Post on 18-Mar-2018
10-09-2009
1
© Copyright by DOOSAN Heavy Industries & Construction Co. 2009
All Rights Reserved.
Development of
Doosan 3MW Offshore
Wind Turbine System
Korea-Denmark Energy
Conference
September 7, 2009
Do-Gyoon Kim, Staff R&PD Engineer
Wind Power Engineering Team
Power Plant
Doosan Heavy Industries & Construction Co.
Ltd.
2
Company Introduction
Status of Korean Wind Energy Market & Policy
Development of 3MW Class Offshore Wind Turbine(WinDS3000TM
)
Blueprint of Korea-Denmark Wind Energy Cooperation
Contents
2
10-09-2009
2
3
Location
3
⊙ Seoul
◎
Changwon
Head Quarter : Changwon, Korea
Foundation year : 1962
No. of Employee : 5,000
Sales : 3,200 mil. EUR in 2008
Organization : 5 Business groups and 5 Departments
I. Company Introduction
Global Leader in Power and Water
4
• Beijing
• Taipei
• Kuala Lumpur
• Tokyo
• CHICO(Sri Lanka )
• HANVICO(Vietnam) :Power & Industrial Plant
• HPL(Papua New Guinea)
• Doosan E&S(India)
• Frankfurt
• DOOSAN IMGB(Rumania) : Steel Manu./
Casting&Forging
• Doosan Bobcock Energy
• Dubai, Abu Dhabi (UAE)
• Kuwait
• New Jersey (US)
• Schenectady (US)
• Pittsburgh (US)
Asia
• Shanghai
• New Delhi
• Hanoi
• Bangkok
• Mumbai
• Riyadh (Saudi Arabia)
• Tripoli
• Windsor (US)
• Pittsburgh
Europe
Middle East
North America
Branch (19)
Corporation (4)
Subsidiary (9)
I. Company Introduction
Global Networks
10-09-2009
3
5
Korean Wind Resource
5
Korean Wind Resource
Source : KIER (Korea Institute
of Energy Research)
Theoretical Available
• Onshore: 186.5 18.6 TWh/yr
• Offshore: 460.5 46.1 TWh/yr
Source : A Renewable Energy Whiter Paper 2005,
Ministry of Knowledge Economy, Korea
Year 2008 2009 2010 2011 2012 2013
Cumulative Capacity
Installed (MW)311 461 711 1011 1411 1911
Growth rate (%) 63 % 48 % 54 % 42 % 40 % 35 %
Korean Wind Capacity Forecast
Source : BTM Consult ApS – March 2009
II. Status of Korean Wind Energy Market & Policy
6
Class
DOOSAN
HYOSUNG
Rated
Power
3,000 kW
750 kW
2,000 kW
750 kW
2,000 kW
1,500 kW
2,500 kW
1650 kW
2000 kW
2,000 kW
IEC IA
IEC IA
IEC IIA
IEC I/II/IIIA
IEC II/IIIA
IEC IIA
IEC IIA
IEC IA
IEC I/II/IIIA
IEC IIA
Rotor Dia.
91.6 m
48 m
90.6 m
50/54/57 m
88/93 m
70 m
90 m
77 m
76/86/93 m
86 m
• WinDS3000
• HS-48
• HS-90
• U-50/54/57
• U-88/93
• HJWT1500
• SAMSUNG
• HQ1650/200
0
• HR-D86
Model Description
• ’06.09~’09.08 (Oct, ’09, prototype test
scheduled)
• ’01.12 ~’04.12 (DEWI-OCC type cert.)
• ’04.04 ~’07.03 (DEWI-OCC type cert.)
• ’01.12 ~’04.12 (DEWI-OCC type cert.)
• ’04.09 ~’07.08 (Prototype testing)
• ’05.12 ~’06.11 (DEWI-OCC type cert.)
• Developing
• Developing
• Developing
• ’08.10 ~ ’11.07 (Developing)
UNISON
HANJIN
Korean Local Manufacturer
SAMSUNG
HYUNDAE
HYUNDAE
ROTEM
II. Status of Korean Wind Energy Market & Policy
6
10-09-2009
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7
2030 Vision & Target of Korea Wind Industry
II. Status of Korean Wind Energy Market & Policy
Korea Wind Industry Support Policy
2011
Global
market 33
GW
Target 2%
(660 MW)
2020
Global
market 75
GW
Target 10%
(7.5 GW)
2030
Global
market 158
GW
Target 20%
(31.6 GW)
2011
Top 20
2020
Top 5
2030
Top 1
2030
Global
wind
market
leader
Source : Ministry of Knowledge Economy,
Renewable Energy RD&D Strategy 2030
PTC (Product Tax Credit)
RPS
(Renewabl
e Portfolio
Standard)
Green
Certificate
FIT (Feed In Tariff)
USA
USA*
Italy England
Australia Belgium
Norway Japan
New Zealand
Ireland
Finland
Austria
New
Germany Spain
Korea Denmark
Czech Rep.
France Portugal Greece Swiss
Canada Holland Hungary
Korea Wind Energy Supply Trend
Source : 2008. Korea Power Exchange
(www.kpx.or.kr)
Cumulative
New Cumulative
8
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
Design Requirements of WinDS3000TM
8
Enhanced Blade Design
Integrated Drive Train
Innovative
Gearbox Design
Multi-Body Dynamics Analysis
PMG + Full Power Converter
Advanced Control System
Component & System Design Concepts: High RAMS + Low COE
SCADA & CMS
High RAMS & Low COE
Simulation-Driven
Hub & Mainframe Design
High Reliability
Maximized
Availability
Reduced O&M Cost
10-09-2009
5
9
Specifications of WinDS3000TM
Power regulation Pitch regulated Electrical
with variable speed Grid frequency 50/60 Hz
Operating data Converter type Full power converter
Rated power 3,000 kW Generator type Synchronous PM
Wind class - IEC Ia Voltage 690 V
Cut-in wind speed 4 m/s
Rated wind speed 13 m/s Main dimension
Cut-out wind speed 25 m/s Blade length 44 m
Operational temperature range -20/50 oC Max. chord 4.15 m
Sound power level at 11.5 m/s 105.6 dB Nacelle dimension
(height x width x length) 5.5 x 4.5 x 12.6 m
Rotor
Number of blade 3
Rotor diameter 91.3 m
Swept area 6,539 m2
Rotor speed (rated) 8 ~ 20.4 (15.71) rpm
Gearbox
Type 2 planetary + 1 parallel
Gear ratio 92.92
Tower
Type Tubular steel tower
Height 77.78 m
9
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
10
10
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
Blade Design & Manufacturing
Length : 44 m
Weight : 10.3 tons (incl. T-Bolt & Nut & Platform)
Aerodynamic load reduction
- Slim blade has been applied for load
reduction
EU-90-2300 (basic
model)
Enhanced Blade
Material & manufacturing process changes
- OCF111A(GFRP) SE1500 (GFRP)
- Hand lay-up Vacuum infusion
Structural design and analysis
- Optimized internal structure for weight
reduction
- 11.2 ton (basic model) 9.9 ton (design
model)
Design Improvement
Specifications
10-09-2009
6
11
Flexible pin
2 Planetary / 1 Parallel
Transmission ratio: 92.92
Compact Size
Light Weight
High Reliability
Differential gear
11
Rotating housing
Multi-planet
Innovative Gear Box Design for Light Weight and High Reliability
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
12
System Efficiency - Windpower 2007, GE
0
50
100
0 5 10 15 20Wind Speed
Eff
icie
ncy,
%
PMG
DFIG
No direct connection
between grid & generator
Easy 50/60Hz grid frequency
conversion
Excellent efficiency
in partial load
Full Power Converter
PMG
Full
Power
Converter
System protection from grid impact
Grid-friendly system
PMG AC/DC DC/AC
Increased annual energy production
- General : 2% more AEP
- Superior AEP in low speed region
12
Permanent Magnet Generator with Full Power Converter
G/B
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
10-09-2009
7
13
13
Torque
Control
Drive Train
Damper
Power
Control
Tower
Control
Individual
Pitch Control
Maximizing power production
below rated wind speed
Reducing gearbox torque vibration
- by active control of generator torque
Limiting power production
above rated wind speed
Reducing tower vibration and load
Reducing load fluctuation due to wind shear
- increase fatigue life of blade & drive train
Control System
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
14
14
Sensors• Key phaser
• Accelerometer
• Pressure
• Temperature
• Fiber strain
TCS
(Turbine Control System) SCADA
Client PC• Configuration S/W
• Display S/W
Field Access
CMS Server
•Configuration S/W
•Direct data access & analysis
MASTER
CMS
Wind Turbine
Condition Monitoring System (CMS) & SCADA
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
10-09-2009
8
15
Gearbox cooling system
- Air to oil cooler
- Pump number : 2 EA
Generator cooling system
- Water to air cooler with shaft integrated fan
- Pump number : 2 EA
Inverter cooling system
- Air to water cooler
- Pump number : 2 EA
: 1 EA for each inverter (master/slave)
Nacelle cooling system
-Air to air heat exchanger
Heating Air Inlet
Cooled Air VentThermal Exchange
Aspirator/Ventilation Duct
15
Cooling System
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
16
Small Jack-up
Barge +
Winch Pulley
System
Doosan WayConventional O&M System
Large Jack-up
Barge +
Crawl Crane
16
Internal Maintenance Crane : Concept
III. Development of 3MW Class Offshore Win Turbine (WinDS3000TM)
10-09-2009
9
17
Enhanced blade design & manufacturing
Weight reduction due to Integrated drive train
Innovative gearbox concept
(rotating housing, differential gear, flexible pin)
Permanent magnet generator with full power converter system
Advanced control system
Condition monitoring system
Isolated nacelle system
Easy maintenance crane concept
Anti-corrosion surface coating against salinity and humidity
Advanced Design
Feature
Offshore Application
WinDS3000 high RAMS and low COE requirements
17
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
18
Test
Setup
2009. 02
Test with
witness
• No Load (step 1) Full Load (step 10)
Load Test
• Inspection Completed
Certification
Back to Back Test
• Simulated condition at -15℃
• VG1000 instead of VG320
• 5℃ Operating Temp.
Low Temp. Test
18
Back to Back Test for Gearbox
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
10-09-2009
10
19
• According to GL Guideline
• Load distribution by 2 whiffle tree sets
Test Loads
• Flapwise & Edgewise direction
• 1st & 2nd Natural Frequencies with Accelerometer
Procedure
Static
Test
• Flapwise max & min (2 Steps)
• Edgewise max & min (2 Steps)
Procedure
Modal
Test
2009. 03
19
Full-Scale Blade Static Test
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
20
• IEC 61400-1
Guideline
Back to Back Test
• Visual Inspection
• Dielectric Test & No Load Test
• Phase Rotation Test
• Over Speed Test
• Demagnetization Test
• Load & Efficiency Test
• Temperature Rising Test
Test
• Winding & Insulation Resistance
• Vibration, Sound Level, THD*
Measure
*THD: Total harmonic distortion
Rotor AssemblyRotor Balancing test Stator Wiring
20
Back to Back Test for Generator
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
2009. 05
Test
Setup
10-09-2009
11
21
Acquisition of
C-Design Assessment
21
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
2009. 02. 25
22
Foundation
ConstructionErection
Blade Transportation
(’09. 06)
(’09. 08)
Prototype Test
Tower Transportation
(’09. 08)
(’09. 09)
(’09. 10~)
Nacelle Transportation
(’09. 08)
22
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
Installation Procedure – Finished & Scheduled
10-09-2009
12
23
1/4
’09 ’10
2/4 3/4 4/4 1/4 2/4 3/4 4/4
• Foundation
• Erection & Test Operation
• Power Curve Assessment
• Load Assessment
• Noise Assessment
• Type Certification
1/4 2/4
’11
Schedul
e• PJT Term : ’09. 05 ~’11.04 (24 months)
• Site : Kimnyeong, Jeju
Project
Scope
• Prototype WinDS3000 Installation
• Operating tests and Measurements
• Type Certification
23
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
3MW Onshore Prototype Test
24
’09 ’11
• WinDS3000 Manufacture
• Foundation Design
• Foundation Manufacture
• Erection
• O&M
Schedul
e
2/4
’12
Project
Scope
• WinDS3000 1 Unit manufacture
• Offshore foundation manufacture and installation
• Offshore windfarm operation and maintenance
1/4 2/4 3/4 4/4 1/4 2/4 3/4 4/4 1/4 2/4 3/4 4/4 1/4 2/4 3/4 4/4
’10
• PJT Term : ’09. 05 ~’12.04 (36 months)
• Site : Offshore near Woljeong, Jeju
24
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
3MW Offshore Prototype Test
10-09-2009
13
25
Doosan Vision for Wind Energy Business
World Best
Products
Desalination Plant
HRSG
Crank Shaft
Work Roll
Mould Steel
8th World Best Product
Offshore Wind Turbine
Cast Steel
26
IV. Blueprint of Korea-Denmark Wind Energy Cooperation
Reliable market approach and extension
by licensing contract
Employing Vestas’s retired and senior
technical engineers as managers and
consultants of Korean wind power man-
ufacturers and related agencies
Utilizing Korea as new Asian service hub
to consider technology and quality
Including prominent Korean component
makers as Vestas’s major supply chain
Mutual patent cross-licensing
Foundation of collaborative research center
Mutual investment, etc
Including leading Danish component
makers as Korean major supply chain
10-09-2009
14
27
Thanks for Your Attention !!
dogyoon.kim@doosan.com
28
I. Company Introduction
28
History
10-09-2009
15
29
II. Status of Korean Wind Energy Market & Technologies
What is Wind Energy?
29
Energy converting system from wind to electrical power
Theoretical maximum energy efficiency can be reached up to 59.3%
The efficiency limited to 20~50 % due to aerodynamic, mechanical, electrical losses
Gear Box Generator Electronics GridRotor
Rotation
Energy
Increase
Speed
Electric
EnergyAD to DC or
DC to AC
Electric
Energy
6
30
Global Wind Energy Market Forecast
30
Global Market Growth Rate 29%: 121GW in 2008 to
190GW in 2010
USA and Asia catch up Europe: New installations
Source: World Wind Energy Report 2008, WWEA
II. Status of Korean Wind Energy Market & Technologies
10-09-2009
16
31
High RAMS
Ocean Wind
Easy Approach
Onshore
Offshore
Salinity & Humidity
- Isolation design
- Anti-corrosion coating
Offshore Condition
Load Condition by Offshore Wind
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
Design Issues for Offshore
31
32
0
20
40
60
80
100
120
0 10 20
Wind vel. (m/s)
He
igh
t (m
)
Onshore
Offshore
Wind
Velocity Onshore Offshore
Wind
Profile
Wind turbine
classI II III
Vref 50 42.5 37.5
Vave 10 8.5 7.5
Vgust50* 70 59.5 52.5
Vgust1** 56 47.6 42
Power factor 0.2
Wind turbine
classI II III
Vref 50 42.5 37.5
Vave 10 8.5 7.5
Vgust50* 62.5 53.125 46.875
Vgust1** 50 42.5 37.5
Power factor 0.14
Wind
Wind speed 10m/s at Hub height 80m
Unit: m/s
*Average max. wind speed during 3sec. with recurrence period of 50 years
** Average max. wind speed during 3sec. with recurrence period of 1 year
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
Difference of Design Load Between Onshore & Offshore
32
10-09-2009
17
33
Conventional Doosan
Way
- Annual failure ratio : 10%
- Average required maintenance cost
during 20 years of design lifetime (unit :
mil. $)
Innovative Customer Value
Creation for maintenance
0.92 G/B
0.92 GEN
1.84
0.52
0.23 GEN
0.23 G/B
0.06 Initial Cost
Immediate ActionSaving Cost (per 1 Unit)
• Small Jack-up Barge Lent
dramatic maintenance time
60 days
Doosan
Way
12 days
Conventional
33
Internal Maintenance Crane : Innovation for Maintenance
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
* 1 $ = 1275 Won
Cost Save : 1.3 mil. $
Cost Reduction Ratio : 72 %
34
III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)
(May ~ August, 2009)
Nacelle Assembly & Nacelle Functional Test
34
10-09-2009
18
35
Site location Youngdeok, Gyeongbuk
Wind park capacity 39.6 MW
Estimated AEP 96,680 MWh/year
WTG model NM82 (V82)
WTG type class IEC IIB
Number of WTG units 24 x 1.65 MW
Weibull parameter Shape factor (A) : 7.8
Scale factor (k) : 1.98
Project status ’05.3 : start operation
Site location Daegwanryung, Gangwon
Wind park capacity 98 MW
Estimated AEP 244,400 MWh/year
WTG model V80
WTG type class IEC IA & IIA
Number of WTG units 49 x 2.0 MW
Weibull parameter Shape factor (A) : 7.95
Scale factor (k) : 1.61
Project status ’06.10 : start operation
II. Status of Korean Wind Energy Market & Policy
Large Wind Farms in Korea
35
36
Korean Wind Farm Status (2008.09)
36
Already installed To be installed
II. Status of Korean Wind Energy Market & Policy
10-09-2009
19
37
Global Wind Energy Forecast
37
2008 2008 2009 2010 2011 2012 2013 Sum Accu.
Total Americas 28,918 9,527 7,650 10,450 12,450 16,200 18,300 65,050 93,968
Total Europe 65,971 9,179 11,580 13,505 15,900 18,080 20,150 79,215 145,186
Total South & East Asia 22,174 8,201 9,650 10,300 12,400 13,400 15,300 61,050 83,224
Total OECD-Pacific 4,256 1,051 1,100 1,350 1,600 1,900 2,250 8,200 12,456
Total other areas 840 232 645 1,035 1,470 1,810 2,520 7,480 8,320
Total MW new capacity every
year:28,190 30,625 36,640 43,820 51,390 58,520 220,995 343,153
Accu. capacity (MW) 122,158 152,783 189,423 233,243 284,633 343,153
Source: BTM Consult ApS - March 2009
Cum
ula
tive
insta
lled
capacity
(MW
)by
end
of
2013
Forecast 2009-2013
Cum
ula
tive
insta
lled
capacity
(MW
)by
end
of
in
2008
Insta
lled
capacity
(MW
) in
2008
Insta
lled
capacity
betw
een
2009-
2013
(incl. Offshore)
II. Status of Korean Wind Energy Market & Policy
© Copyright by DOOSAN Heavy Industries & Construction Co. 2009
All Rights Reserved.
Development of
Doosan 3MW Offshore
Wind Turbine System
Korea-Denmark Energy
Conference
September 7, 2009
Do-Gyoon Kim, Staff R&PD Engineer
Wind Power Engineering Team
Power Plant
Doosan Heavy Industries & Construction Co.
Ltd.