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NR65.5: CHALLENGES IN DESIGN, PRODUCTION AND LOGISTICS … · 2015. 9. 24. · NR65.5: CHALLENGES...
Transcript of NR65.5: CHALLENGES IN DESIGN, PRODUCTION AND LOGISTICS … · 2015. 9. 24. · NR65.5: CHALLENGES...
NR65.5: CHALLENGES IN DESIGN, PRODUCTION AND LOGISTICS OF A VERY LARGE ONSHORE ROTOR BLADE
Stuttgart,
24.09.2015
Platform Strategy one platform … three turbines
New N131 Blade design, materials and manufacturing
XL Blade challenges in production and logistics
AGENDA
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl 2
Platform Strategy one platform … three turbines
New N131 Blade design, materials and manufacturing
XL Blade challenges in production and logistics
AGENDA
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl 3
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NORDEX EVOLUTIONARY DEVELOPMENT
Generation Alpha N80/2500
Generation Beta N90/2500
Generation Gamma N80/2500 N90/2500
N100/2500 N117/2400
2000 2007 2010 2013
Generation Delta N100/3300 N117/3000 N131/3000 N131/3300
Global fleet availability in 2014 ~98 % Turbines under Nordex Service
15 years and
more than 10,000 MW*
*as of Sept.15
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
Rotor diameter
131 m
117 m
100 m
90 m
6,0 6,5 7,0 7,5 8,0 8,5 9,0 9,5 10,0
Wind speed [m/s]
IEC 3a IEC 2a IEC 1a
NORDEX MULTI MW PLATFORM
5
N117/3000
N100/3300
N117/2400
N100/2500
N90/2500
Generation DELTA
Generation GAMMA
N131/3000
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
Platform Strategy one platform … three turbines
New N131 Blade design, materials and manufacturing
XL Blade challenges in production and logistics
AGENDA
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl 6
2014
0 m
20 m
40 m
60 m
80 m
100 m
120 m
140 m
Nordex Rotor Diameter
Industry Average Rotor
Diameter
1987
1997
Blade Specification
Blade Design
Blade Production
Blade Testing
Blade Installation
Blade Service
Lifecycle support
TURBINE BLADES - NORDEX CORE KNOW-HOW FOR OVER A DECADE
Source: iea 2014, technology roadmap
3D-CAD-Modelling Finite Element Calculation
3D-CFD-Calculation Blade Design Verification
Full scale test Quality assurance
7
27m
131m
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
NR65.5 – NEXT STAGE OF NORDEX BLADE EVOLUTION
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NR 50
NR 58.5
NR 65.5
Performance-optimized root section
Max. chord moves further towards root to increase yield and limit loads
Introduction of yield-optimized Nordex flatback profiles
Sound & load-optimized tip section
More slender outboard section to optimize load and wake properties
Selection of proven family of profiles with superior sound power properties
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
NEW N131 BLADE success factors
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NR50 NR58.5 NR65.5
WTG type N100 N117 N131
Length 48.8 m 57.3 m 64.4 m
Weight (1) 10,900 kg 10,200 kg 14,100 kg
Max. Chord 3700 mm 3496 mm 3938 mm
Pre-bend 2000 mm 2000 mm 3000 mm
Projected surface
116 m² 121 m² 153 m²
# of bolts 64 (M36) 64 (M36) 68 (M36)
Bolt circle diameter
2300 mm 2300 mm 2800 mm
Materials GRP GRP & CRP GRP & CRP
• Structural & aerodynamic design are based on the experiences of fully certified in-house developments NR45, NR50 and NR58.5
• Use of proven rotor blade design and carbon fiber composites (CFRP) in spar caps is key performance
• +12% of rotor diameter while adding 26 % to projected surface
• Development of manufacturing concept in cooperation with composite specialist Carbon Rotec
1 Without stud bolts but inclusive transverse bolts.
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
ROOT CAUSE success carbon blades
10
material supplier
Nordex blade
develop
spezial service
rotor blade
btp partner
Nordex lead
factory
btp partner
best
practi
ze s
harin
g
best
sim
& t
est
best
pro
perti
es
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
DESIGN CHALLENGES aeroelastic stability
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Inertia Forces
Elastic
Forces
Aerodynamic
Forces
Dynamic
Aeroelastic
Static Aeroelastic
Flexible TurbineRigid Turbine
Collar-Triangle: classification of force interaction
Static Aeroelastics: • torsion divergence • optimal twist
Dynamic Aeroelastics: • Classical flutter • Limit cycle oscillations
Aeroservoelastics: • Controller interaction
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
light wind turbines more prone to aeroelastic stability problems
• cause of their slender form and
• different loads compared to strong wind turbines.
more accurate torsion stiffness calculation and validation
complete modal analysis
static aeroelastics in optimal blade shape (twist)
dynamic aeroelastics in defining stiffness properties
classical and non-classical flutter limits
DESIGN CHALLENGES aeroelastic stability
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NR65.5
mode s
hapes
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
ANALYSING KEY COMPOSITES STRATEGIES AND CURRENT PRODUCTION METHODS
Costs of Energy / Costs per blade
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl 13
Courte
sy o
f H. R
uckdaeschel, B
ASF S
E
ANALYSING KEY COMPOSITES STRATEGIES AND CURRENT PRODUCTION METHODS
Composites – Simulation as valuable tool to bridge length scales
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl 14
length scale
pro
duct
matu
rity
nm mm m
fiber level
fabric level
application level
molecular level
mm
application level: turbine design blade weight efficiency
fiber level: virtual material characterization:
failure, degradation parametric studies:
voids, sizing, heterogeneities virtual single-fiber-experiments
fabric level: virtual experiments engineering constants first ply failure fiber dominated failure
Courte
sy o
f H. R
uckdaeschel, B
ASF S
E
COMPOSITE MATERIAL VS. DESIGN: WHICH COMES FIRST?
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innovations demand for holistic view – manufacture, design, performance, materials, etc.
Performance
Design Material
Process
final turbine
Courte
sy o
f H. R
uckdaeschel, B
ASF S
E
Comparing spare caps GFRP CFRP Comparable blade design , same design loads.
DEVELOPMENT OF A SLENDER ROTOR BLADE
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Task: Development of a slender rotor blade to fit on an existing turbine • Existing turbine: N100/2500 (medium-wind turbine, IEC II class) • Goal: Turbine for low-wind sites, 117 m rotor diameter, 2400 kW
First try Second try
Carbon fiber No Yes (main spar cap)
Weight 14,4 tons 10,2 tons
Loads
Costs -
N131/3000
Rotor blade test NR65.5
• Static Tests (4 Directions)
• Dynamic Tests
• Edgewise Direction in progress
• Flapwise Direction
• Static Test (Post Fatigue)
Generation Delta
Test & measurement programme well on track
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Platform Strategy one platform … three turbines
New N131 Blade design, materials and manufacturing
XL Blade challenges in production and logistics
AGENDA
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl 18
CHALLENGES IN PRODUCTION
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Courtesy of Carbon Rotec
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
CHALLENGES IN PRODUCTION
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Courtesy of Carbon Rotec
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
CHALLENGES IN PRODUCTION
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Courtesy of Carbon Rotec
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
Transport from production site to windpark Janneby
• No transport permit over motorway
• ship transport necessary
• Increase of transport time and costs
Harbour time
Harbour cranes
• Less flexibility
• By the way: Blade transport on trucks does fit Elbe tunnel
LOGISTICAL CHALLENGES
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Transport by ship Transport by truck
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
XL blades can be transported, but …
• it is time consuming
• it is more expensive than transporting smaller blades
• longer routes may apply
LOGISTICAL CHALLENGES – NEW TRANSPORT SOLUTIONS
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LOGISTICAL CHALLENGES – NEW TRANSPORT SOLUTIONS
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Logistic challenges: installation in forest
Optimized site management and single blade traverse make it possible
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LOGISTICAL CHALLENGES – WE CAN DO IT
NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl
THANKS FOR YOUR ATTENTION.
Nordex Energy GmbH Langenhorner Chaussee 600, D-22419 Hamburg, Germany
Telephone +49 (40) 30030 1000
Fax +49 40 30030 1101
E-Mail [email protected]
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