Wind Turbine Drivetrain Technology and Cost Drivers e.g. Siemens 2.3 MW, some GE 1.5 MW turbines...

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Wind Turbine Drivetrain Technology and Cost Drivers Dr John Coultate R&D and Consultancy Dept. Leader CONFIDENTIAL @ Copyright 2011

Transcript of Wind Turbine Drivetrain Technology and Cost Drivers e.g. Siemens 2.3 MW, some GE 1.5 MW turbines...

Wind Turbine Drivetrain

Technology and Cost Drivers

Dr John Coultate

R&D and Consultancy Dept. Leader

CONFIDENTIAL@ Copyright 2011

Contents

1. Introduction

2. Wind turbine trends and segmentation

3. Drivetrain technology and cost drivers

4. Conclusions

CONFIDENTIAL@ Copyright 2011SHARING INNOVATION IN BEARING, GEARBOX & DRIVELINE

Romax Technology

• Gearbox and drivetrain specialists

• Established in 1989

• 200 employees globally, 120 in UK

• Work in a range of industries

o Automotive, Off-road, Marine

o Wind energy

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o Wind energy

• Head office in Nottingham, UK

• Overseas offices in the US, Germany, France, Japan, Korea, China and India

• RomaxWIND is the best-in-class Virtual Product Development environment for design and analysis of wind turbine drivetrains

• RomaxWIND includes the only gear analysis capability certified by GL

RomaxWIND – Wind Turbine Drivetrain Software

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“RomaxWIND is the first software of its kind to meet the stringent

certification requirements of GL, and is the result of a number of

years of close working between Romax and GL.”Dr Karl Steingroever from GL Renewables Certification

Wind turbine trends and drivetrain technology

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Wind Turbine Markets – 2010 status

100,000

125,000

150,000

175,000

200,000

20,000

25,000

30,000

35,000

40,000

Cumulative MW

MW per year

Installed Wind Power in the World- Annual and Cumulative -

Offshore installed capacity in 2010 = 3,554 MW (1.8% of total installed capacity)

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0

25,000

50,000

75,000

100,000

0

5,000

10,000

15,000

20,000

1983 1990 1995 2000 2005 2010

Cumulative MW

MW per year

Year

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

100,000

125,000

150,000

MW

Annual Global Wind Power Development

Actual 1990-2010 Forecast 2011-2015 Prediction 2016-2020

Wind Turbine Markets – Forecast

Offshore market share forecast to increase to 9.6% of total installed capacity by 2015

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0

25,000

50,000

75,000

1990 2010 2015 2020

MW

Prediction Offshore (Forecast) Forecast Existing capacitySource: BTM Consult - A Part of Navigant Consulting - March 2011

European Market Development

• Offshore market today = Onshore market in 1997 (with same growth forecast!)

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Wind Turbine Markets

Many challenges as the industry grows:

• Reliability and availability must improve

• Reduction in Cost of Electricity (CoE):

• Close the gap with other forms of power

• Less reliance on government incentives

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• Less reliance on government incentives

• Drive down O&M costs

• More experience required offshore:

• Engineering challenges: foundations, siting, operation and maintenance

• How to run a profitable offshore business?

Wind Turbine Markets – Size trends

• Average sizes of wind turbines installed increases each year:

600

800

1,000

1,200

1,400

1,600

1,800

kW

Global Average Annual WTG in kW Source: BTM Consult - A Part of Navigant Consulting - March 2011

Source: EWEA ‘UpWind’ report, March 2010

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0

200

400

1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

2010: global average size = 1,650 kW

Existing technology

2 MW, 80m rotor

Current development

7.5 MW, 164m+ rotor

Future

10 MW? 200m rotor?

Wind Turbine Markets – Size trends

• Forecasts indicate the largest market share will be for turbines ≥ 3 MW

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Source: Emerging Energy Research

Wind Turbine Markets – Segmentation

• Average size trend only tells part of the story

• There is natural segmentation of the market for different sites and wind classes:

Onshore

Class I & II wind sites

Onshore

• 1.5 MW – 3 MW

• 1.5 MW – 4.5 MW

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Onshore

Class II & III wind sites

Offshore

• 1.5 MW – 4.5 MW

• Very large rotor (100m+ diameter)

• ~3 MW – 10 MW+

• Turbines optimised for offshore

• Very large rotor (100m+ diameter)

• CMS as standard

Drivetrain Design

• Drivetrain design decisions have a huge impact on future success of a wind turbine

• Cost of Energy (CoE) includes many factors for the drivetrain, e.g.

o Drivetrain cost (CAPEX)

Turbine OEMs typically focus on this during design development; drives down whole turbine cost

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whole turbine cost

o O&M cost (OPEX) –

Reducing O&M costs is a main driver for the end-user (owners, operators, utilities).

o Drivetrain reliability

Has a direct effect on future liability for the OEM (warranty costs) and for the operator (O&M costs)

CAPEX and OPEX

• Approx. annualised CAPEX and OPEX per MW installed:

24 %

31 %

OPEX

Wind turbine & installation

OPEX costs are significantly higher offshore AND higher

proportion of total costTurbine CAPEX is higher offshore but are a lower proportion of total cost

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21 %

65 %

14 %

Onshore

45 %

Offshore

OPEX

Wind turbine & installation

Electrical Infrastructure, foundations & other

Electrical Infrastructure, foundations & other

Significant increase in electrical infrastructure and

foundation cost offshore

Drivetrain Technology

High speed modular drivetrain

Medium speed drivetrain

Direct drive drivetrain

• Three most dominant drivetrain technologies in the market:

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Overall ratio approx. 100:1

Overall ratio approx. 10:1 to 40:1

Overall ratio = 1:1

Drivetrain Technology Trends

Conventional High Speed

1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW

Size limited by higher ratio requirements and physical limitations on high speed stage (bearings)

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High Speed Geared

Drivetrain

Medium Speed Geared

Drivetrain

Direct Drive with PMG

Drivetrain Technology Trends

Conventional High Speed

1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW

Size limited by mechanical/structural challenges above 6MW, unproven technology at large sizes and rare earth magnets too expensive >6MW

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High Speed Geared

Drivetrain

Medium Speed Geared

Drivetrain

Direct Drive with PMG

Drivetrain Technology Trends

Conventional High Speed

1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW

Removes unreliable high speed gearbox stage and reduces impact of rare earth magnet cost

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High Speed Geared

Drivetrain

Medium Speed Geared

Drivetrain

Direct Drive with PMG

Drivetrain Technology Trends

Conventional High Speed

1MW 2MW 3MW 4MW 5MW 6MW 7MW 8MW 9MW 10MW

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High Speed Geared

Drivetrain

Medium Speed Geared

Drivetrain

Direct Drive with PMG

Drivetrain Design Requirements

• For drivetrain and gearbox design, the main requirements leading to low CoE are:

1. High reliability; high availability

2. Low capital cost (CAPEX)

3. Ease of manufacture and assembly

4. Ease of maintenance

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4. Ease of maintenance

5. High efficiency

• High efficiency can influence factors such as generator type, power electronics and variable ratio gearboxes

• High reliability does not just refer to mechanical reliability – also Low Voltage Ride Through (LVRT), stability of grid connection, etc.

Drivetrain Components and Configurations

1. High speed modular 2-point mounted drivetrain

o Very common configuration – e.g. Vestas V80, Gamesa 2 MW, GE 1.5-77

Generator

2x Main BearingsGearbox

Brake

Flexible

Rear

bedplate

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Low stiffness

(gearbox mount)

Low stiffness (generator mounts)

Planet carrier

Flexible

Coupling

bedplate

(fabricated

steel

structure)

Bedplate

(cast iron)

High stiffness

(bearing housings)

Tower

2. High speed modular 3-point mounted drivetrain

o e.g. Siemens 2.3 MW, some GE 1.5 MW turbines

Generator

1x Main BearingsGearbox

Brake

Flexible

Drivetrain Components and Configurations

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Flexible

Coupling

High stiffness

(bearing housings)

3. Integrated main bearings; integrated mainframe; modular generator

GeneratorGearbox

Brake

Flexible

Drivetrain Components and Configurations

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Flexible

Coupling

Main bearing

integrated into

gearbox housing

Gearbox is flange-

mounted to housing

Shorter, more

compact

drivetrain

• Medium speed is an important concept for next-generation turbines:

o Currently being utilised for large turbines (3 MW+) by many manufacturers, e.g. Vestas V164 7 MW, Areva Multibrid M5000, DSME

Drivetrain Components and Configurations –

Medium Speed

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MW, Areva Multibrid M5000, DSME 7 MW, and Gamesa G10X 4.5 MW

o Requires a careful approach to design and analysis:

• high level of integration and interaction between gearbox and generator

4. Example medium speed concept – integrated generator (in-line); integrated main bearings; integrated mainframe

GeneratorGearboxGenerator is

mounted in-line

onto gearbox

Drivetrain Components and Configurations –

Medium Speed

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Rotor cables routed

through hollow

generator shaft

Main bearing

integrated into

gearbox housing

Gearbox is flange-

mounted to housing

Note: brake may be

mounted on low-

speed shaft or

downwind side of

generator

• E.g. Areva Multibrid M5000:

Drivetrain Components and Configurations –

Medium Speed

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Water-cooled PMG

(integrated into gearbox

housing)

Compound

planetary gear

stage

Integrated mainframe/gearbox

housing

Large diameter

integrated main

bearing

Conclusions

• An overview of technologies have been presented for the mechanical drivetrain

• There is currently a market trend towards Medium Speed concepts which have a number of advantages for large turbines

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Thank you for listening!

CONFIDENTIAL

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[email protected]

Romax Technology is the technology leader in the precision simulation and analysis of bearing, gearbox and driveline systems.

In over 20 years of providing expert engineering services to the global vehicle, aerospace, marine, rail and wind energy industries, Romax created and refined Romax Designer, the world’s first object orientated engineering analysis software package.

Today Romax Designer has evolved into the world’s most comprehensive whole-system simulation and analysis platform, enabling fast, high precision results in one seamless development environment.

Romax believes in excellence through collaborative research and development with leading wind turbine manufacturers and operators; vehicle manufacturers; gearbox and driveline manufacturers; gear and

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manufacturers and operators; vehicle manufacturers; gearbox and driveline manufacturers; gear and bearing manufacturers; and with certification, research and academic institutions.

As an innovative specialist Romax adopts a partnership style with customers and industry players to facilitate knowledge transfer and integrated solutions. Headquartered in Nottingham, UK, Romax provides an award winning localised service through an extensive global network, with 12 offices located in the UK, France, USA, Korea, Japan, China and India.

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