Project Report on

INDUSTRIAL TRAINING IN WINDWORLD INDIA

By

PRABHJOT KHURANA
MAHARAJA AGRASEN INSTITUTE OF TECHNOLOGY, NEW DELHI Wind World (India) Ltd. Submitted for partial fulfilment of the requirements for the award of the certification of completion of Industrial Training successfully

Plot No. 33 Daman Patalia Road Bhimpore Daman - 396210

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ACKNOWLEDGEMENT

I would like to express our heart full thanks to Mr. Amith Sagar (Assistant Manager,WTA) for the opportunity provided to me. He has provided a platform to complete my summer training in Windworld (India) Ltd. Daman, where I gained knowledge related to wind energy and its generation. It is my privilege to express sincere thanks to Col.Bharat Sharma (Dean,WTA) for his unconditional cooperation and support. He has served me with the excellent research facilities, exquisite equipments and helped me in all of his capabilities to make it a fruitful learning experience. I acknowledge with thanks the kind of patronage to Mr. Shivaji Chape (site incharge) for his loving inspiration, timely guidance, for providing me with all the finer details of the Turbines and in all practical concepts of Generation. He has helped me throughout the training in all respects to complete this task. I would like to express my heart full thanks to Dr.Rajveer Mittal (Head of Department Electrical and Electronics), MAIT and other faculty members for encouraging me to take training at such an esteemed organization.

PRABHJOT KHURANA
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ABSTRACT
Practical training in an industry is an essential part of an engineering curriculum towards making a successful engineer. In an industry a student can actually realize the practical implementation of the textbook knowledge acquired in the classroom and gets an exposure to the modern technology. In the field of Electrical and Electronics there has been rapid development to support the ever increasing demand. Students gets an opportunity during training period to gain knowledge about the latest technologies. The training period of six weeks though not sufficient to gain comprehensive knowledge but one is expected to identify components, the process flow in an industry and have a generalized idea of technology used. Due to all the above reasons and in order to bridge the gap between theory and practical, our engineering curriculum provides a provision for practical training. During this period a student gets a hands-on experience in industry and is subjected to various problems incurred during practical implementation. I have undergone a six weeks training (after 3rd year) at WindWorld (India) Ltd., Daman This report has been prepared on the knowledge which I acquired during my training at company.

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CONTENTS 1. Company profile............................................................................................................................8 2. Introduction to wind and wind energy............................................................................16 2.1 2.2 2.3 2.4 Wind..................................................................................................................................16 origin of wind................................................................................................................16 Wind energy..................................................................................................................16 measure application of wind power............................................................16 2.4.1 Application requiring mechanical power...................................16 2.4.2 As off-grid electrical power sources.............................................17 2.4.3 As grid-connected electrical power sources.............................17 2.5 2.6 2.7 advantage of wind power .......................................................................................17 disadvantage of wind energy.................................................................................19 Future prospects.........................................................................................................20

3. Wind turbine Siting...................................................................................................................21 4. Wind turbine................................................................................................................................22 4.1. 4.2. 4.3. 4.4. 4.5. Name detail.............................................................................................................23 Tower........................................................................................................................23 Nacelle assembly..................................................................................................24 Rotor head assembly..........................................................................................24 Rotor blades...........................................................................................................25

5. Power generated by generator............................................................................................26 6. Wind resources development...............................................................................................27 7. Wind energy conversion system.........................................................................................30 8. Synchronous generator...........................................................................................................33 8.1 Introduction..........................................................................................................................33 8.2 Generation of EMF..............................................................................................................34 8.3 Direction of induced e.m.f...............................................................................................38 8.4 Electromagnetic Force.....................................................................................................39 8.5 Elementary AC. Generators............................................................................................41 8.6Advantage of the ENERCON synchronous generator...........................................43 9. Sensors..............................................................................................................................................44 9.1 Actuators........................................................................................................................45
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10. Grid management system......................................................................................................46 11. Some Photographs taken during training.......................................................................47 12. Conclusion....................................................................................................................................49 13. Bibliography................................................................................................................................50

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List of Figures
1. Sales Turnover.....9 2. Installed Capacity....10 3. Wind profile....18 4. Installed Capacity from Renewable Energy as on March 2010......................19 5. Noise Profile20 6. Wind turbine.....23 7. Gearless Technology..24 8. Blade Manufacturing.25 9. Conversion Efficiency26 10. Wind Resources Development Process...............................27 11. Block Diagram Of WEC System...30 12. Generator Manufacturing...34 13. EMF generation ...............................................35 14. Conductor of length l moving through a magnetic field B ..35 15. Sinusoidal voltage waveform...36 16. Effect of change of flux linkages on induced EMF in a conductor...37 17. Flemings right hand rule for direction of induced EMF.38 18. Force on a current carrying conductor in a magnetic field...40 19. Elementary synchronous generator41 20. Sensors....44 21. Grid Management system46

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About WINDWORLD (India)

Background Note
The origins of our story began in 1994, way before the first gusts of an energy crisis blew across our land. It was a time when wind energy emerged not as an alternative, but a mainstream, renewable, eco-friendly source of power generation. 'Since then we've emerged as the country's preferred wind power solution provider, on a number of counts. Wind World (India) Limited (WWIL) formerly Enercon (India) Limited has always been a path breaker, with innovations that have consistently left the others behind. Gearless technology, an energy-efficient grid feeding system and long-lasting warp resistant blades are just cases in point. Our wind farms today straddle seven high wind potential states Karnataka, Maharashtra, Tamil Nadu, Rajasthan, Gujarat, Madhya Pradesh and Andhra Pradesh, spread across 3,000 kms of India. We have installed over 5500 Wind Energy Converters (WECs) with a capacity of over 4000 MW. We are maintaining these WECs round the clock 24 x 7 for optimum performance. We're an ISO 9001:2008 certified company for Manufacturing, Installations and Services. Wind energy converters are manufactured at four plants in Daman; while concrete towers are manufactured at facilities in Gujarat, Karnataka and Tamil Nadu. We employ over 5,600 dedicated people and have set up the Wind World Training Academy at Daman, for training world class operations, maintenance and asset management support teams. In terms of business results, we've achieved a turnover of INR 3636 crores in FY 201011 and recorded highest ever turnover of INR 4270 in FY 2011 -12, WWIL is poised to cross INR 4500 crore mark in the year ahead (FY 2013-14). So what powers our success?

Concept-to-Commissioning-to-Lifetime care solutions. Superior product offering. An obsession with Quality. Trained Manpower.

'Over the years, our passion about wind energy continues to power our sails.

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Business Vision

Our vision is to forge ahead with courage and innovation, to be an exemplary organization. We will synergize ourselves for continued, enhanced performance. We will foster a culture of care for our stakeholders, and channel our efforts with integrity to build their trust.

Business Mission
Our mission is to deliver projects from concept, to commissioning, to lifetime care, using state-of-the-art grid-friendly wind power plants that generate clean and cost-effective energy for our customers.

We will be a motivated and responsive partner, committed to quality and timely performance. We will actively promote and propagate the use of wind energy, as an environment friendly resource. We shall relentlessly pursue growth, by constantly challenging ourselves. We will work towards being the most trusted wind energy company.

Key Statistics
SALES TURNOVER

Fig 1. Turnover

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INSTALLED CAPACITY

Fig 2. Installed capacity Our employees are proudly called WinDirecters. A WinDirecter is one who rededicates himself, to live up to our motto of "Clean Energy Forever" for our country. They are the ones who will bring on Quality Gigawatts in times to come.

Year of commencement: 1994 Employees: 5600 No. of customers: 900 (approx.) Total service technicians trained at WTA: 2230 Market share: 26% overall, > 50 % in the most demanding IPP segment Installed capacity in operation: Exceeding 4,000MW Energy generated by our turbines: 33,000 Million Units Footprint: 7 high wind energy states - Madhya Pradesh, Gujarat, Rajasthan, Maharashtra, Karnataka, Tamil Nadu and Andhra Pradesh Manufacturing: Daman - Blade Plants, Generator Plant, Mechanical Assembly, Electrical Assembly

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Concrete Towers - Gujarat, Karnataka & Tamil Nadu, Rajasthan (under construction)

Wind World Control Center

Wind World (India) Ltd. has implemented state-of-the-art Information Technology infrastructure, with software applications that allow the company to monitor each wind turbine online remotely from a centrally located Wind World Control Centre (WWCC). The environment created, is an automated SCADA (Supervisory Control and Data Acquisition) based wind resource asset management solution, to run wind farms more efficiently and profitably. WWCC is the control centre of a large network connecting over 5000 wind turbines online. It comprises of:

Sensors located on each turbine, which give critical input of parameters like Wind Speed, Wind Direction, RPM, Temperature, Humidity, Power Production, etc. Linking of all turbines using OFC through the SCADA on a wind farm, enabling better wind farm control. Linking of multiple wind farms to the WWCC, through Extended C Band VSAT Communication links.

The WWCC has given rich benefits to the wind farms, and overall enhanced efficiency of Wind World operations through:

Improved visibility and control of wind operations by aggregation of data from multiple turbines into a single view. Minimizing of downtime and unplanned repairs. Lower costs through increased predictive maintenance. Increased revenue through improved turbine availability and wind farm production.

The WWCC is an effective asset management solution which stands to realize significant cost reduction in Operations and Maintenance. The main objective for WWCC is to increase revenue by minimizing wind turbine generator down time and ensure its optimal performance as per the Power Curves, which is achieved by quickly responding to turbine abnormalities round the clock. 'The WWCC uses advanced Business Intelligence (BI) software for in-depth analysis of SCADA data to maximize turbine availability and performance, and reduce turbine fault with an objective of better asset management decisions in near or real time. The WWCC BI application and dashboard gives the operational staff a single view of all multiple wind farms and their turbines at a glance. Archived data of WWCC SCADA application is interfaced and utilized in SAP to carry out preventive and breakdown maintenance of turbines, calculate spares provisioning strategy and also financial budget management.
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The WWCC can remotely reset turbines, thus ensuring against major breakdowns. A large number of faults are diagnosed and reset by the WWCC in an automated mode. The fault status generated by the WWCC and repair protocols from the Document Management System at Wind World, enable faster and more coordinated repair of the wind farm assets. The WWCC team comprises of highly trained engineers, who are experts on wind technology. These engineers continuously monitor and interpret the data which is being received through the turbines, on a 24 x 7 mode.

Wind World Training Academy

A WORLD-CLASS INSTITUTION The idea of establishing the Wind World Training Academy (WTA) germinated from the exponential growth of WWIL. This called for committed teams of highly trained engineers and technicians in adequate numbers, capable of ensuring that all machines operate at top performance levels round the clock, to produce electrical energy. We recruit the best available talent and exhaustively train them in the specifics and technicalities of our business, so they can function efficiently. To ensure that we retain the core values of WWIL at the highest levels, all-round development and grooming of the trainees in these aspects is ensured. WTA provides comprehensive technical training, which comprises of theoretical inputs and practical exposure. While the former enhances analytical skills, the latter enables lateral and creative thinking, in quickly diagnosing and rectifying inconsistencies, which may crop up in normal functioning of the machines. The training ensures extensive coverage on the basics of wind energy, followed by a thorough coverage of the technology of WWIL machines, encompassing all applicable and diverse fields of engineering. Thereafter, a thorough coverage of ERP and SCADA systems as related to our functions, documentation, ISO awareness and material management, ensures the functioning of our organization as a well-oiled machine, with clock-work precision. For hands-on training on wind energy converters and a comprehensive practical overview, the training includes shop-floor orientation programs and visits to various service and project sites. Approximately once a month, the WTA turns out a batch of highly motivated, physically fit, agile and technically sound service teams of 'Wind World Commandos', who embrace their work creatively, passionately and independently. In addition teams for "Installation and Commissioning" activities are also trained with specific skills to execute projects in the most professional manner Established on a sprawling campus of 29540 square meters, the WTA is the first in the wind energy sector globally to have attained an ISO 9001:2008 Certification, from Germanischer Lloyd, Germany, in Sept 2005.

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WTA FACILITIES

The main academic block: comprising well-ventilated spacious classrooms, a technical library and internet browsing room. Simulator & Model rooms: provide hands on practical training to our young technicians and engineers. Mechanical workshop: for mechanical fitters to hone the skills needed for our wind energy converters. Gymnasium & Yoga Training Centre: to build physical fitness and enhance mental alertness. Climbing Tower: a 50 meter tower climbed daily by WTA students, to gear them for climbing the towers of our wind energy converters

SPECTRUM OF TRAINING

The spectrum of training encompasses all levels, right from the basic courses for ITI and Diploma-level fresh entrants, to technical graduates, managerial level and refresher courses. To bridge the gap between trained manpower churned out of WTA and those who had joined the company before WTA was established, Bridge Courses are conducted for these experienced stalwarts. Additionally, specific courses for specialized requirements of departments like, blade manufacturing, mechanical assembly, electrical assembly, generator assembly, wind resource, SCADA, project comprising installation and commissioning are also conducted. WTA has the capability to design and conduct specific 'tailor made' capsule courses for all departments of WWIL at a short notice. Customer Training Capsules for the technical representatives of our customers are also conducted as required. Presently, WTA is in the process of massive expansion, to effectively undertake larger training volumes. In the near future, the WTA may be transformed into an autonomous 'Institute for Wind Energy'.

GROUP INITIATIVES
WIND WORLD (INDIA) POWER DEVELOPMENT PRIVATE LIMITED Wind World (India) Power Development Private Limited (WWIPDPL) is a 100% subsidiary of WWIL. WWIPDPL was strategically set up to manage the latter's wind
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power assets. Either directly, or through various Special Purpose Vehicles (SPV's) promoted by WWIL. This is a crucial task, considering WWIL's corporate commitment to install and operate a portfolio of 1,000 wind energy converters, over the next three years. WWIPDPL'S KEY MANDATES:

Reviewing the functioning of WWIL's wind energy assets, owned by Wind World (India) Ltd. Closely monitoring the technical and financial aspects of the asset's performance Managing day-to-day operations of various SPV's in which these assets are housed. WWIPDPL is staffed with experienced personnel, who have for many years been managing the diverse portfolio of Wind World (India) Ltd's wind power generating assets across seven states, with high levels of prudence and excellence.

WIND WORLD FINANCIAL CONSULTANCY PRIVATE LIMITED Wind World Financial Consultancy Private Limited (WWFCPL) a 100% subsidiary of Wind World (India) Ltd. was set up to organize project finance through innovative financial engineering; to meet Wind World (India) Ltd.'s long term funding requirement for setting up of wind energy projects.. WWFCPL consistently endeavours to provide financial solutions for Wind World (India) Ltd's own Independent Power Projects (IPP), as well as for the EPC (engineeringprocurement-construction) customers of Wind World (India) Ltd. With offices in Mumbai and New Delhi, WWFCPL has successfully arranged project finance for all its projects, to the tune of Rs.2, 000 crores over the past few years. Some of WWFCPL's main fund and non-fund finance achievements include: FINANCE FOR STAND-ALONE INDEPENDENT POWER PROJECTS WWFCPL has been successful in arranging project financing for large size wind energy Independent Power Producing (IPP) projects on a project recourse basis. This is done in line with financing of similar projects internationally with tenures that are comfortably managed by such projects, often at extremely optimum interest cost. WWFCPL has been successful in assisting Foreign Direct Investment in this sector, by advising foreign companies to set up wind energy projects in India through equity infusion from abroad. The balance is being arranged as Rupee debt, at accepted levels of tenure and interest cost, on a project recourse basis. FINANCE FOR PROJECTS HAVING LONG TERM PPAS

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These are done with third parties supplying power to them under the Open Access Regime. One such WWIL project has a long term power purchase agreement signed with private parties, wherein Wind World (India) Ltd. has established the power project and is supplying power to private parties, having a high credit rating. WWFCPL has successfully managed to arrange finance against security of the receivables due from the sale of power, to the private parties. TRADITIONAL WIND POWER PROJECT FUNDING This is done for customers who require funds and are investing in wind based power projects, with a view to avail tax benefits and sometimes save on power cost. Applicability for wind power project funding:

All states where wind energy projects are being installed and have wind power policies in place are eligible for financial assistance. Projects set up for power sold to the state DISCOM for captive consumption and power sold through the Open Access routes, are eligible for financial assistance; subject to detailed due diligence of the project specifics. Generally the debt: equity ratio of customer should be 70:30 or less. This is however subject to the due diligence process. The customer should not have defaulted with any bank/financial institution.

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Introduction to Wind & Wind Energy:2.1 Wind:Wind is the flow of gases on a large scale. On Earth, wind consists of the bulk movement of air. 2.2 Origin of wind: Due to uneven heating of earth surface 2.3 Wind Energy: Wind Energy is generated by harnessing the kinetic energy of atmospheric air. Wind Energy has had been in use for centuries for several other purposes such as sailing, irrigation and for grinding grain. Wind power systems transform kinetic energy of the wind into useful sources of power. Wind energy is the kinetic energy associated with movement of large masses of air. These motions result from uneven heating of the atmosphere is estimated that 1 percent of all solar radiation falling on the face of earth is converted into kinetic energy of the atmosphere, 30 percent of which occurs in the lowest 1000m of elevation. It is thus an indirect form of solar energy. In contrast to diurnal availability of direct solar radiation, wind energy can be available continuously throughout a 24-hours day for much longer periods, though it can vary a great extent including no wind periods. 2.4 Major application of wind power:Wind turbines have been built-in power output range from a kilowatt to a few MW to suit a wide range of applications. Major applications may be grouped in three categories. 2.4.1 Application requiring mechanical power. I. Winds pumps low power turbines are used for producing mechanical power for pumping water in remote areas. These are also known as wind power.
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II.

Heating the direct dissipation of mechanical power produces heat with 100% efficiency using a paddle wheel and other turbulent fluid system. The available hot water is used as such or employed for space heating.

III.

Sea transports Modern racing yachts with a subsurface keel, harness lift forces and are much more efficient and can sail faster than the wind. Large cargo ships requiring power in MW range, driven by improved efficient sails, are now being designed. Also, wind turbines are installed onboard to power propellers in ferries operating on shorts routs.

2.4.2 As off-grid electrical power sources I. Machines of low power with a rotor diameter of about 3m and 40 to1000 W rating can generate sufficient electrical energy for domestic purpose (water heating, battery charging, house cooling). II. Applications for somewhat more powerful turbines of about 50 KW are producing electrical power for navigation signal (light house), remote communication weather stations, and oil drilling platforms. III. For lifting water to a hill.

2.4.3 As grid-connected electrical power sources I. Large aero-generators in the range of a few hundreds of KW to a few MW are planned for supplying power to a utility grid. Large array of aerogenerators, known as wind firms, are being deployed in open plains or offshore in shallow water for this purpose 2.5 ADVANTAGE OF WIND POWER:-

1. The wind is free and with modern technology it can be captured efficiently. 2. Once the wind turbine is built the energy it produces does not cause green house gases or other pollutants.

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Fig 3. Wind profile

3. Although wind turbines can be very tall each takes up only a small plot of land. This means that the land below can still be used. This is especially the case in agricultural areas as farming can still continue. 4. Many people find wind farms an interesting feature of the landscape. 5. Remote areas that are not connected to the electricity power grid can use wind turbines to produce their own supply. 6. Wind turbines have a role to play in both the developed and third world. 7. Wind turbines are available in a range of sizes which means a vast range of people and businesses can use them. Single households to small towns and villages can make good use of range of wind turbines available today.

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Fig 4. Installed Capacity from Renewable Energy as on March 2010 2.6 DISADVANTAGES OF WIND POWER:-

1. The strength of the wind is not constant and it varies from zero to storm force.
This means that wind turbines do not produce the same amount of electricity all the time. There will be times when they produce no electricity at all.

2. Many people feel that the countryside should be left untouched, without these
large structures being built. The landscape should left in its natural form for

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everyone today.

Fig 5. Noise Profile

3. Wind turbines are noisy. Each one can generate the same level of noise as a
family car travelling at 70 mph.

4. Many people see large wind turbines as unsightly structures and not pleasant or
interesting to look at. They disfigure the countryside and are generally ugly.

5. When wind turbines are being manufactured some pollution is produced.

Therefore wind power does produce some pollution.

6. Large wind farms are needed to provide entire communities with enough
electricity. For example, the largest single turbine available today can only provide enough electricity for 475 homes, when running at full capacity. 2.7 Wind Force summary in 2020 12% of global electricity demand, equal to 3,000 TWh Installation of 1,245,030 MW
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 An annual 80 billion business 2.3 million Jobs Cumulative CO2 savings of 10,771 million tonnes Annual CO2 savings of 1,832 million tonnes Cost reduction to 2.45cents/kWh with installation costs of 512/kW Annual production 158,728MW Wind energy industry has set itself very ambitious targets for the next decades. The industry hopes that wind energy can satisfy 20 % of total EU electricity demand by 2020 and 2030.This require a drastic reduction of cost s (manufacturing, transport, erection, and maintenance costs) 20% by 2020. The sector estimated that the additional investment required to achieve this target is around EUR 6 billion over the ten years. In the context of the SET plan the industry has established a technology roadmap until 2020 that depicts the major development steps with milestones and time frame. 3 Wind Turbine Siting:The power available in wind increases rapidly with wind speed. Therefore, the main consideration for locating a wind power generation plant is the availability of strong and persistent wind. A suitable site should preferably have some of the following features. 1. No tell obstructions for some distance (about 3km) in the up wind direction (i.e., the direction of incoming wind) and also as low a roughness as possible in same direction. 2. A wide and open view i.e. open plain, open shoreline or offshore locations 3. Top of smooth well rounded hill with gentle slope (about 1:3 or less) on a flat plain. 4. An island in a lake or the sea. 5. A narrow mountain gap through which wind is channelled. 6. Site reasonably close to power grid.
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7. Soil condition must be such that building of foundation of the turbines and transport of road construction material loaded in heavy trucks is feasible. 8. Production results of existing wind turbines in the area to act as a guide to local wind conditions.

4 Wind Turbines:Special

Fig 4. The world's tallest wind turbine installed in the province of San Juan at a height of 4,110 meters above sea level recorded in the Guinness Book of Records. He belongs to the world's largest gold mining company, Barrack.

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Fig 6. Wind turbine

4.1 Name Detail: - E-48, E stands for Enercon India ltd, 48 stands for Rotor
diameter, hub height is vary according to technology developments, like tower strength, foundation technique and improvements in installation techniques.

4.2 Tower: - tower is used to provide height to hub and to hold nacelle.
It available in two patterns 1. Still tower 2. Concrete tower

Still tower:WINDWORLD tubular steel towers are manufactured in several individual Tower sections, connected using stress-reducing L-flanges. Unlike conventional flange joints (such as those used in steel chimney construction), the welding seam of the Lflange is outside the stress zone

Concrete tower:

Towers comprise 18 sections, each of 3.5 mts height Final 2 sections are of steel
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The total tower height - 74 mts Total weight 470 tonnes approx Towers are made from M55 grade concrete Superior resonance Better corrosion resistance; virtually maintenance free Superior Seismic stability

4.3 Nacelle assembly:-

Fig 7 Gearless Technology

The Nacelle is the main housing of the turbine, which is assembled with the yaw drive; it is directly mounted on the tubular tower.

The main carrier is a single cast frame that permits stable mechanical behaviour and performance. Lightning

4.4 Rotor head assembly:Rotor head production comprises the manufacture and integration of the pitch drive, bearing, axle pin, stator-rotor and balancing assembly, under a single roof. The rotor hub or unit along with pitch drive and annular generator are interconnected to form a single gearless unit. The rotor unit is then mounted on a fixed axis, called the axle pin.

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4.5 Rotor Blades:Windworld (India) Ltd. has three dedicated facilities for blade production, which produce 10 blades a day, and cater to the commissioning of 1000 wind energy converters per annum.

Fig 8 Blade Manufacturing

SALIENT FEATURES OF ROTOR BLADES:

A very unique aerodynamic profile, equipped with an additional part spoiler. Coefficient of power being extracted up to 0.5. Protection - by a time-tested lightening protection system. Snout shape aluminium tip design, to reduce noise and air turbulence, and increase generation output. Superb surface smoothness - avoids fungus and algae formation, and draws maximum air velocity. Weather-proof PU paint system - resists paint erosion. Hollow axial aerodynamic composite blade design - for high strength to weight ratio. Periodic checks & maintenance done on mould - for reliable aerodynamic profile of the blade.

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5 Power Generated by Generator:P= (Cp AV^3)/2

Where Cp: Power coefficient A: Area swept by rotor blades : Air density V: Velocity of wind

Fig 9. Conversion Efficiency

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6 Wind Resources Development:-

Fig 10 Wind Resources Development Process

Wind is the basic resource on which the continuing success of a project is hinged. Windworld (India) Ltd. s dedicated Wind Resource Department (WRD) has a highly skilled and experienced team, focused on finding the best wind sites in India for the development of wind farms. The objective being to maximize investor returns, by optimizing the micro-sitting of Wind Turbines.

1. IDENTIFICATION OF WIND-RICH SITES:The Centre for Wind Energy Technology (C-WET) from time to time releases wind power density maps of India. These wind power density maps are used for initial selection of sites. A continuous watch on the dynamics of wind behaviour is essential in making

certain decisions on the site at the right time. It also helps in deciding the right type of
turbine for the site. WRD is equipped with the right tools and staff specialized in data mining, analytical skills and interpretation.

2. INSTALLATION OF ONSITE MASTS AND WIND DATA MONITORING:-

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Wind masts are installed with required sensors for recording accurate data related to wind and weather. The mast is equipped with Automatic Data Logging System. We collect crosscountry data from wind masts at heights of 50m 125m. Anemometry is used for data collection which summaries:

Site description Data distributions by date, time, wind speed, and wind direction Mean, standard deviation and maximum of wind speed at all measurement heights by date, time, and direction Mean hourly temperature data Monthly and cumulative wind roses Wind direction frequency distribution Correlations of wind speeds at all measurement heights, etc. After monitoring, the core data is summarized according to the requirement

3. WIND DATA ANALYSIS:Using state of art software, the WRD can produce graphical reports characterizing the statistics of wind data, including wind shear patterns, daily and seasonal patterns, wind roses, wind power density, and turbulence intensity.

4. WIND RESOURCE ASSESSMENT:Wind resource mapping and assessment is critical for a given site to decide the optimized placement of turbines resulting in maximum wind farm output. For an accurate wind resource mapping it is important to ensure the accuracy of the data, which is fed into the software. Windworld (India) Ltd. carries out extensive field surveys, using latest GIS techniques backed by latest satellite images to get accurate information of the site. The accuracy of terrain, roughness, wind data, will decide the accuracy of the wind resource map prepared by the program.

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5. MICROSITING & PRODUCTION ESTIMATION:Beyond having a good site and a good wind turbine, it is important to ensure that turbines are put at the right places, to extract the maximum generation out of the wind farm. Windworld (India) Ltd. uses the latest optimization tools widely used by the wind experts across the globe, which carries out several thousand it aerations to arrive at the most optimal micrositing for the site. We ensure the maximum returns without compromising the life time of the turbine for our customers from their wind farm. These tools can take into account varied parameters like topographical variations, variation in wind intensities, different turbine configurations, local issues, noise levels, shadow and flicker issues, etc. The tool works out the best turbine array within the given boundary conditions / limitations and ensures high generation levels.

6.

TURBINE SUITABILITY STUDY & LOAD ANALYSIS:Wind turbines operate in environmental conditions over which no control can be

exercised. Therefore the turbines have to be designed such that they will work without damaging themselves or their environment. Wind turbines are designed and validated by accredited certification bodies to withstand weather conditions that can be quite harsh. The advanced calculations take into account possible extreme wind speeds (Ve50 - extreme wind speed - 3 second gust with a return period of 50 years) and turbulence intensities which has an influence on the fatigue life of the blade and other critical components. Wind turbine design standards fix overall design parameters such as extreme winds, average wind speeds, turbulence intensities, inflow angles that the turbine is expected to withstand over its service life - which is generally taken as 20years. As per IEC 61400-1 there are classes of wind conditions to which a turbine could be designed. Considering the fact that there will be a need to have some flexibility in this, the standard allows a special class to which the turbine could be designed. Under this, the designer can define his own wind conditions to which the design will conform. Windworld (India) Ltd.s E-53 is designed to the special class. The wind speeds are so chosen that they are best suited for Indian wind conditions.
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7 BLOCK DIAGRAM OF WIND ENERGY CONVERSION SYSTEM:-

Machine

Wind

Synchronous A Generator Rotor

Rectifier Cabinet

Step up chopper

3- voltage source inverter

Grid network 950KVA transfor mer

Excitation Cabinet

Pitch system

Pitch motors

Driver IGBT PCB IGBT gate driver circuit

Nacelle I/O Board Grid network 950KVA transformer

Yaw inverter 3, 4quadrant Inverter

Wind measuring device 1. Anemometer 2. Wind vane

Yaw motors 4 nos

Inverter control PCB

Power control PCB Control Cabinet I/O Board

Fig 11 Block Diagram Of WEC System

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DETAILS OF BLOCKS OF WIND ENERGY CONVERSION SYSTEM:Rectifier Cabinet: - When rotor is excited the variable AC voltage is produced at the output of the stator circuit of generator. Rectifier cabinet is used to convert variable AC voltage into variable DC voltage. Step up chopper: - it is used to increase the level of DC voltage of rectifier circuit. The output of step up chopper is constant DC supply. 3- VSI inverter: it is used to convert DC to AC. This three phase AC power is fed to grid via three phase power transformer. Pitch system: this section is used for pitch in-pitch out machine rotor blades via DC motor. Pitch in: this is normal running condition of machine. Pitch out: this is stop condition of machine. IGBT driver PCB: it is used to give driving signals inputs to IGBT circuits. This is used to firing the IGBT switch. Excitation cabinet: in initial case, it converts AC to DC (power from grid). This DC is given to rotor circuit of synchronies generator. When m/c starts its generator (produce power), excitation cabinet receiver power from rectifier cabinet of m/c. excitation cabinet is used to give excitation voltage and excitation current to rotor circuit. Nacelle I/O board: it is acting as a mediator between bottom and top session of control system of m/c. it gives corresponding signal to respective control system. Yaw inverter: this session is used for yawing of nacelle with the help of yaw motors. Wind measuring device; it is used for give information of velocity of wind and its direction to I/O board of nacelle.
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Inverter control PCB: it is used to generate PWM (pulse width modulation) pulsed signal. This PWM signal is fed to IGBT driver PCB via optical link. In inverter PCB closed loop control system used. It gets power curve information from I/O PCB of control cabinet. Power control PCB: - it is used to check grid parameters such as grid voltage, frequency, and phase sequence. It is used to give information of grid synchronization to inverter control PCB. Control cabinet board: this is a main decision making circuit in m/c. it gets the data of wind parameters and rpm of rotor from nacelle I/O board. Depending upon this information it will decide the power graph and it send the information to inverter control PCB. It changes excitation voltage and current accordingly. This information is given to excitation cabinet via nacelle I/O board. Transformer (950KVA) grid network: at starting of m/c, power is taken from electricity grid. The grid initial power is utilized to excite self excited rotor of synchronous generator. The power is taken from grid only to start up one KW generation and AC load functioning. The m/c power is used to give excitation voltage and current to its rotor.

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8 Synchronous Generation o

f Technology Madras

8.1 Introduction:Electric power is the main source of energy for carrying out many functions, as it is a clean and efficient energy source, which can be easily transmitted over long distances. With the availability of Transformer for changing the voltage levels to a very high value (of say 132kV to 400kV) the use of AC power has increased rapidly and the DC power is used only at remote places where AC power cannot be supplied through power lines or cables or for a few social purposes. A synchronous generator is an electrical machine producing alternating emf (Electromotive force or voltage) of constant frequency. In our country the standard commercial frequency of AC supply is 50 Hz. In U.S.A. and a few other countries the frequency is 60 Hz. The AC voltages generated may be single phase or 3-phase
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depending on the power supplied. For low power applications single phase generators are preferable. The basic principles involved in the production of emf and the constructional details of the generators are discussed below.

Fig 12 Generator Manufacturing

8.2 Generation of EMF: In 1831 Faraday discovered that an emf can be Induced (or generated) due to relative motion between a magnetic field and a conductor of electricity. This voltage was termed as the induced emf since the emf is produced only due to motion between the conductor and the magnetic field without actual physical contact between them. The principle of electromagnetic induction is best understood by referring to Fig. 1. The magnetic field is produced by the two fixed poles one being the North Pole from which the magnetic flux lines emerge and enter into the other pole known as the South Pole. It was found that the magnitude of the voltage induced in the conductor is proportional to the rate of change of flux lines linking the conductor.
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Mathematically it is given as

Fig 13 Conductor of length l moving through a magnetic field B generate an EMF

Where = flux in Webbers t= time in second e= average induced EMF in volts The above Eqn. 1 holds well only when the magnetic circuit is physically the same at the end as at the beginning and also during the period of change of flux linkages as well. In practical rotating machinery, however the change of flux linking each individual conductor during rotation (of either the conductors or the poles) is not clearly defined or cannot be easily measured. It is therefore more convenient to express this rate of change of flux in terms of an average flux density (assumed constant) and the relative
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velocity between this field and a single conductor moving through it. For the conductor of active length l moving with a velocity of v in a magnetic field of flux density B, as shown in Fig. 1, the instantaneous induced emf is expressed as,

e=Blv
Where B= flux density in Tesla (Wb/m2) l= active conductor length (m)

volts

(2)

v= relative linear velocity between the conductor and the field (m/s). Thus the instantaneous voltage e and the average value E of the induced emf are

Fig.14- Sinusoidal voltage waveform

The same if the flux density B and the relative velocity v are both uniform and constant. In an alternator we want the instantaneous emf to be varying in a sinusoidal manner as shown in Fig. 2. Hence we should have a field system which will produce a sinusoidal distribution of flux density in the plane perpendicular to the plane of motion of the conductor. Then,

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We have assumed that the conductor is moved in a direction perpendicular to the

Figure 15 Effect of change of flux linkages on induced EMF in a conductor

Magnetic fields as shown in Fig. 1, Eqn. 1 or Eqn. 2 are valid only for this mutually orthogonal condition for B and v. The other possible cases of motion of conductor with respect to B are shown in Fig.3 in addition to the mutually orthogonal condition of Fig. 1. When the conductor moves parallel to B, the induced emf will be zero because the rate of change of flux linkage is zero as the conductor does not link any new flux line/lines. To account for this condition of operation, Eqn. 2 must be multiplied by some factor that takes into account the direction of motion of conductor so as to make e zero for this condition of operation although B, l and v are finite quantities. Intuitively we may infer that this factor must be a sine function as it has a zero value at 0 and also at 180 and a maximum value at 90. Indeed the emf equation for the general case of a conductor moving in any direction with respect to the field as shown in Fig. 3 is given by

e = Blvsin
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(4)

Where is the angle formed between B and v always taking B as the reference. All other quantities are the same as in Eqn. 2.

8.3 Direction of induced e.m.f:

(a) Right-hand rule

(b) orthogonal relations Figure 16 Flemings right hand rule for direction of induced EMF

The direction of the induced emf is given by Flemings Right Hand Rule which states: If the thumb, First finger and the second finger of the right hand are stretched out and held in three mutually perpendicular directions such that the First finger is held pointing in the direction of the magnetic field and the thumb pointing in the direction of
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motion, then the second finger will be pointing in the direction of the induced emf such that the current flows in that direction. As shown in Fig. 4 the induced emf is in a direction so as to circulate current in the direction shown by the middle finger. Schematically we indicate the direction of the emf by a dot as shown in Fig. 5(a) to represent an emf so as to send current in a direction perpendicular to the plane of the paper and out of it. A cross will indicate the emf of opposite polarity; see Fig. 5(b). Although the Right Hand Rule assumes the magnetic field to be stationary, we can also apply this rule to the case of a stationary conductor and moving magnetic field, by assuming that the conductor is moving in the opposite direction. For example, as shown in Fig. 4 the direction of the induced emf will be the same if the poles producing the field had been moved upwards.

8.4 Electromagnetic Force:The motion of the conductor in a magnetic field can be imparted by the application of an external mechanical force to the conductor. In such a case the mechanical work done in moving the conductor is converted to an electric energy in agreement with the law of conservation of energy. The electric energy is not produced by the magnetic field since the field is not changed or destroyed in the process. The name electro mechanical energy conversion is given to the process of converting energy from mechanical form obtained from a prime mover, such as an IC engine, water/steam turbine etc, into electric energy. The emf induced in the conductor will circulate a current through it if a closed circuit is formed by an external connection. The direction of the current flowing in the conductor will be such as to oppose the cause of it as stated by Lenzs Law. A current carrying conductor located in a magnetic field will exp erience a force given by Biot-savarts law: f = Bli (5)

In other words, whenever a change in flux linkages occur, an emf is induced that tends to set up a current in such a direction as to produce a magnetic flux that opposes the cause of it. Thus if a current carrying conductor is placed in a magnetic field as

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shown in Fig. 5 the current tends to produce a magnetic field in the direction shown by the dotted circles.

(a)Current, coming out of the plane of paper

(b)Current entering the plane of paper Fig 17 Force on a current carrying conductor in a magnetic field

The direction of the flux lines around the current carrying conductor can be easily determined by Corkscrew Rule - which states that the flux lines will be in the same direction as the rotation of a right threaded screw so as to advance in the direction of flow of current. As a result the magnetic field, for the case shown in Fig. 5(a), is strengthened at the top and weakened at the bottom of the conductor, thereby setting
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up a force to move the conductor downwards. For the case of a Generator, the conductor must be moved up against this counter force or the opposing force. Similarly the current is to be supplied to the conductor against the emf generated (known as the counter emf or back emf) in the conductor as it moves due to the motor action. Thus, the same machine can be operated as a generator or a motor, depending on whether we supply mechanical power or electrical power to it, respectively.

8.5 Elementary AC. Generators:-

Fig 18 Elementary synchronous generator

The generators shown in fig. 1 and fig. 4 and discussed in the earlier sections are clearly impractical for a number of reasons. The main reason is that such generators require a prime mover that imparts linear or reciprocating motion to the conductor. Most of the commercial prime movers provide rotary motion in the commercial generators. The conductors of most commercial generators are rotated about a central axis of a shaft.
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The conductors are housed in slots cut in a cylindrical structure (made of magnetic material) known as the armature. The armature is supported at both ends by means of bearings attached to the shaft that goes through the center of the armature. The armature is rotated inside the field structure by providing a small gap between these two members. This gap is known as the air gap and is usually of the order of 1 to 1.5 cms. If the air gap is maintained constant throughout the spread of the pole arc, we have a fairly constant flux density under it in a plane perpendicular to the plane of the conductors motion. I.e. In a radial direction with respect to the field and armature structure. Since the emf is also proportional to b, the flux density in the air gap of ac generators is arranged to be distributed as closely to a sine wave as possible by suitable shaping (chamfering as it is technically known) of the pole shoe. Since the relative motion between the conductors and the magnetic flux lines is responsible for the production of emf, it is immaterial whether the conductors are rotated or the magnetic flux producing poles are rotated. In most of the alternators it is the field that is rotated rather than the conductors. Moreover the load current supplied by the alternator can be easily supplied from stationary coils without any difficulty as there will be no sparking and wear and tear of the brushes and slip rings. Whereas the low values of DC excitation current to the field coils can be easily sent through the slip rings and brush arrangement. Thus the usual arrangement in an elementary synchronous generator is as shown in fig. 6. The conductors are housed in slots cut in the armature structure. Only a single coil of n turns, indicated in its cross-section by the two coil sides a and -a placed in diametrically opposite slots on the inner periphery of the stator (i.e. the armature, as it is a stationary member here) is shown in fig. 6. The conductors forming these coil sides are parallel to the shaft of the machine and are connected in series by end connections (not shown in the figure). The coils are actually formed by taking a continuous copper wire of suitable cross section round a diamond shaped bobbin. The copper wire is usually of fine linen covered, cotton covered or enamel covered so as to have sufficient insulation between the conductors of the same coil.

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8.6 Advantages of Synchronous Generator:

Starting RPM - 12 with O/P Frequency 5 Hz Maximum RPM - 29 with O/P Frequency 15 Hz Combined with the rotor hub it provides an almost frictionless flow of energy Smooth running of fewer moving components guarantees minimal material wear Minimal mechanical wear, which makes it ideal for particularly heavy demands and a long service life. No direct coupling with grid, Proper Isolation provided Low machine stress due to high level of speed variability The sensors activation temperature is well below the continuous temperature resistance of the insulating materials used in the ring generator. This means that overloading caused by excessive temperature is prevented.

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9 Sensors:Wind farms run on sensors. They make condition monitoring and SCADA systems possible. Without sensors, no system can be controlled. One pearl of wisdom often dropped by control engineers says that a control is only as good as what it measures, and an event cannot be controlled if it cannot be measured. For wind professionals, the most important sensors are vibration, temperature, and pressure. There are others, such as debris monitors for oil.

1. Anemometer:An anemometer is a device for measuring wind speed, and is a common weather station instrument. The term is derived from the Greek word anemos, meaning wind, and is used to describe any airspeed measurement instrument used in meteorology or aerodynamics. The first known description of an anemometer was given by Leon Battista Alberti around 1450.

Fig 19 Sensors

2. Wind vane:

- A wind vane (also called a weather vane) is a pointer that freely

rotated on the top of a fixed vertical rod. It was designed to swing easily and point to the direction from which the wind was blowing. The instrument had its

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beginnings in ancient history, because such information was important to shipping fleets, armies, navies, fishing and farming. 3. Cable twist sensor (switch):-cable twist sensor, sense the twist in copper cables used to carry generated power, due to yawing. After reaching at its limited value it comes back at its initial position. 4. Temperature sensor:-temperature sensors, sense the temperature, and provide control signal to control system. These are connected at nacelle, control cabinet. 5. Moisture sensor: - The heaters protect equipment from harsh environments by providing heat at cold temperatures and by keeping components within an enclosure or near the heater at a safe temperature. 6. Tower oscillation sensor:-it is used to monitor the oscillation of tower of wind turbine. (GEL 3010 tower oscillation monitor) 7. Vibration sensor:-vibration sensor is used to measure the vibration of nacelle.

9.1 Actuators:In engineering, actuators are a subdivision of transducers. They are devices which transform an input signal (mainly an electrical signal) into motion. Electrical motors, pneumatic actuators, thermal actuators, hydraulic bimorphs, digital pistons, relays, comb micromirror drives, piezoelectric devices and electroactive

polymers are some examples of such actuators. Motors are mostly used when circular motions are needed, but can also be used for linear applications by transforming circular to linear motion with a bolt and screw transducer. On the other hand, some actuators are intrinsically linear, such as piezoelectric actuators. In virtual instrumentation actuators and sensors are the hardware complements of virtual instruments. Computer programs of virtual instruments use motion into linear motion, or vice versa. Conversion is commonly made via a few simple types of mechanism including.

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10 Grid management systems:-

Fig 20 Grid Management system

1. Generator is totally isolated from grid. 2. Power factor is nearly unity without use of capacitor bank. 3. Generators full fill the all limitations of Grid Guideline.

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11 Some photographs taken during training

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Conclusion
Wind is one of the most flexible and tractable of all energy sources, since the mechanical energy derived directly from the wind can be readily and efficiently converted to other forms of energy. The cost of power generation from wind farms has now become lower than diesel power and comparable to thermal power in several areas of our country especially near the coasts. Thus Wind power can be used in centralized utility applications to drive synchronous AC electrical generators.

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12 BIBILOGRAPHY 1. Non conventional Energy Resources By (B H khan) 2. www.google.com Google search Engine 3. www.btechguru.com 4. www.nptel.com 5. Site visiting 6. Company staff (Engineers and technicians)

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