ENGLISH

foreword 3

foreword
ENERCON began its road to economical/ecological success when graduate engineer Aloys Wobben founded the company in 1984. Since the companys launch, research and development have always determined the extent of innovation. And in 1991 ENERCON pioneered the development and manufacture of the worlds first gearless wind energy turbine system. This concept gave the decisive impetus for our claim: Energy for the world ENERCON began series production of gearless wind turbines in 1993 in response to high demand and fundamental advantages in terms of output, reliability and service life. All key components such as the rotor, the annular generator and the grid feeding system have always been developed and manufactured in-house. A concept with which ENERCON has maintained its position as the German market leader and has set standards in technology, quality and safety on all continents. With the new E-70 power class, ENERCON continues it's success story of extremely economical wind power utilisation. Due to the optimisation of major turbine components such as the new rotor blade geometry, the E-70 sets new standards in its power class in terms of yield, sound emission and service life. With its innovative grid feeding system, the E-70 meets the latest grid connection requirements and can therefore be incorporated into all supply and distribution structures. Numerous tower versions and hub heights of up to 113 metres also provide higher yield, both in coastal areas and inland.

drive system 5

Innenansicht einer E-70 Gondel

drive system
ENERCON E-70 rotor blade

DRIVE SYSTEM

drive system 7

Tip of an E-70 rotor blade

drive system
ROTOR BLADE CONCEPT
The new rotor blade concept of the ENERCON E-70 sets new standards with regard to yield, noise emission and stress minimisation. Because of their modified design, the blades also use the inner part of the rotor area and considerably increase the energy yield. The new E-70 rotor blades are also less susceptible to turbulence and provide an even flow along the entire length of the blade profile.

Advantages of ENERCON rotor blades:

~ Higher efficiency due to modified blade geometry ~ Less noise emission due to optimised blade tips ~ Longer service life due to reduced stress ~ Easier transport due to streamlined blade design
ENERCON E-70 rotor blades are manufactured using the so-called sandwich method. This comprises a laminate made of fibreglass-reinforced epoxy resin with a dense foam and balsa wood core. A special vacuum infusion process used during the production of the rotor blades guarantees pore-free material bonding and eliminates air pockets from forming in the laminate.

A new rotor blade geometry uses the even airflow around the nacelle and increases the energy yield

The blade tips have also been optimised with regard to noise emission and energy yield. Turbulences that occur at the blade tips due to overpressure and underpressure are effectively removed from the rotor plane. The entire length of the blade is therefore utilised without any loss of energy caused by turbulences.

Top layer made of PUR gel coat varnish for optimum weather protection Fibreglass-reinforced epoxy resin lends the blade its solid structure and provides the required rigidity

High-resistance foam and balsa wood form the core of the lightweight blade structure

Fibreglass-reinforced epoxy resin for solid structure and rigidity

Structure of an E-70 rotor blade (sandwich construction)

DRIVE SYSTEM

drive system 9

An ENERCON rotor blade with a double-row bolt connection guarantees additional security through even load distribution

The drive system of the ENERCON E-70 is simple: fewer rotating components reduce mechanical stress and increase the technical service life of the equipment. Maintenance and service costs for the wind turbine are lower (fewer wearing parts, no gear oil change etc.) and operating expenses are reduced. In the E-70, the rotor hub and the annular generator are directly connected to each other as a fixed unit without gears. The rotor unit is mounted on a fixed axle, the so-called axle pin. Compared to conventional geared systems that have a large number of bearing points in a moving drive train, the drive system of the E-70 has just two slowly moving roller bearings. The reason for this is the low speed of the ENERCON direct drive.

In order to effectively withstand wind stress over the entire usage period, the E-70 rotor blades have an extremely large blade flange diameter. The double-row bolt connection specially developed by ENERCON also provides additional strength by creating even load distribution. This is an important factor, particularly in extreme wind locations with large stress fluctuations.
Revs in bn As indicated by the load diagram, the load (F) is reduced by using a larger blade adapter diameter (D). In other words, the loading capacity increases. 8

F (%) 300

Apex bolt load

Conventional turbines

200

100 Gearless E-70 Fmax 1 2 D (m)

ENERCON direct drive: fewer rotating components increase the lifespan

0 10 20 years

E-70

The generator of an E-70 undergoes the same number of rotations in 20 years as the generators in conventional wind turbines in three months.

DRIVE SYSTEM

DIRECT DRIVE

drive system 11

ENERCON cast part processing

POWER FLOW CONCEPT

In addition to the ENERCON direct drive, the mechanical load is further reduced by a specially developed power flow concept that carries dynamic loads directly away from the rotor unit to the tower. In order to avoid possible excessive stress at welded seams, only cast parts are used in the vicinity of major components. ENERCON always collaborates closely with the foundries to further develop cast parts. All cast components are drawn on a 3D CAD system and calculated using the finite element method to test strain increases at the critical points. Functionality is tested and optimised by the designer during the entire prototype phase. In order to guarantee the identification and traceability of each cast component when the goods are received by ENERCON, each part is given a specific barcode, from which the serial number can be obtained in the event of quality problems, for example. The cast components are not released for further steps in the ENERCON manufacturing process until comprehensive quality testing has taken place. This guarantees that the high ENERCON quality standards are also fulfilled in the cast component supply sector. A few years ago only the rotor hub was made from cast steel, nowadays the use of modern spheroidal graphite cast iron makes it possible to manufacture other major components such as blade adaptors, axle pins and main carriers with this process.

The ENERCON power flow concept reduces mechanical loads

Quality testing procedure at ENERCON for cast components:

~ ~ ~

Structural investigation on the component Ultrasound test X-ray test

DRIVE SYSTEM

annular generator 13

annular generator
ENERCON E-70 annular generator production

ANNULAR GENERATOR

annular generator 15

Stator and rotor of the ENERCON E-70 annular generator

annular generator
The ENERCON annular generator is of primary importance in the gearless system design of the E-70. Combined with the rotor hub it provides an almost frictionless flow of energy, while the gentle running of fewer moving components guarantees minimal material wear. Unlike conventional asynchronous generators, the ENERCON annular generator is subjected to hardly any mechanical wear, which makes it ideal for particularly heavy demands and a long service life. Time-consuming repair work and the associated turbine downtimes are prevented at the same time. The ENERCON annular generator is a low-speed synchronous generator with no direct grid coupling. The output voltage and frequency vary with the speed and are converted for output to the grid by a DC link and inverter. This achieves a high degree of speed variability.

STATOR AND ROTOR

According to ENERCONs service life requirements the copper winding in the stator, the stationary part of the annular generator, known as closed, single-layer basket winding is produced in insulation class F (155 C). It consists of individual round wires that are gathered in bundles and varnish insulated. The copper winding is installed by hand at ENERCON. In spite of increasing automation in other manufacturing areas, preference has been given to manual labour in this case for good reason. It ensures that the insulating materials used can be fully tested. Furthermore, a special processing method also allows for continuous windings to be produced. Each wire strand is without interruption from the point of insertion to the exit.

Advantages of the ENERCON annular generator:

~ Yield-optimised control ~ High level of grid compatibility ~ No gear ~ Low wear due to slow machine rotation ~ Low machine stress due to high level of speed variability

Advantages of continuous winding:

~ ~ ~ ~

Prevents processing faults in the production of electrical connections Maintains the high-quality copper wire insulating system No contact resistance No weak points susceptible to corrosion or material fatigue

ANNULAR GENERATOR

annular generator 17

Pole shoes on the ENERCON E-70 disk rotor

QUALITY ASSURANCE
In order to guarantee the high ENERCON quality, the annular generators are all manufactured in the companys own production facilities. Top-class materials are used in all cases. Close collaboration with supplier companies has proved to be a reliable way of providing maximum material quality. For example, the enamelled copper wires are subjected to more testing than is specified in the standard and samples are archived, while surge voltage tests are performed on the pole shoes and chokes and then documented in the computer system.

The magnetic field of the stator winding is excited via so-called pole shoes. These are located on the disk rotor, the moving part of the ENERCON annular generator. Since the shape and position of the pole shoes have a decisive influence on the noise emission of the annular generator, the ENERCON Research & Development department has dedicated particular attention to this aspect. The result: optimum adaptation of the pole shoes to the running of the slowly rotating ENERCON annular generator means that no noise is generated.

TEMPERATURE BEHAVIOUR
The ENERCON annular generator features optimised temperature control. The hottest areas in the annular generator are constantly monitored by a large number of temperature sensors. The sensors activation temperature is well below the continuous temperature resistance of the insulating materials used in the annular generator. This means that overloading caused by excessive temperature is prevented.

Temperature Limit, enamelled copper wire (200 C) Limit, impregnating 200 resin (180 C) Actual temperature, copper conductor 100 Actual temperature, impregnating resin

Limit, insulation class F (155 C)

Actual temperature, superficial insulation

Actual temperature, winding surface

The highest operating temperature in the ENERCON E-70 annular generator is well below the limits applicable to the materials used

Limits for the insulating materials used Operating temperatures in the annular generator

Surge voltage test on pole shoes

ANNULAR GENERATOR

system control 19

system control
ENERCON E-70 control panel in the tower

SYSTEM CONTROL

system control 21

system control
ENERCON E-70 wind turbines are equipped with state-of-the-art microelectronic control technology developed in-house. The MPU (main processing unit), the central element of the E-70 control system, is in continuous contact with the peripheral control elements, such as the yaw control and active pitch control system. Its function is to adjust the individual system parameters to ensure that the ENERCON E-70 operates at optimum yield in all weather conditions.

ENERCON control system for a yield-optimised turbine operation under all weather conditions
SYSTEM CONTROL

~ evaluation of the measurement data from the wind sensor ~ Variable speed for optimal efficiency of the wind turbine at
Adaptive yaw control of the nacelle by means of constant every wind strength, and elimination of undesirable output peaks and high operating loads

Wind sensor on the ENERCON E-70 nacelle

MONITORING GRID CONNECTION

Ensuring correct feeding of electricity from the ENERCON E-70 into the grid requires grid connection monitoring. Grid parameters such as voltage, current and frequency are measured on the low-voltage side between the ENERCON inverter and the system transformer. The measured values are continously transmitted to the E-70 system control, enabling the turbine to react immediately to changes in the grid voltage or frequency. If the defined limit values of the system protection are exceeded, the E-70 wind turbine is reliably shut down and the service teams informed. As soon as the voltage and frequency return within the permissible tolerances, the E-70 wind turbine is automatically started up again. Prolonged downtimes are thus avoided.
For more details, please refer to the Grid connection chapter

~ Active pitch control system to set the ideal flow angle at the
rotor blades ensures maximum yields and load reductions for the entire wind turbine

~ ENERCON brake system for extreme turbine reliability by

means of three independently operating pitch mechanisms with standby power supply (batteries) in case of supply failure

~ Tower and generator monitoring by means of vibration and acceleration sensors to check the deflections in the tower ~ Temperature and air gap sensors between rotor and stator
ensure reliable operation in the ring generator

System control

Grid measurement Voltage Frequency

Generator

Rectifier

Inverter

Transformer

Monitoring grid feeding on ENERCON wind turbines

system control 23

ENERCON STORM CONTROL

ENERCON E-70 wind turbines are operated with a special storm control, which enables reduced turbine operation in the event of very high wind speeds. This avoids the otherwise usual stoppages and the considerable yield losses that result. The schematic diagram of the power curve of a wind turbine without ENERCON storm control looks like this:

ENERCON E-70 wind turbines operate on a different principle at high wind speeds. They are equipped with special storm control software which prevents sudden shutdowns.

Power

P(rated) Power

P(rated)

V1

V2

VStorm Wind speed

Power curve of a wind turbine with ENERCON storm control

V1

V2

V4

V3 Wind speed

Power curve of a wind turbine without ENERCON storm control

The diagram shows that the wind turbine stops at a defined shutdown speed V3. The reason being that a specified maximum wind speed has been exceeded. In the case of wind turbines without storm control, this occurs for example at a wind speed of 25 m/s within the 20 second mean. The turbine only starts up again when the average wind speed drops below the shutdown speed or a possibly even lower restart speed (V4 in the diagram; so-called strong wind hysteresis). In gusty wind, this may take some time, which means that considerable yield losses are incurred.

The power curve diagram with ENERCON storm control demonstrates clearly that the E-70 wind turbine does not shut down automatically when a certain wind speed VStorm is exceeded, but merely reduces the power output by lowering the rotational speed. This is achieved by turning the rotor blades slightly out of the wind. Once the wind speed drops, the E-70s blades turn back into the wind, and the turbine immediately resumes operation at full power. Yield-reducing shutdown and start-up procedures are thus avoided.

Example:
Yield loss due to two days of gusty wind per year 2 days x 2,000 kW = 96,000 kWh 2 4 % of yearly income

SYSTEM CONTROL

grid connection 25

grid connection
ENERCON E-70 wind turbines

GRID CONNECTION

grid connection 27

grid connection
In collaboration with German and foreign grid operators, ENERCON Research and Development has developed a grid connection system that provides problem-free integration of ENERCON wind turbines into existing power supply and grid structures. The ENERCON grid connection system meets all the new connection stipulations for wind turbines, such as those from E.ON Netz GmbH, and has been classified as very good by power supply companies because of its adaptability and grid-supporting effect. ENERCON wind turbines are available for integration in transmission grids (Transmission version) or distribution grids (Distribution version).

~ If necessary, wind farms must be able to contribute to

maintaining voltage stability in the grid by supplying or accepting reactive power

~ Wind farms must be able to be integrated in the grid control

centre for telemonitoring and remote control of all systems in the grid

Typical requirements for wind turbines in transmission grids.

~ Wind turbines must be able to remain connected to the grid

without power reduction even if considerable voltage and frequency deviations occur

~ If voltage dips occur because of grid problems, wind turbines must remain connected to the grid for a defined period ~ Short circuit current feeding may be demanded during a grid problem ~ After a fault has been remedied, a wind farm must resume its
power feed as quickly as possible and within specified maximum times

The energy generated in the ENERCON annular generator is fed to an inverter via a rectifier and a so-called DC link. This ensures that the output power is regulated in accordance with grid specifications. This is where the stipulated requirements for each individual turbine in a wind farm, such as voltage, frequency and reactive power, are implemented. The wind turbines transformer makes the conversion from 400 V to the appropriate grid voltage.
GRID CONNECTION
20 kV 110 kV Control station grid operator

Wind farm 3

Wind farm 2

Wind farm 1

~ Wind farms must be able to be operated with reduced power output without any time restrictions ~ For coordinated load distribution in the grid, the increase in
power output (power gradient), for example when the wind farm is started up, must be able to be restricted in accordance with the grid operators specifications

Wind farm SCADA 3

Wind farm SCADA 2

Wind farm SCADA 1

Substation

ENERCON substation control

Operating technology

~ Wind farms must make a contribution to the reserve power in

the grid. If the grid frequency increases, the power output of a wind farm must be reduced
Connecting ENERCON wind farms to the grid

grid connection 29

STAYING ON THE GRID WHEN GRID PROBLEMS OCCUR

Similar to the way in which power stations operate, wind turbines in transmission grids should not disconnect from the grid as quickly as possible when short circuits occur. They should be capable of remaining connected to the grid for up to three seconds if voltage dips occur due to grid problems. An ENERCON wind turbine has this capability. If necessary, the turbine also supports the grid voltage if problems arise. This is achieved by feeding in variable short circuit current. After the problem has been remedied and the grid voltage has been restored, the wind turbine immediately continues feeding power.
Power WEC/current P(rated) |Short circuit Power e.g. 0.5 P(rated) Current

VOLTAGE REGULATION IN DISTRIBUTION GRIDS

If a wind farm is connected to a transformer substation together with the consumers, the automatic voltage regulator (AVR) and the underlying voltage of the wind farm are regulated by the ENERCON Voltage Control System (VCS). This specially developed system helps to maintain the quality of the grid voltage and also prevents voltage changes and grid shut-offs when rapid switching operations occur.
Wind turbine Transformer station H.V. GRID

AVR

Voltage control system

ENERCON substation control

Voltage quality

Short circuit current

Grid short circuit

COORDINATED GRID FEEDING IN NETWORK

In order to provide reliable economical grid operation, the power feed timing has to be regulated. In order to ensure that this takes place, variable setpoint values for maximum permitted power gradients can be specified for ENERCON E-70 grid feed. For example, when the wind turbine or wind farm is started, the power feed can be controlled according to specifications. This gives the grid operator the possibility to adapt the load flow and voltage stability in the grid and to optimise the interaction between the power generators and consumers.
Wind farm power Grid failure Grid recovery

COMPENSATING FOR REACTIVE POWER BALANCES

Reactive power must be regulated when operating transmission and distribution networks. It is necessary to compensate for transmission equipment such as cables and transformers, and to maintain voltage stability. The ENERCON E-70 has a wide operating range for exchanging reactive power that can be provided to the grid as a system service. In this case the ENERCON E-70 process data interface (PDI) provides the necessary conditions for communication between grid operators and the wind turbine.
Real power 100 %

Time [minutes]

Power gradient

Reactive power, overexcited

Reactive power, underexcited

Reactive power management

GRID CONNECTION

grid connection 31

FEEDING INTO WEAK GRIDS

Not all regions have sufficient transmission capacity available to manage each lowload and strong wind situation. ENERCON bottleneck management offers the possibility of connecting wind farms to this type of grid. If grid operation is threatened, the wind farm output can easily be reduced on demand using the ENERCON process data interface (PDI).
Line 1 Bottleneck (e.g. line 1 fails) P100% Wind farm output (can be infinitely adjusted during bottlenecks at the grid operators request) Signals from the grid operator Wind farm Line 2

The ENERCON 10-point grid formula Optimum adaptation to many different grid types

~ Maximum utilisation of grid connection capacity for feeding in power ~ Sinusoidal feed current ~ If grid problems occur (e.g., short circuit) the turbine remains
on the grid for up to 3 seconds and optionally supports the grid voltage by feeding in a short circuit current. When the problem has been remedied the turbine immediately resumes the power feed

Overload I max

Current transmission line 2 Bottleneck rectified Time

~ During the start-up procedure the turbine is connected with

zero current and runs up to nominal power in a controlled manner

Bottleneck management

POWER REGULATION FOR OPTIMUM YIELD

If the cumulative (nominal) output of a wind farm is greater than the grid connection capacity, ENERCON wind farm power regulation ensures that the capacity is used efficiently at all times. If a wind turbine in the wind farm fails or generates less power, the other turbines are operated at an appropriately higher capacity. This is dealt with automatically by the ENERCON generation management system.
Power output wind turbine 100% P 80% Grid capacity = 80% of the cumulative rated power installed (equivalent to the energy supply without generation management) P Rated power installed per turbine

~ The power factor of the turbine can be electronically adjusted ~ The flicker values are negligible ~ Active contribution to frequency stability by reducing power and increasing the frequency, even if grid problems occur ~ Voltage regulating facility in distribution grids, therefore maintaining the voltage quality ~ Optimum operation, even at weak grid points of common coupling ~ No system perturbation caused by switching operations such as
generator stages or capacitors

Wind turbine

If there is no generation management for the energy supply in this case, the available grid capacity cannot be exploited to the full.

Generation management

GRID CONNECTION

tower and foundation 33

tower and foundation

Manufacturing of ENERCON tubular steel towers

TOWER AND FOUNDATION

tower and foundation 35

Production of ENERCON prefab concrete towers

TOWER VERSIONS
Depending on the location and the service conditions, different tower versions made of steel and concrete are available for the ENERCON E-70.

Hub height 64 m 85 m 98 m 113 m

Tubular steel tower X X X

Prefab concrete tower

X X

tower and foundation

ENERCON tower versions for E-70 wind turbines

TOWER CONSTRUCTION
The load dynamic design of materials and structure used in ENERCON towers provides the best conditions for transport, installation and use. Over and above the binding national and international norms (e.g.: DIN and Eurocode) ENERCON sets its own specifications which surpass quality and safety standards. Virtual 3D models of the tower designs are produced during the development phase using the finite element method (FEM), with which all the stresses to which the wind turbine is subjected in reality are simulated. This means that accurate predictions concerning the stability and service life of the towers are not left to chance before building a prototype. The evaluation of additional measurements, which ENERCON continuously carries out on existing turbines, contributes to providing further verification of the calculated data. ENERCONs calculations are confirmed by the results produced by specially commissioned certification bodies, research institutes and engineering firms.

Hub height

Hub height 113 m

98 m

98 m

64 m +33% +14%

Yield comparison of E-66 (E-70 predecessor) wind turbines with 64 and 98 m hub heights at the Aurich/Knigsmoor site (time-frame: 01/03 to 12/03)

Yield comparison of E-66 (E-70 predecessor) wind turbines with 98 and 113 m hub heights at the Ermke site (time-frame: 12/03 to 03/04)

TOWER AND FOUNDATION

tower and foundation 37

ENERCON foundation section with adjust tubular steel tower to the foundation

TUBULAR STEEL TOWER

ENERCON tubular steel towers are manufactured in several individual tower sections, which are connected using component-protecting L-flanges. Unlike conventional flange connections (such as those used in steel chimney construction), the welding seam of the L-flange is outside the stress area. Other advantages of this connecting technology are: dispenses with complex and costly welding work on site rapid, reliable assembly to the highest quality standard full corrosion protection, applied under best production engineering conditions The ENERCON tubular steel towers are attached to the foundations using a specially developed foundation section that is aligned with millimetre accuracy by means of adjusting bolts before concreting takes place. The ENERCON form follows function principle has been efficiently applied in the development of the foundation section: high strength and good dimensional stability ENERCON series quality components time-saving compact system assembly less crane time saves money

Manufacturing of ENERCON tubular steel towers

Like all other components, the tubular steel towers are subject to strict ENERCON quality standards. Quality assurance is already integrated in the development of new tower types during the construction phase. This determines whether the prototype meets all requirements before it goes into series production.
In the case of the L-flange used by ENERCON, the welding seam is located outside the tension range

Conventional flange connections with a welding seam (red) in the tension range

TOWER AND FOUNDATION

tower and foundation 39

Reinforcing steel in the ENERCON round foundation

PREFAB CONCRETE TOWER

ENERCON prefab concrete towers are made using specially developed prestressing steel reinforcement. The individual tower sections and the foundation are fastened together as an inseparable unit using bracing wires that run through the core of the concrete tower wall in jacket tubes. The tower sections themselves are manufactured entirely in the precasting plant. The high degree of manufacturing accuracy for the individual concrete sections is provided by specially constructed steel formwork. This manufacturing process minimises dimensional tolerances and guarantees a high degree of fitting accuracy during erection. Here too, strict checking by ENERCONs quality assurance department is mandatory. Detailed procedural and work instructions are available for each manufacturing area. This ensures that each individual work stage and the materials used can be completely retraced.

FOUNDATION CONSTRUCTION
The foundation transmits the weight and the wind stress of the wind turbine into the ground. ENERCON foundations are always circular.

Since the ground can only absorb a certain amount of compressive strain depending on the location, the foundation surfaces must be adapted accordingly. The design of the ENERCON round foundations, usually installed as shallow foundations, is based on this extremely simplified finding. If necessary, (in soft soil) a special deep foundation provides force distribution down to deeper load-bearing soil strata. The piles are arranged symmetrically and slightly inclined so that the imagined extended pile centre lines meet at a point above the centre of the foundation. This provides optimum power/load flow distribution over the entire surface.

ADVANTAGES OF ENERCON ROUND FOUNDATIONS

The forces are equal in all wind directions, whereas asymmetrical foundation pressure is possible with square bases or cross-shaped foundations. The circular design has been proven to reduce the amount of reinforcement and concrete required. The circular design reduces the size of the formwork area. Backfilling the foundation with the soil from the excavation pit goes into the structural analysis as a load. This means that less reinforced concrete is needed to make the foundation stable.

Both pictures: Weight distribution in the case of flat and deep ENERCON round foundations

Tower segments for ENERCON prefab concrete towers

TOWER AND FOUNDATION

service and maintenance 41

service and maintenance

ENERCON on-site service

SERVICE AND MAINTENANCE

service and maintenance 43

Each customer has a designated service centre contact

SERVICE MANAGEMENT
Each ENERCON E-70 wind turbine has a modem link to the central remote data transmission facility. If the turbine signals malfunction, the service centre and the responsible service branch are notified via the SCADA remote monitoring system. The message is automatically transferred into the ENERCON deployment planning software and displayed on the screen of the office employee. With the aid of a specially developed locating system (GIS Geoinformation System), the deployment planning system automatically locates the service team that is closest to the wind turbine. The service teams can access all the turbine-specific documents and data using so-called pentops (robust, portable computers with a link to the service centre). This guarantees that all maintenance is dealt with as quickly and efficiently as possible. A new standard in service management.

service and maintenance

DECENTRALISED SERVICE STRUCTURE
The aim of the ENERCON Service Department is to ensure and maintain the operational readiness of all ENERCON wind turbines. In accordance with the Speedy service through local presence principle, approximately 1100 employees at 113 service stations worldwide (as at 12/2004) provide the quickest possible maintenance and servicing of the wind turbines. This guarantees short distances for the service technicians and provides a high degree of availability (average in the last years more than 98.5 %). A well-coordinated office team is also an important factor for efficient field service organisation. More than 100 employees coordinate global service operations at ENERCON, from both a technical and commercial point of view. Each customer has a designated service centre contact. This generates trust and ensures that detailed knowledge of the local conditions of the wind turbines is available.

Wind farm

Meteorological analysis

Customer interface

PDI

Power management

Pentop service technicians

Wind farm display

Prescribed set value, utility

Set values

SCADA management Remote control Customer Telephone SMS | Fax | E-mail SIP | WWW CONTROL CENTRE SMS | GSM | GPRS IP | Tel | GSM

ENERCON Service performance profile:

~ Servicing and maintenance of all wind turbines erected by ENERCON ~ Turbine monitoring via remote data transmission ~ Maintenance of technical availability of wind turbines serviced by ENERCON ~ Customer care in all technical and commercial matters ~ Operator training

ENERCON service management sets new benchmarks

SERVICE AND MAINTENANCE

ENERCON development

Call-out planning

service and maintenance 45

http://sip.enercon.de

Service Information Portal (SIP)

The Service Information Portal (SIP) provides ENERCON customers with a simple and rapid way of obtaining all the information they require about their own wind turbines via the Internet from anywhere in the world. All that is needed to do this is a computer with a so-called Web browser (e.g. Microsoft Internet Explorer) and an Internet connection. A changing PIN, an individual password and encrypted transmission routes provide three levels of data protection in accordance with the latest security criteria. The clear menu structure of SIP provides rapid and individual access to all turbine data. Work processes that would normally take hours, such as producing analyses of wind turbines, checking maintenance logs or producing up-to-date yield overviews can be done in a matter of minutes using SIP. A boost to efficiency that not only serves to increase customer satisfaction but also improves the flow of information (among partners in a wind farm, for example).

ENERCON PARTNERKONZEPT (EPK)

The ENERCON PartnerKonzept (EPK) gives customers the guarantee of consistently high turbine availability for the first twelve years of operation with calculable operating costs. From servicing to safety work, maintenance and repairs, all eventualities are covered by a single agreement. Because of its economical service reliability, the EPK has long since become an acknowledged ENERCON quality feature. More than 90 % of all E-66 wind turbines (E-70 predecessor) operators have signed an appropriate EPK agreement.

Damage caused by unforeseeable events such as acts of nature and vandalism can be covered by a specially developed EPK additional insurance policy. Significantly cheaper than conventional machine failure insurance, the EPK additional insurance is now available through all well-known insurance companies.

EPK at a glance:

100% 75% 573 50% 25% 6 0% 1997 1998 1999 2000 2001 2002 2003 66 140 280 1057 1513

~ Guarantee of at least 97% technical availability ~ All servicing costs covered ~ All maintenance costs covered (including wear costs etc.) ~ All repair costs covered ~ Agreement term of twelve years (with possible extension) ~ Agreement can be terminated with three months notice at any
the term
SERVICE AND MAINTENANCE

time; ENERCON can only terminate the agreement at the end of

E-66 wind turbines (E-70 predecessor) with EPK

technical specifications 47

technical specifications

TECHNICAL SPECIFICATIONS

technical specifications 49

1 3 4 5
1 2 3 4 5 6 Main carrier Yaw motors Ring generator Blade adaptor Rotor hub Rotor blade

TECHNICAL DATA
Rated power: Rotor diameter: Hub height: Turbine concept: Rotor Type: Direction of rotation: Number of blades: Swept area: Blade material: Rotational speed: Tip speed: Pitch control: Drive train with generator Hub: Main bearings: Generator: Grid feeding: X
TURM- & FUNDAMENTBAU TECHNICAL SPECIFICATIONS PLANUNG SERVICE & & WARTUNG Technik

2000 kW 71 m 64 113 m (various towers and bases) Gearless, variable speed, variable pitch control

SYSTEM MANUFACTURING
ENERCON E-70 wind turbines are individually manufactured taking the location, the conditions of service and the applicable regulations and guidelines into consideration.

OPTIONS AND ACCESSORIES:

Tower versions

Upwind rotor with active pitch control Clockwise 3 3959 m2 Fibreglass (epoxy resin); integrated lightning protection Variable, 621.5 rpm 2280 m/s ENERCON blade pitch system, one independent pitching system per rotor blade with allocated emergency supply Rigid Dual-row tapered/single-row cylindrical roller bearings Direct-drive ENERCON annular generator ENERCON inverter 3 independent blade pitch systems with emergency supply Rotor brake Rotor lock Active via adjustment gears, load-dependent damping 2.5 m/s 13.5 m/s 2834 m/s ENERCON SCADA

Hub height 64 m 85 m 98 m 113 m

Tubular steel tower X X X

Prefab concrete tower

Braking systems:

Personnel lift (for towers up to 98 m) Special tower paint Shallow foundations and deep foundations Grid characteristics (transmission / distribution / chopper cabinets / UPS) Transformer substations Day and night identification / synchronisation Shadow shut-off Blade heater Heated anemometer External display

Yaw control: Cut-in wind speed: Rated wind speed: Cut-out wind speed: Remote monitoring:

NETZANBINDUNG

ANLAGENSTEUERUNG

RINGGENERATOR

ANTRIEBS SYSTEM

references 51

GERMANY
Number of installed wind turbines: 5,617 Total power: 6.0 GW

enercon wind turbines at a glance

WORDLWIDE
Number of installed wind turbines: 8,453 Total power: 8.1 GW

As at: 11/2005

REFERENCES

International Dept. ENERCON GmbH Otto-Lilienthal-Strasse 25 28199 Bremen GERMANY Phone +49 421 244 15 20 Fax +49 421 244 15 39 sales.international@enercon.de
ENERCON GmbH Austria Hauptstrasse 19 2120 Wolkersdorf AUSTRIA Phone +43 2245 828 28 Fax +43 2245 828 38 ENERCON Benelux B.V. Paxtonstraat 1 a 8013 RP Zwolle THE NETHERLANDS Phone +31 38 422 82 82 Fax +31 38 422 80 10 ENERCON GmbH France 8, Chemin d Armancourt 60200 Compigne cdex FRANCE Phone +33 3 44 37 35 10 Fax +33 3 44 37 35 20 ENERCON GmbH Italy Via Luciano Manara, 5 00044 Frascati (Roma) ITALY Phone +39 06 94 01 69 1 Fax +39 06 94 01 69 299 ENERCON GmbH Portugal c/o Gellweiler, S.A. Travessa do Alecrim, 32 1200-019 Lisboa PORTUGAL Phone +351 21 340 71 60 Fax +351 21 340 71 69 ENERCON GmbH Spain Valncia Parc Tecnolgic Av. Juan de la Cierva, 27 46980 Paterna (Valncia) SPAIN Phone +34 961 36 62 90 Fax +34 961 36 78 75 ENERCON GmbH Brazil Wobben Windpower Lda. Av. Fernando Stecca n 100 Distrito Industrial CEP 18087450 Sorocaba So Paulo BRAZIL Phone +55 15 21 01 17 00 Fax +55 15 21 01 17 01 ENERCON GmbH Egypt c/o Zaki International Trading 23 Kasr El-Nil Street Cairo 11111 EGYPT Phone +20 2 392 36 70 Fax +20 2 417 00 23 ENERCON India Ltd. Kolsite House, Plot No. 31 Shah Industrial Estate Veera Desai Road, Andheri (West) Mumbai 400 053 INDIA Phone +91 22 56 92 48 48 Fax +91 22 26 73 00 85 ENERCON GmbH Canada Wind Power Inc. Suite # 222 Lebel Mansion 696 Kettles Street, Pincher Creek Alberta TOK 1WO CANADA Phone +1 403 627 29 23 Fax +1 403 627 32 39

ENERCON GmbH Great Britain Axiom House, Station Road Stroud, Glos. GL5 3AP GREAT BRITAIN ENERCON Hellas S.A. Phone +44 1493 78 20 18 20, Pentelis Avenue Fax +44 1493 78 90 94 15235 Vrilissia, Athens GREECE Phone +30 210 683 84 90 ENERCON GmbH Denmark Fax +30 210 683 84 89 Bredkr Parkvej 62 8250 Egaa DENMARK ENERCON Servis Ltd. Sti. Phone +45 87 43 03 88 Bagdat Cad. No 187 A Blok daire 5 Fax +45 87 43 03 44 Selamicesme Kadikoy Istanbul TURKEY ENERCON GmbH Sweden Phone +90 216 385 47 15 c/o Energy Converter AB Fax +90 216 360 64 92 Stenldersgatan 19 21376 Malm SWEDEN ENERCON GmbH Australia Phone +46 40 14 35 80 Export Drive Fax +46 40 22 24 20 Darwin Business Park Berrimah 0828 Northern Territory AUSTRALIA Phone +61 889 47 09 33 Fax +61 889 47 09 25

ENERCON GmbH Dreekamp 5 D-26605 Aurich Phone +49 4941 92 70 Fax +49 4941 92 71 09 www.enercon.de