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Gamesa Eólica New 2 MW WT: Gamesa G87-2.0 MW & G90-2.0 MW
February 2006
2 │▼
Gamesa Profile.1
Gamesa Eolica product development2
R&D Development.I
Modular Vertical Integration.II
Platform approach as the basis for Product Portfolio developmentIII
IV Gamesa G87-2.0 MW & Gamesa G90-2.0 MW Technologies
Agenda
3 │▼
RenewableEnergies
Aeronautics
Wind TurbineProduction
Advanced Services
Solar Installations
-Promotion
-Sell
-Prediction
-Agent
-Design
-Production
-Components
-O&M
-Turn Key
-Installation
-Civil work
-O&M
-Thermal
-Photovoltaic
Development and sell of
Wind Farms
1. Gamesa ProfileBusiness Areas.
4 │▼
Gamesa operates in the wind energy sector through three business units, leaders of their respective areas of promotion, manufacturing and services
Advanced Services
Depending on the local developers demand, Gamesa is able to provide a complete solution or a partial solution
Control %
Business Unit
Activity
100%100%100%
Wind Turbine ProductionPromotion of Wind Farms
Gamesa Energía Gamesa Eólica Gamesa Servicios
Resource Evaluation
MicrosittingFinancing Structure
WTG Design & Manufacturing
Turn-key contracts
Operation & Maintenance
Transfer to 3rdComponents
Design&Manufacturing
1. Gamesa Profile. Renewable Energies AreasBusiness Units.
Renewable Energies Areas
5 │▼
Major investments in R&D allow Gamesa Eólica to guarantee its state-of-the-art technology in the long-term
5 R&D centers in Pamplona, Bilbao and Denmark.
247 employees.
60.9 mill. € invested in 2004, equivalent to 3.4% of the group turnover.
Gamesa was ranked 5th in Spain by R&D investment. Gamesa is among the top 200
European companies investing in R&D in 2004.
35 patents granted and 17 requested (by end of 2004).
In 2004 Gamesa collaborated with 49 scientists and technologists in R&D projects.
Gamesa UPB: Highly Accelerated Life Testing center.
2. Gamesa Eólica product developmentR&D Development.
6 │▼
Gamesa Eólica transfers the maximal quality and cost advantages to its customers through this strategy
Gamesa Eólica considers the tailor-made development of the major components as a necessary element for the excellence in the design and production of the wind turbines
Blades Control Software
Gearboxes Generators Power Electronics
Towers
Design
Manufacturing
O&M
% of WTG Cost 20% 5% 15% 10% 5% 20%
100% In House 100% In House
100% In House
50% In House 60% In House
50% In House 60% In House100% In House
100% In House 100% In House 100% In House 100% In House 100% In House 100% In House
100% In House 50% In House
50% In House
2. Gamesa Eólica product developmentModular Vertical Integration.
30% In House
7 │▼
Number of Manufacturing Plants
Constructed Surface Total Surface
23 169.350 m2 552.940 m2
Gamesa Eólica counts on a large & geographically distributed industrial capacity to reduce logistics costs and enhance local value
2. Gamesa Eólica product developmentModular Vertical Integration. Annual Production Capacity.
Towers Blades Root joints Blade Moulds Generators & Converters
Gearboxes
2.310 MW 275 u. 2.416 MW 4.400 u. 8 G8X 1.200 MW 1.465 MW
6
Manufacturing Plants
2
Manufacturing Plants
6
Manufacturing Plants
1
Manufacturing Plant
1
Manufacturing Plant
3
Manufacturing Plants
4
Manufacturing Plants
Nacelle
8 │▼
PLATFORM RATED POWER PRODUCTS CHARACTERISTICS
Gamesa G5X – 850 KW 850 kW G52, G58Experience and
Profitability
Gamesa G8X – 2.0 MW 2 MW G80, G83, G87, G90Versatility and
Production
2. Gamesa Eólica product developmentProduct Portfolio. Platform approach as the basis for Product development
Modular strategy designing horizontal components for our product platforms which provide improved quality control, greater efficiency and flexibility
9 │▼
MODEL IEC DIBTRATED
POWER
GRID
CODE
TOWER
HEIGHTSNRSTM 50Hz 60Hz
G52
G58
G80
G83
G87
G90
IA
IIIB
IA
IIA
IIA
IIIA
WZII
WZII
WZII-III
WZII
WZII
850kW
850kW
2.000kW
2.000kW
2.000kW
2.000kW
44,55,60,65,74
44,55,60,65,71
60,67,78,100
67,78
67,78,100
67,78,100
Gam
esa
G5X
-850
kW
Gam
esa
G8X
-2.0
MW
2. Gamesa Eólica product developmentProduct Portfolio. Models and versions.
Complete range of the multi-MW market through models with rotors adapted to site conditions to maximize Value and Profitability
10 │▼
2. Gamesa Eólica product developmentProduct Portfolio. G8X Protopypes roadmap.
2002 200620042003 2005
Jun 2005
G90 Protopype
Almendarache (SPAIN)
May 2004
G87 Protopype
Lubián (SPAIN)
Sept 2002
G80 Protopype
Aguallal (SPAIN)
Sept 2003
G83
Protopype
Cinseiro (SPAIN)
Nov 2003
G80 60Hz Protopype
Koshizaki (Japan)
11 │▼
Model GAMESA G87
Rotor diameter 87m
Rated power 2.000 kW
Technology Pitch
Dobly fed generator
3 stages gearbox
Tower Heigh (m) 67, 78, 100
IEC Class IIA
Maximizing cost efficiency per kwh by maximizing
production in medium wind speeds.
42,5m blade using state-of-the-art manufacturing
technology based on glass fibre, carbon fibre and
pre-peg method for a lighter rotor design.
Reduced sound level and Gamesa NRSTM for
maximizing production while complying to specific
noise restrictions.
Grid connection technology that assures full
national grid codes compliance.
Gamesa SMP for predictive maintenance and
Gamesa SGIPE for remote operation.
Power density of 336 kW/m2
230 WTG installed by Dec. 2005.
2. Gamesa Eólica product developmentProduct Portfolio. Gamesa G87-2.0 MW.
12 │▼
Model GAMESA G90
Rotor diameter 90m
Rated power 2,000 kW
Technology Pitch
Doubly fed generator
3 stages gearbox
Tower heigh (m) 67, 78, 100
IEC Class IIIA
Maximizing cost efficiency per kwh by maximizing
production in low wind speeds.
44m blade using state-of-the-art manufacturing
technology based on glass fibre, carbon fibre and
pre-peg method for a lighter rotor design.
Reduced sound level and Gamesa NRSTM for
maximizing production while complying to specific
noise restrictions.
Grid connection technology that assures full
national grid codes compliance.
Gamesa SMP for the predictive maintenance and
Gamesa SGIPE for the remote control.
Power density of 314 kW/m2
2. Gamesa Eólica product developmentProduct Portfolio. Gamesa G90-2.0 MW.
13 │▼
5 5,5 6 6,5 7 7,5 8 8,5 9
Gamesa G80-2.0 MW 100% 100% 100% 100% 100% 100% 100% 100% 100%
Gamesa G87-2.0 MW 115% 114% 113% 112% 111% 110% 109% 108%
Gamesa G90-2.0 MW 121% 120% 118% 117% 115% 114%
Annual Energy Production (in comparison to Gamesa G80)
Mean Wind Speed (m/s)Model
2. Gamesa Eólica product developmentGamesa G87-2.0 MW and Gamesa G90-2.0 MW. AEP
Enhanced production for any wind resource through Gamesa G87 and Gamesa G90
14 │▼
2. Gamesa Eólica product developmentGamesa G87-2.0 MW and Gamesa G90-2.0 MW. WT Components
GEARBOXINTERCOOLERS
CRANE
TRANSFORMER
BEARING HOUSES
MAIN SHAFT
MAIN FRAME
COUPLINGGENERATOR
DISC BRAKE
A modular drive train for a reliable torque transmission to gearbox
15 │▼
SUBSYSTEMS MAIN FEATURES
ENVIRONMENTAL
CONDITIONS
Wind turbines designed for ambient temperatures ranging from –30º C to
+40º C , with versions for corrosive or sandy enviroments.
MECHANICAL SYSTEMS
&
AERODYNAMICS
Modular 3-stage gearbox
Main and secondary brake
Active Yaw system
Carbon and glass fiber reinforced composite blades
ELECTRICAL SYSTEMS Doubly-Fed variable speed generator
Built-in transformer
CONTROL & INFORMATION
SYSTEMS
Pitch regulated and variable speed control
SCADA: Gamesa SGIPE
CMS: Gamesa SMP
GRID CONNECTION
Low Voltage Ride Through: Active Crowbar and Oversized Converter
Active and Reactive power regulation: modules integrated in Gamesa
SGIPE
Frequency regulation: Embedded algorithm in PLC
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies.
16 │▼
2. Gamesa Eólica product developmentG87-2.0 MW and G90-2.0 MW Technologies. Environmental conditions I.
LOW TEMPERATURE
[-30º, +30º]
STANDARD
[-20º, +30º]
HIGH TEMPERATURE
[-20º, +40º]
Close nacelle cover Close nacelle cover
Air in lets and out lets, for the cooling system
Air outlets for hot air from generator, converter and transformer
Air heater to the main components of the nacelle
Electric cabinets with heating resistances included.
Inner air for gearbox, converter, hidraulic unit and generator.
Direct inlet for gearbox
Intercooler for the hydraulic unit
Temperature Versions
Na
ce
lle
c
ha
ng
es
Co
mp
on
en
ts
ch
an
ge
s
Nacelle tune to match environmental conditions
17 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Aerodynamics Systems I.
G90: 43,8 m.G90: 43,8 m.
G80: 39 m.G80: 39 m.
G87: 42,3 m.G87: 42,3 m.G83: 40,5 m.G83: 40,5 m.
G8X blades
6.500 Kg
7.300 Kg
6.150 Kg
5.800 Kg
Carbon fiber is used for obtaining more stiffness with lighter weights
18 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Aerodynamics Systems II.
State-of-the-art manufacturing process. Blades made of composite with glass and
carbon fiber reinforcement.
Carbon fiber is used for obtaining more stiffness with lighter weights.
Pre-preg manufacturing method
Lightining protection system
Delft University airfoils
G8X blades characteristics
19 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Mechanical systems I.
Improvements in Gamesa Active Yaw System
The yaw is active with hydraulic brake clamp that can be
regulated gradually.
The system is composed of 5 clamps avoid fatigues and
failures in the Yaw system.
4 electrical motors operated by WT controller based on
information received from the anemometers mounted on top of
the nacelle
Subjected to High Accelerated Life Testing at Gamesa UPB
Gamesa Active Yaw provides maximum adaptability to complex terrain
20 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Mechanical systems II.
Front Frame
One-piece casted part
Larger yaw-gears to improve yaw control
Approx. weight: 10,600 kg.
Subjected to High Accelerated Life Testing at Gamesa UPB
The one piece casted part front frame assures unique adecuation to the original design and
resistance to (i) support the weight of the nacelle and (ii) transmit the loads to the tower
21 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Mechanical systems III.
Gamesa UPB
HALT of a Front Frame in the Gamesa UPB facilities
High Accelerated Life Testing
facilities for frames and yaw system.
Frames and Yaw systems are
subjected to cycles of extreme loads
and fatigue.
Results obtained help to assure
high quality standards as well as
giving feedback for design
improvements
The life testing facility assures critical mechanical components reliability in design process
22 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Mechanical systems IV.
Designed for the load envelop of the whole platform: 2MW
DFM IEC IA/IIA/IIIA and DIBtII/III
3 combined steps, one planetary and two parallel helicoidall
Enjoys a lubrication system with an associated filtering
system.
Subjected to fatigue testing
New Gearbox design
Control sensors and Gamesa SMP accelerometers for predictive maintenance
23 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Electrical systems I.
Generator
Synchronous behaviour
4 poles Doubly-fed induction generation
Variable Speed through rotor currents control
Active and Reactive power control through control of rotor
current amplitude and phase
DF maximizes production and minimizes loads and noise levels in the most efficient way
24 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Electrical systems II.
Transformer
Three-phase, dry encapsulated type.
Output Voltage from 6,6 to 34,5 kV
Mounted inside the nacelle in G8X for reducing energy losses
and visual impact
LV protections
Fuses in stator and rotor bushbar
Neutral current relay
Temperature sensors
MV protections
MV switchgear
Spark sensor
MV Surge Arrester
25 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Control systems I.
Gamesa SGIPE
SCADA designed and developed by GEOL
Integrates WT management, weather masts and the electrical
substations
Graphic interface and Web access
Optional modules: Active power, Reactive power regulation,
Gamesa NRSTM , Wake effect control system and Shadow
control.
Modules for active and reactive power regulation, noise levels emission, wake effect control and
shadow control
26 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Control systems II.
Certified by Germanischer Lloyd
Monitors critical parts of the WTG, process the data and gives
information through SGIPE
Predictive maintenance core technology
Up to 8 accelerometers simultaneous management
Gamesa SMP
Serial CMS to anticipate to potential failures
27 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Control systems III.
Noise reduction system. Interchangeable control version depending on the noise emission
scheduling
Assures maximum energy production complying with local regulations
Several programmable parameters: date, day&night, season, wind direction, etc.
Gamesa NRSTM
28 │▼
ADVANCED VERSION
Low Voltage Ride ThroughFullfilment of main grid codes (REE, E.ON, FERC and others) for
simmetrical and unsimmetrical faults
Reactive regulation0,95 lead – 0,95 lag in output terminals of the generator for all the power
range.
Active Regulation Response time: 5% Pr/s
Frequency Regulation
f<101% 100% Pr
f>103% 65% Pr
Response time: 5% Pr/s
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Grid connection I.
Performance Summary
P
f
29 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Grid connection II.
Low Voltage Ride Through
Active Crowbar
Oversized Converter
Torque limiter
Fullfilment of the low voltage ride-through requirements defined in the FERC, EON, Spanish, Ireland & Others Regulations
30 │▼
2. Gamesa Eólica product development G87-2.0 MW and G90-2.0 MW Technologies. Grid connection III.
Reactive Power
Reactive Power (cos PHI 0.95 as an option in 690V)
~
PLC
. . . .
Power measurement
cos P (MW)
f (Hz)~
PLC
~
PLC
~
PLC
SGIPESET controlP, cos , f
for automatic control
P, Q
setpointRTU RTUDispatching
Electrical Utility
NetworkM.V.
GAMESA SGIPE manages wtgs and SET equipment reactive output through connection to SET
31 │▼
G87-2.0 MW and G90-2.0 MW Conclusions
G80
G83
G87
G90
IA
IIA
IIA
IIIA
WZII-III
WZII
WZII
2.000kW
2.000kW
2.000kW
2.000kW
60,67,78,100
67,78
67,78,100
67,78,100
Gamesa G87 & Gamesa G90 complete the Gamesa multi MW portfolio for medium and low winds
MODEL IEC DIBT RATED
POWER
GRID
CODE
TOWER
HEIGHTS
NRSTM
50
Hz
60
Hz
Gamesa G87 & Gamesa G90 provide the most efficient cost per kwh through the use of
technologies to maximize production
THANK YOU VERY MUCH FOR YOUR ATTENTION