Vestas V90

151

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Vestas V112
3 MW wind turbine Rotor diameter 112 m Traditional geared turbine with one bearing on main shaft

152

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Vestas V112

153

3.5.2011 MERVENTO

Vestas V112

154

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Vestas V164
6 MW wind turbine Rotor diameter 164 m Semigeared

155

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WinWinD WWD-3
Semigeared 3 MW Rotor diameters 90 and 100 m Multibrid-technology Two stage planetary gear Prototype in 2004 yp Serial production 2005 Annual volume approximately 20 pp y Coming years volume 50 y annually Nacelle 127 t Total weight nacelle + rotor 163 t

156

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WinWinD WWD-3

157

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WinWinD WWD-3

158

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WinWindD 3
3 MW Rotor diameters 100, 109 and 120 Frequency converter and transformer down to tower base Nacelle weight 80 t (without hub?)

159

3.5.2011 MERVENTO

Market positioning

Established turbines
150m 140m 130m Rotor diamete er 120m 120 110m
Siemens SWT 3.6-107 Siemens SWT 2.3-101 Alstohm E100 MWT92 Siemens SWT 3.6-120

RePower 5M Bard 5.0 Areva M5000

Enercon E-126

100m 90m 80m

Vestas V90

Established turbines mainly in the 2,5 MW class The rotor diameter depends on the wind class Mainly high speed double fed turbines

Enercon E-82

2 MW

3 MW

Direct drive Old fashioned technology

4 MW

5 MW
161

Medium speed Modest technology

6 MW

High speed Future technology

7 MW

8 MW
3.5.2011 MERVENTO

New prototypes
150m 140m 130m Rotor diamete er 120m 120 110m
Nordex 2.4-117 RePower 3.2M114 Siemens SWT 2.3-113 RePower 3.2M114 SL3000/105 RePower 3.4M104 Siemens SWT 3.0-101 Leitwind LWT101

Gamesa G128

RePower 6M

Vestas V100 100m

New prototypes mainly in the 3 MW class 90m 80m

Leitwind LWT93 Doosan WinDS3000 SL3000/90

The rotor diameter depends on the wind class High speed approximately 50% of new developments d l t The number of direct drive new developments has increased recently

2 MW

3 MW

Direct drive Old fashioned technology

4 MW

5 MW
162

Medium speed Modest technology

6 MW

High speed Future technology

7 MW

8 MW
3.5.2011 MERVENTO

New developments
150m 140m 130m Rotor diamete er 120m 120 110m

Vestas V164

Sinovel 128 Goldwind ? Dong Fang ? g g

WinWinD 3 Mervento 3.6-118 Mervento 4.5-118 Darwind 5MW Shanghai Electric ? GE 4.0-110 WinWinD 3 Goldwind 2,5MW

Alstohm ? Vestas 6MW ? Bard 6,5 Mitsubishi PSE ? Areva M6000 ?

100m
Avantis AV928

New developments mainly in the 3 MW and 5-6MW classes The rotor diameter depends on the wind class High speed approximately 50% of new developments d l t The number of direct drive new developments has increased recently

90m 80m

2 MW

3 MW

Direct drive Old fashioned technology

4 MW

5 MW
163

Medium speed Modest technology

6 MW

High speed Future technology

7 MW

8 MW
3.5.2011 MERVENTO

Wind class III

150m 140m 130m Rotor diamete er 120m 120 110m Previously the class III turbines has been 2,5 MW class
Doosan WinDS3000 WinWinD 3 Acciona AW3000 Nordex 2.4-117 RePower 3.2M114 Siemens SWT 2.3-113

Vestas V100 100m

90m 80m

All latest developments are 2 - 3 MW with very large rotor diameters or The class III turbines are mainly geared machines. The direct drive new comers are immediately focusing on class II and class I wind conditions.

2 MW

3 MW

Direct drive Old fashioned technology

4 MW

5 MW
164

Medium speed Modest technology

6 MW

High speed Future technology

7 MW

8 MW
3.5.2011 MERVENTO

Wind class II
150m 140m 130m Rotor diamete er 120m 120 110m

Gamesa G128

Enercon E-126

Mervento 3.6-118 Vestas V112 Acciona AW3000 SL3000/105 RePower 3.4M104 Enercon E-101 Alstohm E100 Previously Avantis AV928 MWT92 Vestas V90 Enercon E-82

100m 90m 80m

the class II turbines has been 2,5 MW

class All latest developments are 3 MW with very large rotor diameters Gamesa G128 i probably aiming f class I G is b bl i i for l The class II turbines are becoming more and more direct drive (33%).

2 MW

3 MW

Direct drive Old fashioned technology

4 MW

5 MW
165

Medium speed Modest technology

6 MW

High speed Future technology

7 MW

8 MW
3.5.2011 MERVENTO

Wind class I
150m 140m 130m Rotor diamete er 120m 120 110m

Vestas V164

RePower 5M Bard 5.0 Siemens SWT 3.6-120 Mervento 4.5-118 Areva M5000 GE 4.0-110 Siemens SWT 3.6-107 SWT 3.0-101 Siemens SWT Siemens AW3000 2.3-101 Acciona Leitwind LWT93 SL3000/90

RePower 6M Bard 6,5

100m 90m 80m

The class I turbines are very scattered There are lot of new developments g g on p going focusing mainly on the 5-6 MW segment Dong Fang 5MW, Sinovel 5MW, Siemens 5-6MW, Vestas 6MW, Darwind 5MW, Hyundai +5MW, Mitsubishi 5-7MW, Clipper Britannia 7,5MW, RePower 6M, Areva 6MW, Alstohm +5MW, Mitsubishi PSE 6MW 5 MW
166

2 MW

3 MW

Direct drive Old fashioned technology

4 MW

Medium speed Modest technology

6 MW

High speed Future technology

7 MW

8 MW
3.5.2011 MERVENTO

Offshore
150m
Size of turbine Number of turbines 130 79 210 96 8 7 Total T t l capacity it supplied *) MW 299 284 420 288 40 25

Vestas V164

140m 130m Rotor diamete er 120m 120 110m

Supplier Siemens Vestas REpower GE Wind

1

2.3 MW 3.6 MW 2 MW 3 MW 5 MW 3.6 MW

RePower 5M

RePower 6M Bard 6,5

Source: BTM Consult Aps - October 2009 (*As per January 2009)

Bard 5.0 Siemens SWT 3.6-120 Mervento 4.5-118 Areva M5000 GE 4.0-110 Siemens SWT 3.6-107 SWT 3.0-101 Siemens SWT Siemens AW3000 2.3-101 Acciona

100m 90m 80m

SL3000/90

The class I turbines are very scattered Enercon is not offshore (for the time ( being) The big offshore players are Siemens and Vestas Other with a small track record are RePower, Areva, Bard, GE, Sinovel, WinWinD 5 MW
167

2 MW

3 MW

Direct drive Old fashioned technology

4 MW

Medium speed Modest technology

6 MW

High speed Future technology

7 MW

8 MW
3.5.2011 MERVENTO

Direct Drive turbines

Top 15 suppliers in 2009 Total market 38,103 MW

Clipper (US); 1,6 16% United Power (CHI); 2,0 % Nordex; 2,8 % RePower (GE); 3,4 % Mitsubishi (JP); 1,5 15% Mingyang (CHI); 1,5 % Others; 11,9 % Vestas (DK); 12,5 12 5 % GE Wind (US); 12,4 12 4 %

Siemens (DK); 5,9 % Suzlon (IND); 6,4 % Dongfang; 6,5 g g; , % Gamesa (ES); ( ); 6,7 %
169

Sinovel (CHI); 9,2 % GoldWind (CHI); 7,2 % Enercon (GE); 8,5 %

3.5.2011 MERVENTO

Source: BTM Consult ApS March 2010

Direct drive
Approximately 16% of the market 2009 was direct drive turbines The market share of the Enercon direct drive turbines is in Germany 60% (continously growing) The most produced turbine in the world is the Vensys 1,5 MW direct drive by a number of licensees eg GoldWind In Sweden Pite will the worlds largest wind power plant with 1101 turbines be built with Enercon direct drive turbines Siemens i d Si is developing di t d i t bi l i direct drive turbines i 3MW and 5 6MW in d 5-6MW According to information from suppliers 80% of the new developments are i E d l t in Europe f focused on di t d i d direct drive There is not any direct drive turbine aimed for the offshore yet (in progress Darwind 5MW GE 4 1MW Siemens 3MW and 5MW, 4,1MW, 6MW as well as Mervento 4-4,5 MW)
170 3.5.2011 MERVENTO

Direct Drive Inner rotor designs

171

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Direct Drive Outer rotor designs

172

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Development of direct drive ( ) (DD) concepts p in the market from 2007 to 2010

Company Enercon GmbH Germany 1) Goldwind (CN) Vensys Mtorres (ES) Mt Impsa (Argentina) Vensys GE- Scanwind (NO) Zephyros (NL) Siemens Wind Power (DK/GE) Others: Dongfang New Energy(CN) Hara XEMC (CN) Zephyros STX Heavy Industries (formerly Harakosan) (JP) Zephyros Total MW % of world market

Type/Size DD wound magnets DD PMG DD wound magnets DD PMG DD ? DD PMG DD PMG DD PMG DD PMG DD PMG

2007 MW 2,769

2008 MW 2,809 395

2009 MW 3,221 1,914 n.a 29 2) 39

2010 MW 2,846 3,495 n.a 100

18 -

n.a -

3 3

80

128

454

507

2,867 14.50%

3,339 11.80%

5,663 14.90%

6,951 17.60%

Source: BTM Consult - A Part of Navigant Consulting - March 2011

Notes: Enercon s track-record is outstanding. It has delivered 22,644 MW of its DD concept since 1994 in all models from 500 kW up to 7,5 MW. Scanwind's figure Scan ind's fig re of 39 MW is c m lati e capacit b the end of 2009 cumulative capacity by
173 3.5.2011 MERVENTO

Siemens SWT- 2 3-113 SWT 2.3 113 Direct-Drive WTG

Source: Siemens Renewable Energy - Press release 14. March 2011

174 3.5.2011 MERVENTO

Main permanent magnet g generator suppliers

Company
Ingeteam ABB The Switch Siemens Weier Converteam Sicme Motori Elin TM4 Inc Danoteck WindGen Wi dG Potencia Industrial Hyundai CSR Electric Nanqi Hui Quan Yuanda Xiangdian Xi an Dunan Yongyi

Location
Spain Switzerland Finland Germany Germany France Italy y Austria Canada US US Mexico South Korea China China China China China China China

Source: BTM Consult - A Part of Navigant Consulting - March 2011

175 3.5.2011 MERVENTO

Comparison of direct drive and traditional drive train designs

Advantages of DD No gearbox and related wear an tear on mechanical components Simpler turbine with fewer parts Higher electrical (PM) and overall drive train efficiency, producing higher energy yield Lower maintenance and greater reliability with less downtime y Improved thermal characteristics due to absence of field losses Full power conversion improves the turbine s grid compatibility

Disadvantages of DD Larger diameter of generator/nacelle complicates transportation and installation. Higher top-mass weight ') Expensive PM material potentially uncertain security of supply More complex assembly of generator using PMs g Demagnetisation of PM at high temperature More advanced cooling system required Full F ll power rather th th than partial power ti l conversion makes the turbine more expensive

Comments: This Thi comparison i b i is based on a t diti d traditional d i t i comprising a d bl f d i d ti generator and l drive train i i doubly feed induction t d a 3-4 stage gearbox. *) The general trend towards higher top-mass weight for direct drive turbines seems to have been brok en by the new DD turbine SWT 3.0 from Siemens Wind Power When comparing the PMG solution to the Enercon DD design, the latter is heavier and the absence of a permanent magnet creates excitation loss when magnetising the coils, but the concept has an impressive track record from more than 20 GW of capacity in operation.
Source: BTM Consult - A Part of Navigant Consulting - March 2011
176 3.5.2011 MERVENTO

Geared versus Direct Drive - today

Geared + Lower weight + Smaller overall size Direct drive + Low noise level + Low vibration level + Reliability + Components with shortest possible supply chain + Higher total efficiency Weight Size Transportation Erection

Strengths

Noise Reliability Reputation Availability Time-toTime-to-market

Challenges g

177

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Direct drive turbines

Existing direct drive turbines Enercon (2,3MW 7,5MW), GoldWind (1,5MW), Leitwind (1,5MW 1,8MW), Mtorres (1,65MW), XEMC (Lagerway, Harakosan 2MW) GE/ScanWind (3 5MW) 2MW), (3,5MW) Prototype direct drive turbines Enercon (3MW), EWT (2MW with China Energine), GoldWind (2,5MW), Leitwind (3MW), Avantis (2,5MW), Dong Fang (1,5MW), Siemens (3MW), Impsa (2,1 MW) New d N developments l Shanghai Electric Company (5,4MW), Wind Direct (2,5MW), Schuler (2 7MW) Unison 3MW Mervento (3,6MW), (2,7MW), 3MW, (3 6MW) GE/ScanWind (4MW), XEMC Darwind (5MW), Siemens (6MW), GoldWind (5-6MW), Nordex (6MW), Sway (10MW), AMSC Windtec (10MW HTS technology)
178 3.5.2011 MERVENTO

Direct drive turbines

Engineering companies developing wind turbines Garrad Hassan (owned by GL), Aerodyn, AMSC Windtec, W2E Wind to Energy (Fuhrlnder), Wind-Direct GmbH, Tembra (developing components for Schuler 2 7MW) EDAG Windrad 2,7MW), EDAG, Engineering (not complete turbines), Windforce, Rotorwerk GmbH, S & G GmbH, P.E. Concepts, Engineering companies that has developed direct drive Garrad Hassan (for Dong Fang in co-operation with Enmac and The Switch), P.E. Concepts (Sharpower 3MW China), Tembra (developing components for Schuler 2 7MW) Aerodyn (first DD 2,7MW), developments for Unison) In reality there is not any engineering company with skill and competence to develope direct drive turbines
179 3.5.2011 MERVENTO

Mervento 3 6-118 turbine 3.6-118

Main parameters
Wind turbine class Vref 10 minutes mean extreme wind speed within 50 years at hub height Turbulence intensity at 15 m/s Iref Extreme temperature range for stand-by Ambient t A bi t temperature range i operation t in ti Nacelle temperature range in operation Vave annual average at hub height Rotor diameter Hub h i ht H b height Design tip speed ratio Max tip speed Nominal turbine speed Cut-in Cut in wind speed Cut-out wind speed Nacelle tilt angle Hub cone angle Blade cone angle Rated wind speed Nominal rating At sea level, 15C, rated wind speed Mechanical hub power at rated wind speed Maximum torque Rotational speed at cut in Wind speed at nominal turbine speed Maximum power coefficient Cp Power coefficient Cp at rated wind speed Theoretical capacity factor at Rayleigh distribution
181

Near-shore S, IIA with extended temperature range 42,5 m/s 0,16 -40C +50C -30C 30C +40C 40C -20C +60C 8,5 m/s 118 m 90 / 125 m 9,0 78,0 m/s 12,6 rpm 4 m/s 25 m/s 3 3 1 1 11,5 m/s 3,6 MW 4,0 MW 3,067 3 067 MNm 5,8 rpm 8,7 m/s 0,48 0,40 0 40 48,7%

Offshore S, IB with extended temperature range 50,0 m/s 0,14 -40C +50C -30C 30C +40C 40C -20C +60C 10,0 m/s 118 m 90 m 9,0 87,0 m/s 14,1 rpm 4 m/s 25 m/s 3 3 1 1 12,8 m/s 4,5 MW 5,1 MW 3,423 3 423 MNm 5,8 rpm 9,4 m/s 0,48 0,38 0 38 55%
3.5.2011 MERVENTO

MERVENTO 3.6-118
Generator in front of tower

Common bearings for turbine rotor and generator rotor

Total weight competitive with geared turbines

182 3.5.2011 MERVENTO

Main circuit diagram Power losses for dimensioning

Rotor power 4000 kW Mechanical after bearing 4000 5 = 3995 kW Power after generator 3995 190 = 3805 kWel

Power after tower cabling 3805 12 = 3793 kWel 4440kVA Power after transformer 3705 39,5 (1,1%) = 3665,5 kWel

150kVA Self consumption nacelle + electrical station 400V 1 71 100 kWel, average 86 kWel

Power after frequency converter and filters 3793 88 (2,3%) = 3705 kWel

Power after MV switch gear 3594 3565 kWel Average 3579 kWel

Vacuum circuit b k b f V i it breaker before f frequency converter t The accurate powers are in the power curve calculation. These powers to be used only in dimensioning of the components. y g p
183 3.5.2011 MERVENTO

Medium voltage electrical system benefits

More silent frequency converter Higher reliability Lower total weight Lower total cost Makes it possible for a topology with frequency converter and p p gy q y transformer at tower base Topology ready for even higher voltage levels in range 10 13 kV enabling turbines without transformer and centralized electrical station for several turbines

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Advantages with electrical station at tower base

Less weight in the nacelle to be erected Lower nacelle weight decreases g tower weight Longer life time and longer mean time between failure of frequency converter and transformers Easier maintenance of frequency converter and transformers Cooling water system at ground level, maintenance at ground Control room at ground level Electrical station manufactured, assembled and tested at factory Shorter erection and commisioning time Lower total costs Total weight approximately 35 tons
185

3.5.2011 MERVENTO

Electrical station General overview

Overall dimensions (mm) L x W x hmax = 11227 x 4654 x 4210
Curvature shape roof Door to control room Doors f main t D for i transformer f

186

3.5.2011 MERVENTO

Frequency converter PCS6000

ABB four quadrant (4Q) PCS6000 Medium Voltage frequency converter, nominal voltage 3,9 kV Three phase, th Th h three l level l semiconductors IGCT (Integrated Gate Commutated Thyristor) power stack
187

Voltage ride through (4 seconds at full power) and reactive power capability (no p p y( additional Statcom needed) In-line design. Size: 5112mm x 1244mm x 2466mm (L x W x H) Weight: ~6580kg
3.5.2011 MERVENTO

Low weight direct drive

188

3.5.2011 MERVENTO

Power curve comparison

189

3.5.2011 MERVENTO

Turbine maintenance costs over the life cycle

190

3.5.2011 MERVENTO

MERVENTO 3.6-118 Higher investment g & Higher revenue

&
Lower total cost of ownership (TCO)

=
Superior net present value NPV
191 3.5.2011 MERVENTO

Comparison of Gross Margin g

2 x Mervento 3.6-118 > 3 x 3MW-100 m

192

3.5.2011 MERVENTO

Direct Reliability

Mervento 3.6-118 3.6The first completely gearless wind turbine

193 3.5.2011 MERVENTO