V112-3.0 MW Harnessing low and medium onshore winds for you. Gianfranco Gianfranco Leoni Leoni - Vestas Vestas Italia
Agenda
2
1
The The V1 V112 12-3 -3.0 .0 MW – ha harn rnes essi sing ng low low and and me medi dium um on onsh shor ore e win winds ds for for you you
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The V112-3.0 V112-3.0 MW is designed to optimize your energy production and reduce energy costs
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The The V112 V112-3 -3.0 .0 MW de deliv liver ers s bu busin sines ess s case case cert certai aint nty y
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Vestas estas wind wind turb turbine ines s also also be benef nefit it from from adva advance nced d moni monitor toring ing solutio solutions ns
Vestas’ new wind turbine: The V112-3.0 MW
DESIGNED FOR IECIIA and IECIIIA ...
IEC III
IEC II
IEC I V80-2.0 MW
Existing WTGs
V90-1.8 MW V100-1.8 MW V90-3.0 MW
New WTG
112
V112-3.0 MW
6
6.5
7
3.0
7.5
8
8.5
9
9.5
m rotor
MW rated power
10
Wind Speed [m/s] The V112-3.0 MW covers almost three wind classes
3
Optimized for onshore locations with low and medium wind speed
V112-3.0 MW AEP Benchmarking
V112-3.0 MW Power Curve
Probability @7.5 m/s
3500
12
3000
AEP [MWh]
V112-3.0 MW
10
2500 8
] w k [ 2000 r e w o 1500 P
15.000
12.000
6
4
1000 2
500
9.000
0
0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1617 18 19 20 21 22 23 24 25
Wind Speed [m/s]
6.000
Approved
for IECIIa and IECIIIa
Optimized
3.000
Industry Range
Nominal
for wind speed 8,5 m/s
rating 3.0 MW
0 5,0
5,5
6,0
6,5
7,0
7,5
8,0
8,5
Annual Average Wind Speed [m/s] High productivity Standard Air Density 1.225 kg/m3 4
% c n e u e r F
Agenda
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1
The V112-3.0 MW – harnessing low and medium onshore winds for you
2
The V112-3.0 MW is designed to optimize your energy production and reduce energy costs
3
The V112-3.0 MW delivers business case certainty
4
Vestas wind turbines also benefit from advanced monitoring solutions
Unprecedented energy production and reliable performance Permanent magnet generator & Full scale converter Excellent grid support capability Reduced maintenance cost Highly adaptable for future requirements HCCBA bearings (High Capacity Bearing)
Pitch System Double feeding pump system ensuring redundancy and reliability Solutions for safe work in hub integrated in design
Vestas CoolerTop TM Operation up to 2,000 m altitude without derating No power consumption for fans No noise emission from cooling system
Drive train Integrated rotor lock system to improve maintenance ability • Best performing gear solutions (proven from VPDC data) implemented.
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Blade 55% larger swept area over V903.0 MW Large root diameter ( Φ2.6 m) ensures blade bearing longevity Lightning receptors and internal grounding cable integrated Robust performing profiles less sensitive to dirt Reduced noise level
Yaw System: 8 yaw gears Robust plain bearing with build in frictions
Robust Design High Reliability Lower energy costs
Reducing noise impacts power production minimally Power reduction of various noise modes
Sound power 110
Site
Mode 0
specific operation modes possible
Mode 1
105
Mode 2 High
production during low noise operation due to
Low
noise blade profiles
The
full-scale converter
Permanent
100
95
magnet generator
90 3
4
5
6
7
8
9
10 11
12 13 14
Annual Average Wind Speed [m/s]
Power Reduction of Various Noise Modes STANDARD MODES 105.0 DB(A)*
AEP REDUCTION @ 8 M/S
Mode 0
3.000
Mode 1 Mode 2
2.000
MODE 1: REDUCED SOUND EMISSION AT LOW WIND SPEED
0.3%
1.000
MODE 2: MAXIMUM SOUND EMISSION 104.5 DB(A)
4.3%
0 3
4
5
6
7
8
9
10
11
12
13
Annual Average Wind Speed [m/s]
Higher yield
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V112-3.0 MW platform – the new power system
Permanent magnet generator Synchronous No slip rings/brushes needed for operation Internal ventilation and water jacket cooled Compact design Low weight H brid bearin s ceramic Full scale converter Water cooled Modular layout Transformer 650 V – 10-35 kV, air cooled High voltage cable Switchgear
Simple and effective power system with high efficiency and excellent fault ride through capabilities
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The new power system
u gr comp ance Voltage range Frequency FRT Reactive current injection Power Recovery Short-circuit contribution Max short-circuit level Fast ramp up
0,8 – 1,2 45-65 Hz Yes Yes Yes 1.5 pu 23 kA Yes
eatures Designed for superior grid support Power factor range: ± 0.9 Zero Voltage Ride Through: 0.5 s Fast run back to 20%, spinning reserve 20% to 100%
Excellent grid support capability Reduced Maintenance Cost Highly adaptable for future requirements
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Reactive power capability Q (pu)
Power Factor = +/- 0.90
0.5 0.4 0.3 0.2 0.1 pu
. -0.1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
-0.2 -0.3 -0.4 -0.5 Over-excited Leading Capacitive Under-excited Lagging Inductive
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Improved Grid Capability Higher Power Efficiency
Low voltage ride through Voltage FRT-profile (WTG) 1,2 1,1
0,00; 1,10 10,00; 0,90
1,0 0,9
0,00; 0,90
2,60; 0,80
0,8 0,7
) u p 0,6 (
10,00; 0,80
U
0,5
Designed for FERC 661A regulations
Tested for FERC 661A regulations
0,4 0,3
0,00; 0,00
0,2 0,1
0,45; 0,00
0,0 -0,5
0, 0
0 ,5
1, 0
1, 5
2 ,0
2, 5
3 ,0
3,5
4 ,0
4,5
5,0
5,5
6, 0
6,5
7,0
7,5
8, 0
8, 5
9 ,0
9, 5
1 0,0
10, 5 11 ,0
Time (s)
Designed AND tested
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Reduced BOP cost
Lower foundation costs Advanced control algorithms (Load Management System) reduce the loads Low top head mass reduce the dynamic loads
Reduced substation cost Full converter reduces the substation size and cost by
Reduced road and crane pad stand cost No components weigh more than 70 tones' Replacement of components can be done by tower crane
Reduced BOP cost
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Designed for uncomplicated transport Turbine split in modules “Easy”
transport: In terms of weight, height and width, all of its components comply with local and international limits for standard transportation
Standard
trailers useable for main components
Easy
to use jacking system
Easy to transport
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Designed for easy service area in nacelle increased by 60% over previous Vestas turbines
Work
Nacelle
designed with technicians in the Virtual Reality Centre to ensure good working environment (easy access to tools, enough space to do service, etc)
Service
conditions improved by direct crane access to converter modules for quick and safe maintenance.
Switch
gear is controlled via internet connection
Serviceability build into
design. Easy-to-understand storyboards describe exchange of all critical components
Modular
design allows easy access and fast component replacement
Designed for serviceability
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First of its kind – Vestas’ virtual technology improves the arrangement in the hub
Virtual Reality helps you make sure that service technicians can perform their jobs safely Visualisation and simulation technique allows Vestas to communicate and move knowledge much faster to you
Easy training of staff
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Agenda
16
1
The V112-3.0 MW – harnessing low and medium onshore winds for you
2
The V112-3.0 MW is designed to optimize your energy production and reduce energy costs
3
The V112-3.0 MW delivers business case certainty
4
Vestas wind turbines also benefit from advanced monitoring solutions
V112-3.0 MW design based on proven technology Permanent magnet generator & Full scale converter PM generator: Designed by key employees Vestas acquired from ePower LLC, which has 3 decades of experience in motor and generator technology VND The full-scale converter in the V112 is based on 10(+) years experience from design, operation and manufacture of converters for DFIG system
Control system Desi n based on V90-3.0 MW
Pitch System Design based on V90-3.0 MW Double feeding pump system ensuring reliability
Blade Design based on V90-3.0 MW Red
Drive train Based on V90-2.0 MW gear technology Best performing gear solutions (proven from VPDC data) implemented
Yaw System: Design based on V90-3.0 MW and V90-2.0 MW Robust plain bearing with build in frictions 17
Towers: Designed based on V90-3.0 MW technology
Robust Design High Reliability
Vestas Test Center ensures V112-3.0 MW platform reliability
RIGOROUS TESTING OF NEW COMPONENTS For the new gearbox MONITORING OF 20+ FAILURE MODES IN 12 SEVERE USER SEQUENCE TESTS has been conducted to identify known and unknown potential failure modes
GEARBOX GENERATOR
Generator R = 90.0% L10 20 years CI = 50%
Housing
Stator
Bearings
R = 99.8% L0.1 @ 20 years CI = 50%
R = 94.0% L6 @ 20 years CI = 50%
R = 99.1% L0.9 @ 20 years L10mh @ 400 kh MTBR = 10.7 y CI = 50%
Stator core
Windings
R = 99.9% L0.1 @ 20 years CI = 50%
R = 99.8% L0.2 @ 20 years CI = 50%
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Rotor
Bearing hardware R = 99.9% L0.1 @ 20 years CI = 50%
Rotor core
Magnets
R = 99.9% L0.1 @ 20 years CI = 50%
R = 99.4% L0.6 @ 20 years CI = 50%
R = 99.0% L10 @ 20 years CI = 50%
Magnet retention system R = 99.9% L0.1 @ 20 years CI = 50%
Insulation system
Electrical connections
Temperature sensors
R = 99.0% L1 @ 20 years CI = 50%
R = 98.5% L1.5 @ 20 years CI = 50%
R = 96.7% L3.3 @ 20 years CI = 50%
Encoder, ground brushes and lubrication system R = 99.0% L1 @ 5/20 years MTBR = 5 years CI = 50%
Fan and hub
Shaft
R = 99.8% L0.2 @ 20 years CI = 50%
R = 99.99% L0.01 @ 20 years CI = 50%
Comprehensive testing has been applied to ALL CRITICAL COMPONENTS
ENCODER
Stressors causing failure modes have been identified and TESTED IN SPECIALIZED RIGS to ensure reliability of each component
Specific procedures are in place for severe testing of new design elements
IDENTIFY FAILURE MODES & MECHANISMS
DESIGN THE TEST
CONDUCT THE TEST & EXTRAPOLATE
SETUP THE TEST
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Vestas has identified all critical processes for both in-house and sub-supplier production and is systematically installing and monitoring quality controls
5 sigma performance target to ensure EACH COMPONENT IS IDENTICAL to the validated design specifications
5 SIGMA PRODUCTION PERFORMANCE DESIGN SPECIFICATIONS • ………… •…………. •…………. •………….
QUALITY CONTROLS ACROSS PRODUCTION Nacelles 46%
Span of Control
99
Main Processes with Control
VESTAS HAS A CLEAR OVERVIEW of span of control and sigma performance levels at component, platform, factory and process level
213
Count of Main Processes Span of Control
2MW Nacelle 53%
2MW Hub 23%
3MW 38%
32
10
60 1,51
44 4,06
Main Processes with Control Count of Main Processes Lowest Sigma Level
o N (
g r o b i V
n i j n a i T
n o t h g i r B
n o e L
g n i b ø k g n i R
n i j n a i T
n e g a k S
n o e L
3MW Hub 35%
V52 56%
13
6
10
34 3,67
17 3,94
18 0
g n i b ø k g n i R
g n i b ø k g n i R
o t n a r a T
4 i a n n i j n n e a i h T C
o t n a r a T
50%
55%
%
55%
45%
45%
0%
0%
35%
41%
35%
56%
56%
Main Processes with Control
10
11
0
11
5
5
0
0
6
7
6
5
5
10
Count of Main Processes
20
20
0
20
11
11
11
11
17
17
17
9
9
13
4,01
2,04
1,51
4,06
3,67
4,5
3,94
Span of Control
Lowest Sigma Level
Quality Assurance
20
1.6 7
77%
4,5
Agenda
21
1
The V112-3.0 MW – harnessing low and medium onshore winds for you
2
The V112-3.0 MW is designed to optimize your energy production and reduce energy costs
3
The V112-3.0 MW delivers business case certainty
4
Vestas wind turbines also benefit from advanced monitoring solutions
Vestas performance & diagnostic center offers prevention through prediction Identify performance deviation and issues in the fleet based on predictive models and INITIATE PREVENTIVE MAINTENANCE though conditioning monitoring system & Vestas Turbine monitor
Global 24/7/365 COVERAGE OF 16,227 TURBINES with more than 50,000 high speed data tracks per month
MONITOR IDENTIFY & INITIATE
Findings are used to improve predictive models to provide RELIABLE PERFORMANCE AND YIELD MANAGEMENT
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LEARN & IMPROVE
PLAN & REPAIR
Planning of maintenance based on weather forecast & making repairs to MINIMIZE LOST PRODUCTION FACTOR
Vestas condition monitoring (CMS) - predicting costly mechanical failures Vibration level Functional loss Corrective service
WITHOUT condition monitoring
Production loss Damage detected Inspect damage
Order spare parts
Repair work
Predictive service
Using condition
Inspect component
Order spare parts
Repair work Time
Assessment
of the "health" of a machine by analysis of measured signals
Estimation
of time of failure optimised planning of maintenance activities Cost reduction Optimization of maintenance efficiency Maximized availability and production
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VestasOnline® – Vestas’ SCADA solutions
Grid meter
This SCADA system turns a group of wind turbines into a wind power plant
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VestasOnline® is the most advanced system on the market today
Standard features Plant Layout view Event notification Basic Statistics Online Production View Event View 24/7 surveillance Standard Production Reports
Add-on features Production Control Grid Control 3rd Party grid integration Plant Customization Maximized production at PCC Customized Reports
Allows monitoring of complete park including substation
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THANK YOU FOR YOUR ATTENTION
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