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Design of the Z72 wind turbine with direct drive PM generator

Design of the Z72 wind turbine with direct drive PM generator. Introduction The turbine design The conversion system Testing and operational experience Commercial advantage of the Z72 Does it sell How to improve C.J.A. Versteegh (R & D manager) Trondheim, June 15, 2004. The LW 750kW.

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Design of the Z72 wind turbine with direct drive PM generator

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  1. Design of the Z72 wind turbine with direct drive PM generator • Introduction • The turbine design • The conversion system • Testing and operational experience • Commercial advantage of the Z72 • Does it sell • How to improve C.J.A. Versteegh (R & D manager) Trondheim, June 15, 2004 permanent performance

  2. The LW 750kW Introduction • In 2000 a consortium has been established to upscale the Lagerwey DD turbine. Participation of ABB in generator and converter design • In April 2003 Zephyros has become an independent wind turbine manufacturers with Triodosbank and Renerco as shareholders. • Presently:- prototype track record 1.5 year - multi discipline small organisation - franchise business model - 30 turbines in the order book permanent performance

  3. Zephyros in value chain 1 2 3 4 5 6 7 8 • Wind turbine design (>100 years of experience) • Certification (Germanische Lloyd / Det Norske Veritas) • Wind turbine sales (direct + franchise) • Manufacturing components (suppliers) • Wind turbine assembly (in own assembly hall) • After sales / service • Electricity production • Electricity sales permanent performance

  4. Design of the Z72 wind turbine with direct drive PM generator • Introduction • The turbine design • The conversion system • Testing and operational experience • Commercial advantage of the Z72 • Does it sell ? • How to improve permanent performance

  5. Design requirements • Top of range design (1999) • Integrated design • Single bearing concept • Minimum number of components • Full size 4-q converter • No transport restrictions; minimum hoisting capacity permanent performance

  6. Base design parameters • Rotor diameter 70 m • Nominal rotational speed 18 (<100 dB(A)) • Nominal power 1500 kW • Protection IP 54 • Maximum transport size 4 m • Maximum transport weight 50 tonnes • Offshore application; no noise restriction permanent performance

  7. permanent performance

  8. permanent performance

  9. Installation hoist permanent performance

  10. Design of the Z72 wind turbine with direct drive PM generator • Introduction • The turbine design • The conversion system • Testing and operational experience • Commercial advantage of the Z72 • Does it sell ? • How to improve permanent performance

  11. Single line diagram permanent performance

  12. The conversion system Use of voltage source converter • Universal 50 - 60 Hz design • Good connectivity to grid • Electric braking and positioning of rotor • Generator loaded with minimum AC current • Capable to operate under line dips • Sensor less drive permanent performance

  13. The structural design permanent performance

  14. The voltage level permanent performance

  15. The stator winding Preformed wire Advantage : Slot fill factor of 0.7 : High quality insulation Disadvantage : More connections : Magnetic slot wedges Vacuum impregnated stator permanent performance

  16. permanent performance

  17. permanent performance

  18. permanent performance

  19. Generator specifications permanent performance

  20. permanent performance

  21. Design of the Z72 wind turbine with direct drive PM generator • Introduction • The turbine design • The conversion system • Testing and operational experience • Commercial advantage of the Z72 • Does it sell? • How to improve permanent performance

  22. Full scale B2B test • Light load test 5 Endurance test • Overspeed 6 Optimisation grounding concept • Short circuit test 7 Optimisation closed loop control • Firing through permanent performance

  23. Full scale B2B test permanent performance

  24. Results permanent performance Results: • Good dynamic response • Controllable generator current Limitations: • Poor dynamic test conditions • Poor cooling conditions

  25. Track record (dec 2002 – feb 2004) Capacity factor 28% 4500 MWh produced Overall availability 2003: 84% Performance permanent performance

  26. Heat run Maximum Tstator 86 °C, Tbearing 75 °C and Tambient 17 °C Heat run at full load during 24 hours permanent performance

  27. Improvements Prototype modifications • Improvement of noise level • Improvement of control algorithm • Safety and control software fine tuning • Modifications ventilation system Design modifications • Double row TRB (option) • State of art PLC and SCADA • Nacelle casted and not welded • Hydraulic yaw brakes • Modifications ventilation system permanent performance

  28. Design of the Z72 wind turbine with direct drive PM generator • Introduction • The turbine design • The conversion system • Testing and operational experience • Commercial advantage of the Z72 • Does it sell? • How to improve permanent performance

  29. Benefits Competitive with catalogue price of 1500 k€ Costs of operation during life-time • maintenance costs (-30%) € 3,000 • availability (+1% point) € 3,000 • insurance fee (-25%) € 2,500 • higher electricity yield (+2%) € 6,000 compared to identical machine but with conventional generator • reservation for repairs (-2,500) € 2,500 1 in 5 turbines need to replace gearbox after warranty. Cost of new gearbox + lost production: € 250,000€17,000 per year Capital costs • lighter crane needed (- € 25,000 to – € 50,000) • Installation on 600kW locations permanent performance

  30. 1.5 – 2.0 MW Upgrade to 2 MW • Conversion system designed for 2 MW • Make use of 7 kV insulation system • Optimum use of variable speed behaviour • Noise level increase 3 dB(A) • PPV improvement of 8 % (for class 3 wind climate) • Minor extra investment cost • DNV prototype certificate for both obtained permanent performance

  31. Design of the Z72 wind turbine with direct drive PM generator • Introduction • The turbine design • The conversion system • Testing and operational experience • Commercial advantage of the Z72 • Does it sell? • How to improve permanent performance

  32. The market • Wind market 2002: $7bn • Past 5 years : CAGR >30% • Till 2012: CAGR 10-20% • Trends: - offshore development - large scale wind farms - big multi MW turbines permanent performance

  33. Strengths The design; ±2 years ahead of market with 2MW PMDD design Partners involved, esp. ABB Flexibility, independence Opportunities Market moving towards DD Offshore gaining importance Worldwide network can be rolled out very quickly Weaknesses Track record Financial power Control over manufacturing Threats Other players developing DD Enercon (price reductions) GE patent (in US only) patent issue in Europe is solved! Zephyros SWOT analysis permanent performance

  34. Design of the Z72 wind turbine with direct drive PM generator • Introduction • The turbine design • The conversion system • Testing and operational experience • Commercial advantage of the Z72 • Does it sells ? • How to improve permanent performance

  35. Cost distribution permanent performance

  36. Future developments Short term development Improvement of PPR with 10 % by: • Make use of existing structural design • Increase of rotor diameter to 78 m Development areas: • Independent blade pitching (to reduce fatigue loads) • Low solidity blade design (to reduce extreme loads) • Integrated blade pitch and converter control permanent performance

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