly in the 2,5 MW class
80mØEnercon E-82 The rotor diameter depends on the wind class
Mainly high speed double fed turbines
161© MERVENTO
3.5.20117 MW2 MW 3 MW 4 MW 5 MW 6 MW 8 MW
ØDirect drive Medium speed High speedØOld fashioned technology ØModest technology ØFuture technology
New prototypes
150m
140m
120
130mRePower 6MGamesa G128
er
110m
120mRePower 3.2M114
diam
ete
RePower 3.2M114Ø Siemens SWT 2.3-113Nordex 2.4-117
100m Ø Siemens SWT 3.0-101RePower 3.4M104
ØLeitwind LWT101
SL3000/105
New prototypes mainly in the 3 MW class
Rot
or
Vestas V100
90m Doosan WinDS3000ØLeitwind LWT93
SL3000/90
New prototypes mainly in the 3 MW classThe rotor diameter depends on the wind classHigh speed approximately 50% of new
d l t80m
developmentsThe number of direct drive new developments has
increased recently
162© MERVENTO
3.5.20117 MW2 MW 3 MW 4 MW 5 MW 6 MW 8 MW
ØDirect drive Medium speed High speedØOld fashioned technology ØModest technology ØFuture technology
New developments Vestas V164
150m
140m
120
130m
Bard 6,5er
Sinovel 128
Dong Fang Ø?Ø Vestas 6MW Ø?
Alstohm Ø?Goldwind Ø?
110m
120mØ Mervento 3.6-118
ØGE 4.0-110
WinWinD 3
WinWinD 3diam
ete
Ø Darwind 5MWØ Mervento 4.5-118
Areva M6000 Ø?
g g
Shanghai Electric Ø?
Mitsubishi PSE Ø?
100m
WinWinD 3
New developments mainly in the 3 MW and 5-6MW classes
Rot
or
Goldwind 2,5MW
90mØ Avantis AV928 classes
The rotor diameter depends on the wind classHigh speed approximately 50% of new
d l t80m developmentsThe number of direct drive new developments has
increased recently
163© MERVENTO
3.5.20117 MW2 MW 3 MW 4 MW 5 MW 6 MW 8 MW
ØDirect drive Medium speed High speedØOld fashioned technology ØModest technology ØFuture technology
Wind class III
150m
140m
120
130m
er
110m
120mAcciona AW3000
RePower 3.2M114
WinWinD 3
diam
ete
Ø Siemens SWT 2.3-113Nordex 2.4-117
100m Previously the class III turbines has been 2,5 MW class
Rot
or
Vestas V100
90m All latest developments are 2 - 3 MW with very large rotor diameters or
Doosan WinDS3000
80m The class III turbines are mainly geared machines. The direct drive new comers are immediately focusing on class II and class I wind conditions.
164© MERVENTO
3.5.20117 MW2 MW 3 MW 4 MW 5 MW 6 MW 8 MW
ØDirect drive Medium speed High speedØOld fashioned technology ØModest technology ØFuture technology
Wind class II
150m
140m
120
130mØEnercon E-126
Gamesa G128
er
110m
120mØ Mervento 3.6-118
Acciona AW3000
Vestas V112
diam
ete
100m
Acciona AW3000
RePower 3.4M104
Alstohm E100ØEnercon E-101
SL3000/105
Previously the class II turbines has been 2,5 MW class
Rot
or
90m Vestas V90
Ø Avantis AV928MWT92
classAll latest developments are 3 MW with very large
rotor diametersG G128 i b bl i i f l I
80mØEnercon E-82 Gamesa G128 is probably aiming for class I
The class II turbines are becoming more and more direct drive (33%).
165© MERVENTO
3.5.20117 MW2 MW 3 MW 4 MW 5 MW 6 MW 8 MW
ØDirect drive Medium speed High speedØOld fashioned technology ØModest technology ØFuture technology
Wind class I Vestas V164
150m
140m
120
130mRePower 5M RePower 6M
Bard 5.0 Bard 6,5er
110m
120mØ Mervento 4.5-118
Siemens SWT 3.6-120
ØGE 4.0-110
Areva M5000
diam
ete
100m Acciona AW3000Siemens SWT 2.3-101Ø Siemens SWT 3.0-101
Siemens SWT 3.6-107
The class I turbines are very scatteredThere are lot of new developments going on
Rot
or
90mØLeitwind LWT93
SL3000/90
p g gfocusing mainly on the 5-6 MW segment
Dong Fang 5MW, Sinovel 5MW, Siemens 5-6MW, Vestas 6MW, Darwind 5MW, Hyundai +5MW,
80m Mitsubishi 5-7MW, Clipper Britannia 7,5MW, RePower 6M, Areva 6MW, Alstohm +5MW, Mitsubishi PSE 6MW
166© MERVENTO
3.5.20117 MW2 MW 3 MW 4 MW 5 MW 6 MW 8 MW
ØDirect drive Medium speed High speedØOld fashioned technology ØModest technology ØFuture technology
Offshore Vestas V164
150mT t l it
140m SupplierSize of turbine Number of
turbines
Total capacity supplied *)
MW2.3 MW 130 2993.6 MW 79 2842 MW 210 420
Siemens 1
Vestas
120
130mRePower 5M RePower 6M
Bard 5.0
2 MW 210 4203 MW 96 288
REpower 5 MW 8 40GE Wind 3.6 MW 7 25Source: BTM Consult Aps - October 2009 (*As per January 2009)
Vestas
Bard 6,5er
110m
120mØ Mervento 4.5-118
Siemens SWT 3.6-120
ØGE 4.0-110
Areva M5000
diam
ete
100m Acciona AW3000Siemens SWT 2.3-101Ø Siemens SWT 3.0-101
Siemens SWT 3.6-107
The class I turbines are very scatteredEnercon is not offshore (for the time
Rot
or
90m SL3000/90
(being)
The big offshore players are Siemens and Vestas
80m Other with a small track record are RePower, Areva, Bard, GE, Sinovel, WinWinD
167© MERVENTO
3.5.20117 MW2 MW 3 MW 4 MW 5 MW 6 MW 8 MW
ØDirect drive Medium speed High speedØOld fashioned technology ØModest technology ØFuture technology
Direct Drive turbinesDirect Drive turbines
Top 15 suppliers in 2009Total market 38,103 MWTotal market 38,103 MW
Vestas (DK); 12 5 %
Clipper (US); 1 6 %
Mitsubishi (JP); 1 5 %
Others; 11,9 %12,5 %
GE Wind (US); 12 4 %
United Power (CHI); 2,0 %
1,6 % 1,5 %Mingyang
(CHI); 1,5 %12,4 %
RePower (GE);
Nordex; 2,8 %
RePower (GE); 3,4 %
Siemens (DK);
Sinovel (CHI);Suzlon (IND);
5,9 %
Sinovel (CHI); 9,2 %
Enercon (GE); GoldWind Gamesa (ES); Dongfang; 6,5
Suzlon (IND); 6,4 %
169© MERVENTO
8,5 %(CHI); 7,2 %( );
6,7 %g g; ,
%3.5.2011Source: BTM Consult ApS – March 2010
Direct drive
Approximately 16% of the market 2009 was direct drive turbinesThe market share of the Enercon direct drive turbines is in Germany 60% (continously growing)The most produced turbine in the world is the Vensys 1,5 MW direct drive by a number of licensees eg GoldWindIn Sweden Piteå will the worlds largest wind power plant with 1101 turbines be built with Enercon direct drive turbinesSi i d l i di t d i t bi i 3MW d 5 6MWSiemens is developing direct drive turbines in 3MW and 5-6MWAccording to information from suppliers 80% of the new d l t i E f d di t d idevelopments are in Europe focused on direct driveThere is not any direct drive turbine aimed for the offshore yet (in progress Darwind 5MW GE 4 1MW Siemens 3MW and(in progress Darwind 5MW, GE 4,1MW, Siemens 3MW and 6MW as well as Mervento 4-4,5 MW)
170© MERVENTO
3.5.2011
Direct DriveInner rotor designsInner rotor designs
171© MERVENTO
3.5.2011
Direct DriveOuter rotor designsOuter rotor designs
172© MERVENTO
3.5.2011
Development 2007 2008 2009 2010Company Type/Size MW MW MW MWDevelopment
of direct drive (DD) concepts
Company Type/Size MW MW MW MWEnercon GmbH DDGermany 1) wound magnetsGoldwind (CN) DDVensys PMGMt (ES) DD
395 1,914 3,495
2,769 2,809 3,221 2,846
( ) pin the market from 2007 to 2010
Mtorres (ES) DDwound magnets
Impsa (Argentina) DDVensys PMGGE- Scanwind (NO) DD
18 n.a n.a
2) 39
n.a
- - 29 100
2010 ?Zephyros (NL) DD
PMGSiemens Wind Power (DK/GE) DD
PMG
2) 39
- - - -
37 3PMG
Others:Dongfang New Energy(CN) DD PMG 3
Hara XEMC (CN) DD PMG 80 128 454 507ZephyrosZephyrosSTX Heavy Industries (formerly Harakosan) (JP) DD PMGZephyrosTotal MW 2,867 3,339 5,663 6,951% of world market 14.50% 11.80% 14.90% 17.60%Source: BTM Consult - A Part of Navigant Consulting - March 2011
Notes:• Enercon’s track-record is outstanding. It has delivered 22,644 MW of its DD concept since 1994 in all models from 500 kW up to 7,5 MW.
Scan ind's fig re of 39 MW is c m lati e capacit b the end of 2009
173© MERVENTO
• Scanwind's figure of 39 MW is cumulative capacity by the end of 2009
3.5.2011
Siemens SWT- 2 3-113 -Siemens SWT 2.3 113 Direct-Drive WTG
174© MERVENTO
Source: Siemens Renewable Energy - Press release 14. March 20113.5.2011
Main Company Location Main permanent magnet
Ingeteam SpainABB SwitzerlandThe Switch FinlandSiemens Germanyg
generator suppliers
Siemens GermanyWeier GermanyConverteam FranceSicme Motori ItalyyElin AustriaTM4 Inc CanadaDanoteck USWi dG USWindGen USPotencia Industrial MexicoHyundai South KoreaCSR Electric ChinaCSR Electric ChinaNanqi ChinaHui Quan ChinaYuanda ChinaXiangdian ChinaXi’an Dunan ChinaYongyi China
175© MERVENTO
Source: BTM Consult - A Part of Navigant Consulting - March 2011
3.5.2011
Comparison of Disadvantages of DDNo gearbox and related wear an tear on Larger diameter of generator/nacelle
Advantages of DDComparison of direct drive and traditional
No gearbox and related wear an tear on mechanical components
Larger diameter of generator/nacelle complicates transportation and installation.
Simpler turbine with fewer parts Higher top-mass weight ')
Higher electrical (PM) and overall drive Expensive PM material potentiallydrive train designs
Higher electrical (PM) and overall drive train efficiency, producing higher energy yield
Expensive PM material – potentially uncertain security of supply
Lower maintenance and greater reliability with less downtime
More complex assembly of generator using PMsy g
Improved thermal characteristics due to absence of field losses
Demagnetisation of PM at high temperature
Full power conversion improves the turbine’s grid compatibility
More advanced cooling system required
F ll th th ti lFull power rather than partial power conversion makes the turbine more expensive
Comments:
Thi i i b d t diti l d i t i i i d bl f d i d ti t d
*) The general trend towards higher top-mass weight for direct drive turbines seems to have beenbroken by the new DD turbine SWT 3.0 from Siemens Wind Power
This comparison is based on a traditional drive train comprising a doubly feed induction generator anda 3-4 stage gearbox.
When comparing the PMG solution to the Enercon DD design, the latter is heavier and the absence ofa permanent magnet creates excitation loss when magnetising the coils, but the concept has animpressive track record from more than 20 GW of capacity in operation.
176© MERVENTO
Source: BTM Consult - A Part of Navigant Consulting - March 2011
3.5.2011
Geared versus Direct Drive - today
Geared Geared Direct driveDirect drive
+ Lower weight+ Lower weight + Low noise level+ Low noise level+ Smaller overall size+ Smaller overall size + Low vibration level+ Low vibration level
+ Reliability+ Reliability Strengths+ Components with shortest + Components with shortest possible supply chainpossible supply chain+ Higher total efficiency+ Higher total efficiency+ Higher total efficiency+ Higher total efficiency
–– NoiseNoise–– ReliabilityReliability
––WeightWeight–– SizeSizeReliabilityReliability
–– ReputationReputation–– AvailabilityAvailability
SizeSize–– Transportation Transportation –– ErectionErectionChallenges
–– TimeTime--toto--marketmarketg
177© MERVENTO
3.5.2011
Direct drive turbines
Existing direct drive turbinesEnercon (2,3MW – 7,5MW), GoldWind (1,5MW), Leitwind (1,5MW – 1,8MW), Mtorres (1,65MW), XEMC (Lagerway, Harakosan 2MW) GE/ScanWind (3 5MW)Harakosan 2MW), GE/ScanWind (3,5MW)
Prototype direct drive turbinesPrototype direct drive turbinesEnercon (3MW), EWT (2MW with China Energine), GoldWind (2,5MW), Leitwind (3MW), Avantis (2,5MW), Dong Fang (1,5MW), Siemens (3MW), Impsa (2,1 MW)
N d lNew developmentsShanghai Electric Company (5,4MW), Wind Direct (2,5MW), Schuler (2 7MW) Unison 3MW Mervento (3 6MW)Schuler (2,7MW), Unison 3MW, Mervento (3,6MW), GE/ScanWind (4MW), XEMC Darwind (5MW), Siemens (6MW), GoldWind (5-6MW), Nordex (6MW), Sway (10MW), AMSC
178© MERVENTO
Windtec (10MW HTS technology)3.5.2011
Direct drive turbines
Engineering companies developing wind turbinesGarrad Hassan (owned by GL), Aerodyn, AMSC Windtec, W2E Wind to Energy (Fuhrländer), Wind-Direct GmbH, Tembra (developing components for Schuler 2 7MW) EDAG Windrad(developing components for Schuler 2,7MW), EDAG, Windrad Engineering (not complete turbines), Windforce, Rotorwerk GmbH, S & G GmbH, P.E. Concepts,
Engineering companies that has developed direct driveGarrad Hassan (for Dong Fang in co-operation with Enmac and The Switch), P.E. Concepts (Sharpower 3MW China), Tembra (developing components for Schuler 2 7MW) Aerodyn (first DD(developing components for Schuler 2,7MW), Aerodyn (first DD developments for Unison)
In reality there is not any engineering company with skill and competence to develope direct drive turbines
179© MERVENTO
3.5.2011
Mervento 3 6-118 turbineMervento 3.6-118 turbine
Main parametersNear-shore Offshore
Wind turbine class S, IIA with extended temperature range
S, IB with extended temperature range
Vref 10 minutes mean extreme wind speed within 50 years at hub height
42,5 m/s 50,0 m/s
Turbulence intensity at 15 m/s Iref 0,16 0,14Extreme temperature range for stand-by -40ºC +50ºC -40ºC +50ºCA bi t t t i ti 30ºC 40ºC 30ºC 40ºCAmbient temperature range in operation -30ºC +40ºC -30ºC +40ºCNacelle temperature range in operation -20ºC +60ºC -20ºC +60ºCVave annual average at hub height 8,5 m/s 10,0 m/sRotor diameter 118 m 118 mH b h i ht 90 / 125 90Hub height 90 / 125 m 90 mDesign tip speed ratio 9,0 9,0Max tip speed 78,0 m/s 87,0 m/sNominal turbine speed 12,6 rpm 14,1 rpmCut in wind speed 4 m/s 4 m/sCut-in wind speed 4 m/s 4 m/sCut-out wind speed 25 m/s 25 m/sNacelle tilt angle 3º 3ºHub cone angle 3º 3ºBlade cone angle 1º 1ºBlade cone angle 1 1Rated wind speed 11,5 m/s 12,8 m/sNominal rating At sea level, 15°C, rated wind speed 3,6 MW 4,5 MWMechanical hub power at rated wind speed 4,0 MW 5,1 MWMaximum torque 3 067 MNm 3 423 MNmMaximum torque 3,067 MNm 3,423 MNmRotational speed at cut in 5,8 rpm 5,8 rpmWind speed at nominal turbine speed 8,7 m/s 9,4 m/sMaximum power coefficient Cp 0,48 0,48Power coefficient C at rated wind speed 0 40 0 38
181© MERVENTO
3.5.2011
Power coefficient Cp at rated wind speed 0,40 0,38Theoretical capacity factor at Rayleigh distribution 48,7% 55%
MERVENTO 3.6-118
Generator in front of tower
Common bearings forCommon bearings for turbine rotor and generator rotor
Total weight competitiveTotal weight competitive with geared turbines
182© MERVENTO
3.5.2011
Main circuit diagramPower losses for dimensioningPower losses for dimensioning
Rotor power 4000 kW
Mechanical after bearing 4000 – 5 = 3995 kWPower after generator 3995 – 190 = 3805 kWel
4440kVA
Power after tower cabling 3805 – 12 = 3793 kWel
150kVASelf consumption nacelle + electrical station 400V1 100 864440kVA
Power after transformer 3705 –39,5 (1,1%) = 3665,5 kWel
71 – 100 kWel, average 86 kWel
Power after MV switch gear 3594 3565 kWelPower after
frequency converter and filters 3793 – 88 (2,3%) = 3705 kWel
3594 – 3565 kWelAverage 3579 kWel
V i it b k b f f tVacuum circuit breaker before frequency converterThe accurate powers are in the power curve calculation. These powers to be used only in dimensioning of the components.
183© MERVENTO
3.5.2011
y g p
Medium voltage electrical systembenefitsbenefits
More silent frequency converterHigher reliabilityLower total weightLower total costMakes it possible for a topology with frequency converter and p p gy q ytransformer at tower baseTopology ready for even higher voltage levels in range 10 – 13 kV enabling turbines without transformer and centralized electrical station for several turbines
184© MERVENTO
3.5.2011
Advantages with electrical station at tower baseat tower base
Less weight in the nacelle to be erectederectedLower nacelle weight decreases tower weightgLonger life time and longer mean time between failure of frequency converter and transformersconverter and transformersEasier maintenance of frequency converter and transformersCooling water system at ground level, maintenance at groundControl room at ground levelControl room at ground levelElectrical station manufactured, assembled and tested at factoryShorter erection and commisioning timeLower total costs
185© MERVENTO
Lower total costsTotal weight approximately 35 tons 3.5.2011
Electrical stationGeneral overviewGeneral overview
Overall dimensions (mm) L x W x hmax = 11227 x 4654 x 4210Curvature shape roofDoor to control room
D f i t fDoors for main transformer
186© MERVENTO
3.5.2011
Frequency converter PCS6000
Voltage ride through (4ABB four quadrant (4Q) PCS6000 Medium Voltage
Voltage ride through (4 seconds at full power) and reactive power capability (no PCS6000 Medium Voltage
frequency converter, nominal voltage 3,9 kVTh h th l l
p p y (additional Statcom needed)In-line design. Size: 5112mm x 1244mm x 2466mm (L x W x H)Three phase, three level
semiconductors IGCT (Integrated Gate Commutated Thyristor)
1244mm x 2466mm (L x W x H)Weight: ~6580kg
187© MERVENTO
Gate Commutated Thyristor) power stack
3.5.2011
Low weight direct drive
188© MERVENTO
3.5.2011
Power curve comparison
189© MERVENTO
3.5.2011
Turbine maintenance costs over the life cyclethe life cycle
190© MERVENTO
3.5.2011
MERVENTO 3.6-118
Higher investmentg&
Higher revenue
&&Lower total cost ofLower total cost of
ownership (TCO)
=Superior net present
value NPV191
© MERVENTO3.5.2011
Comparison of Gross Marging
2 x Mervento 3.6-118 > 3 x 3MW-100 m
192© MERVENTO
3.5.2011
Direct Reliability
Mervento 3.6Mervento 3.6--118118The first completely gearless wind turbineThe first completely gearless wind turbine
193© MERVENTO
3.5.2011
The first completely gearless wind turbineThe first completely gearless wind turbine