BREMEN

1st September, 2016

ION AROCENA DE LA RÚA

Nabrawind Project ManagerANTONIO UGARTE

CENER Wind Energy Directorwww.nabrawind.com

www.cener.com

Advanced Validation Strategy for Nabrawind Self Erected Tower

NABRAWINDAdvanced Wind Technologies

1 Introduction

Drastic Cost Reduction

Modularity Proven Technologies

Modular Blade Joint

Self Erected Tower

Nabrawind Introduction

1 Introduction

Cost Increase€HH140=1.6·€HH100

Most Expensive Component HH>120

LogisticsRoads / Bridges Limiting Concepts

Assembly CranesLack of AvailabilityLarge Mobilization and Rental Costs

Installation RateNew Concepts Delaying Wind Farm Installation Rates

WTG IntegrationControl Challenges in Soft-Soft TowersSoft-Stiff Unfeasible for XXL Steel Towers

XXL Tower Challenges

2 XXL Tower Alternatives Evaluation

TubularSteel

SegmentedSteel

PrecastConcrete or

HybridLattice Nabrawind

SET

Tower Cost

Logistics

Assembly & Erection

Modal Coupling

Operation Proven Life

Good Poor

Nabrawind SET

3 Nabrawind Self Erected TowerAdvanced Lattice Structure

Client WTG

Client WTG

Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly

3 Nabrawind Self Erected TowerAdvanced Lattice Structure

80 100 120 140 160 180

Tota

l Cos

t [k€

]

Hub Height [m]

Tower + Installation Cost

Steel Tubular

Hybrid Tubular

NBW -30%+40m

3 Nabrawind Self Erected TowerAdvanced Lattice Structure

Self ErectionNo Large Cranes

Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly

3 Nabrawind Self Erected TowerAdvanced Lattice Structure

Self ErectionNo Large Cranes

Fast Assembly2-Days WTG Erection (Wind >15m/s)Prefab Foundation (T<0ºC)

0 5 10 15

SET160m

Concrete140m

Steel100m

Steel60m

Installation Days

Crane Inst

WTG Inst.

Crane Des

WTG Installation Sequence (no Foundation)

0 10 20 30 40 50 60

SET160m

Concrete140m

Steel100m

Steel60m

Installation Days

FoundationFound. CuringCrane InstWTG Inst.Crane Des

WTG Installation Sequence

Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly

3 Nabrawind Self Erected TowerAdvanced Lattice Structure

Self ErectionNo Large Cranes

Fast Assembly2-Days WTG ErectionPrefab Foundation

Easy WTG IntegrationSoft-Stiff Tower H>180No Functional Affection

Freq

uenc

y [H

z]

Rotor speed [rpm]

1P

3P

6P

1st Bending

2nd Bending

1st Torsion

⍉130 HH160 Campbell Diagram

Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly

3 Nabrawind Self Erected TowerAdvanced Lattice Structure

Simple Logistics and OperationPackable in Standard 40ft ContainersMaintenance Free Structure and Connections

Self ErectionNo Large Cranes

Fast Assembly2-Days WTG ErectionPrefab Foundation

Easy WTG IntegrationSoft-Stiff Tower H>180No Functional Affection

Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly

TubularSteel

SegmentedSteel

PrecastConcrete or

HybridLattice Nabrawind

SET

Tower Cost

Logistics

Assembly & Erection

Modal Coupling

Operation Proven Life

Nabrawind Self Erected TowerTower Alternatives Comparison3

4 CENER Introduction21 M€ In 2016 the annual budget is

20,5€ million. 70% self-financing

190 190 employees

100 M€ Total investments (2002-2016): ~ 101€ million

NUMBERS:• Wind Power• Photovoltaic• Solar thermal• Biomas• Grid integration• Bioclimatic architecture

AREAS

5 Advanced Tower Validation WTG Blades vs Towers Validation Strategy Comparison

FullScaleTests

SubcomponentTests

Coupon Tests

WTG Blades

Component Verification √

Design Details

Validation√

Material Allowables Definition

√

5 Advanced Tower Validation WTG Blades vs Towers Validation Strategy Comparison

FullScaleTests

SubcomponentTests

Coupon Tests

WTG Blades

WTGTowers SET

Component Verification √ X √

Design Details

Validation√ ∼ √

Material Allowables Definition

√ ∼ √

6 Fatigue Full Scale Tower TestTest Objectives

Tower & Foundation Accelerated Proven Life

0

5

10

15

20

25

0 5 10 15 20

Ope

rativ

e Pr

oven

Life

[yea

rs]

Time [years]

Accelerated Test

Operational Proven Life Acceleration

Conventional Operation

6 Fatigue Full Scale Tower TestTest Setup

Hot SpotsLattice Members

Foundation SettlementBolt Preload Control

Tower Head MassTower Head Exciter

Strain GaugesLVDTLVDT

Bolt Load Sensors

6 Fatigue Full Scale Tower TestTest Design

Tow

er H

eigh

[m]

Bending Moment Ranges [kNm]

20y Design Loads20y Eq. Test LoadsFinal Test Loads

γt

Full Scale Test Load Distribution

Tower DesignFatigue Loads20/25 years

Test EquivalentLoads

>20/25 years

Test Loads

Damage-Equivalent Ranges Analysis

IEC61400-23 based Test Factor (γt):- Conseq. Failure- Tower Variation- Fatigue Formulation

7 XXL Tower Alternatives EvaluationAfter SET Full-Scale Test

TubularSteel

SegmentedSteel

PrecastConcrete or

HybridLattice Nabrawind

SET

Tower Cost

Logistics

Assembly & Erection

Modal Coupling

Operation Proven Life

Tower Tests

8 Nabrawind Self Erected Tower ProjectProject Summary

Design Certificate

2015 2016

Company / Project Funding

SET TechnologyDevelopment

HH160 Tower Detailed Design

2017 2018

HH160 Tower Prototype Manuf. & Erection

Tower Certificate

TowerPreserials

8 Nabrawind Self Erected Tower ProjectProject Summary

Thanks for your Attention

www.nabrawind.com

www.cener.com