1. 1 Casemir Nils 2014/05/12

2. 2 Table of content - Historic of WTG - Actual Wind turbine models - Highlight of wind turbines - Design basics - From foundation to rotor blades - Foundation - Tower - Machine house (nacelle) - Rotor head (hub) - Blades - Q & A 3. 3 Historic wind mills Mechanical Wind power machines Early samples of windmills were used to grind grain. In ancient Persia. These were developed around 600 A.D. They had a vertical rotor driveshaft and a Horizontal rotation plane. 600 4. Historic wind mills Windmills in Europe Wind mills have been known in Europe since the 12th Century. From the start, they were designed as lift based horizontal axis wind turbines, which is still a basic principle of moderndays wind turbine generator. 12 Sail WTG used in Mediterranean for irregation Post mill: oldest European WTG , design, 12th to 16th Century, using for grain 12~16 5. Historic Wind Mills Smock Mill: As of the 16th Century Main use: Grinding grain, drainage 16 Around in the middle of the 19th century there were over 200,000 wind mills all over Europe. 19 20 End 2013 in Germany were 23.645 modern WTG installed. 2013 23,645 5 6. Historic Wind mills Wind energy in China since Han Dynasty (~ 220 a.D) for dewatering. 6 7. Historical Wind mills The American water pumping wind mill Technology didnt take big steps forward until 19th century 19 The American Western Mil used to pump water mainley in North America, was the first Wind mill in history to pitch automatically out of the wind during storm ~ multi bladed wind turbine (dia. 3 5 m) ( 3~5 ) ~ reciprocating pump for drawing water ~ tens of thousands still in operation in Australia, Argentina, US etc. 7 8. Historical wind mills Electricity producing wind turbines In 1887 1888, Charles F. Brush constructed the first fully automatic wind turbine for electricity production. 1887~1888 Brush With a rotor diameter of 17 meters and a total of 114 blades this machines dimensions were gigantic by the standard of the time. 17 114 For 20 years this turbine supplied enough energy to charge a bank of batteries in the basement of the house. Despite the turbines enormous size the generator was only rated 12 kW. 20 Brush 12kW 8 9. Historical wind mills Electricity producing wind turbines Poul la Cour was a Danish Folk High school teacher. Cour Encouraged by the Danish government, which was exploring different avenues to supply electricity also to the rural areas of Denmark, la Cour built an experimental wind turbine in 1891 to power an generator. Cour 1891 He used the direct current geranerated by his wind turbine for electrolyis and stored the produced hydrogen. In this way, the school grounds in Askov could be lighted with gas lamps from 1885 to 1902. 1885~1902 9 10. Historical wind mills Savonius rotor The Savonius rotor is a vertical axis wind turbine. It was invented by Finnish engineer Sigurad Savonious around 1925. 1925 Savonious Advantages : Simple design and easy assembly High torque at relatively low rotational speed Independent of wind direction, no yaw needed Operational even at extremly low wind speed (2 3 m/s) Disdvantages : Low efficiency (max 28%) Greatly varying load due to continuously changing angle of attach The above puts a limit on the size of this size of turbine. 10 11. Historical wind mills Darrieus rotor The Darrieus rotor is a type of vertical axis wind turbine. It was developed by French engineer Georges Darrieus and patented in the U.S. in 1931 Georges Darrieus Darrieus 1931 Advantages : Function independent of wind direction Generator/gear close to the ground ( ) Efficiency greater than of the Savonius rotor (~40%) Savonius rotor 40% Disdvantages : Great varying load due to contiunously changing Angle of attack Which results the fatique the world largest Darrieus rotor named Eole is more than 100 m height and rated power of 4 MW Darrieus 100m 4MW 11 12. Historical wind mills Development in Germany In Germany at that time were ideas and trials by Wihlem Teubert, Ferdinand Porsche and Hermann Honnef Wihlem Teubert, Ferdinand Porsche Hermann Honnef Among others a test field with wind turbines up to 17 kW was installed on the Mathiasberg hill near Berlin Vision of H. Honnef of an 20 MW WTG (500 m height, dia. 160 m), dated 1930. H. Honnef 1930 20MW 500m 160m( ) Mathiasberg 17kW 12 13. Historical wind mills 13 Smith Putnam turbine Smith-Putnam Another milestone was the installation of the 1,25 MW Smith Putnam wind turbine by Palmer Cosslett Putnam 1941 in Vermont, USA. 1941 Palmer Cosslett Putnam (1.25MW) Except some interruptions, this Wind turbine remained in operation until 1945 when one of the blades failed. The materials and the material quality required for turbines this size simply were not available at the time. 1945 14. 14 Historical wind mills Ulrich W. Httner In 1951, Ulrich W. Htter, a German Austrian wind energy pioneer erected a 10 kW wind turbine with an rotor dia. of 11 m. 1951 10kW 11 Some 200 turbines were exported mainly to south Africa, Argentina and India. 200 In 1957 Htter constructed the prototype of all modern wind turbines, the StGW 34 with 100 kW. The rotor diameter was 34 m. 1957 StGW-34 100kW 34 15. 15 Historical wind mills Gedser wind turbine Gedser Johannes Juul, a former student of Poul la Cour constructed the worlds first wind turbine for producing alternating current. Juul Cour This design set the trend for all of todays modern wind turbines and for a long time it was also the world largest Wind turbine (200 kW, 24 m dia, 1957) It distinguished itselfs by its high reliability because it ran for eleven years without maintenance. . 11 16. Historical wind mills The Danish concept The Gedser wind turbine designed by Juul was based on the Danish concept which became very popular later. Wind turbines used this principle until the early 1990s. Juul Gedser 1990 16 Features : The rotor spins at a fixed rotational speed Power limitation is ensured by stalling (or stall regulation) The rotor drives an asynchronous generator via a gearbox. Due to fixed rotational speed of the asynchronous generator connected directly to the grid there is only one wind speed at which the rotor achieves its maximum efficiency. 17. Historical wind mills Further development Favourable tax policies in California ushered in the breakthrough of wind power in 1985. 1985 Since only the Danes were able to supply operational systems at that time, wind turbines all sudden became a staple item in Denmark, which was produced several thousand times a year. Standard size were units of 125 kW and an rotor dia. of 20 m. 125kW 20 17 18. Historical wind mills Development of WTG size demonstrated on wind turbines (Enercon) Enercon 18 19. Historical wind mills Development of WTG size demonstrated on wind turbines (Enercon) Enercon 19 20. Historical wind mills Development of wind energy demonstrated by WTG from Enercon Enercon 20 ENERCON 21. Historical wind mills Development of wind energy demonstrated by WTG from Enercon Enercon 21 22. Historical wind mills Development of wind energy demonstrated by WTG from Enercon Enercon E 40 first gearless WTG with 500 kW (1992) 1992 500kW Later upgraded to 600 kW with 44 m dia. 600kW 44 Nacelle design changed 2001 2001 22 23. actual wind mills Development of wind energy demonstrated by WTG from Enercon Enercon E 66/1,5 MW First prototype 1995 later upgraded to 1,8 MW. Replaced in 2005 by E 70 1995 1.5MW 1.8MW 2005 E70 E 70/2 MW, first prototype 2004 , hub height 57 to 113 m. Later upgraded to 2,3 MW 2004 57~113 2.0MW 2.3MW E 82/2 MW: prototype 2005, hub height 78 to 138 m. Later upgraded to 2,3 MW in 2009. 2005 78~138 2009 2.0MW 2.3MW E 82/3 MW: designed for higher wind class, prototype 2010 2010 E 92/2,3 MW: prototype 2012 2012 E 115/3 MW: prototype 2011, hub height 99 to 147 m. 2011 99~147 E 112/4,5 MW prototype 2005, after 9 units changed to E 126 2005 9 E126 E 115/3 MW: prototype 2013, hub height 92 to 149 m 2013 92~149 E 126/7,6 MW: prototype 2007 serial production starting 2009 23 24. Highlights of Wind turbines Some other wind turbine highlights biggest commercial WTG: Enercon E 126 with 7,6 MW. Dia. 127 m, hub height 135 m, Foundation ar. 3,500 to. Tower 2,800 to, nacelle 128 to, Generator 220 to, rotor head 364 to. Enercon E126 7.6MW 127 3500 2800 128 220 364 24 25. Highlights of Wind turbines Biggest prototype (output): Vestas V 164 8,0: 8 MW, prototype installed beginning 2014 ( ) Vestas V164 8.0 8MW 2014 25 26. Highlights of Wind turbines Biggest prototype (diameter): Samsung S7.0 - 171, prototype installed beginning 2014 Samsung S7.0 171 2014 27. Highlights of Wind turbines Biggest hub height : 160 m lattice tower with FL 2500 (2,5 MW Fuhrlnder, dia. 90 m). Installed in 2006 160 Fuhrlnder FL2500 ( 2.5MW 90 ) 2006 27 28. Design basics 28 29. Design basics PWind = x x F x vx v2 x C (acc. to Betz ) = specific gravity F = rotor area v = wind speed The max theoretical possible efficiency is 16/27 (59,3%) 59.3% 29 30. Design basics Resulting power curve (Enercon E 70 2.3 MW) 30 31. Design basics 31 IEC 61400-22 32. Design basics Wind speed acc. IEC 61400 - 1 32 Wind Class/Turbulence / Annual average wind speed at hub- height (m/s) ( / ) Extreme 50-year gust in m/s 50 ( / ) IV 6.0 42.0 IIIb Low wind - Lower Turbulence 16% B 16% 7.5 52.5 IIIa Low wind - Higher Turbulence 18% A 18% 7.5 52.5 IIb Medium wind - Lower Turbulence 16% B 16% 8.5 59.5 IIa Medium wind - Higher Turbulence 18% A 18% 8.5 59.5 Ib High wind - Lower Turbulence 16% B 16% 10.0 70 Ia High wind - Higher Turbulence 18% A 18% 10.0 70 33. Design basics Resulting foundation loads 33 34. From foundation to rotor blades Foundation The foundation is necessary to transfer the dead load and the load from wind force to WTG to the surrounding ground. Depending on the underground flat (shallow) foundation or Pile foundation will be used. / 34 35. From foundation to rotor blades Foundation Bolt cage To connect the tower to the foundation concrete there are two standard methodes. Bolt cage are high strength steel with upper and lower flange, enbedded inside the concrete. 35 36. From foundation to rotor blades Foundation Foundation section The other standard is foundation section, an tower piece with bottom flange enbedded inside foundation concrete 36 37. From foundation to rotor blades Foundation Foundation Rebar: SD 420 or SD 490 SD420 SD490( 4200 4900kg/cm^2) Concrete 240 kg/cm or 280 kg/cm 240 kg/cm 280 kg/cm In case of pile foundation all standard piling system can be used the connecton to the foundation will be adjusted. 37 38. From foundation to rotor blades Foundation Excavation flat foundation (bottom) Driven pile installation (right) 38 39. From foundation to rotor blades Foundation Installation Foundation section (bottom) Planted pile installation (right) 39 40. From foundation to rotor blades Foundation Foundation section with first rebar (bottom) Plate loading test (right) 40 41. From foundation to rotor blades Foundation Foundation before concreting (right) Foundation concreting finished (bottom) 41 42. From foundation to rotor blades Tower For the tower following methods can be used: tubular steel, concrete, lattic tower or even wooden tower. Combinations of these are possilbe as well called Hybrid tower. ( ) In Taiwan, due to the lower hub height till now only tubular steel tower are in use. Tower are made of up to 36 mm thick high strength steel. Section length are up to 30 m, connection is done by flanges. 36mm 30m Enercon is using L flanges to optimize the stress flow through the flange. ENERCON L 42 43. From foundation to rotor blades Tower The tower were produced locally, in our cases from CSMC ( ) The flanges are bolted by M 48 HV (high strength bolts) M48 HV ( ) Painting in Taiwan is a special painting normally used in off shore conditions. Total weigh of an 63 m tower is 140 to. 63m 140 43 44. From foundation to rotor blades Transportation tower section 1 44 45. From foundation to rotor blades Transport section 3 46. From foundation to rotor blades Lifting first tower section 46 47. From foundation to rotor blades Installation of 1st tower section Waiting for second tower sectio 47 48. From foundation to rotor blades Erection of 2nd tower section Inside tower passing platform 48 49. 49 From foundation to rotor blades Look from top to loop ( ) Climbing up the tower 50. 50 From foundation to rotor blades Machine house The connection part between tower and machine house is the bearing. The iron cast machine barrier 51. Machine house Fully equipped main carrier with yaw drives Different power and control cabinets. 51 From foundation to rotor blades 52. Machine house Fully preassembeld machine house with outer cover, wind measurement units and optional obstruction lights. ( ) 52 From foundation to rotor blades 53. 53 From foundation to rotor blades Preassembeled nacelle 54. 54 From foundation to rotor blades Yaw motors left ( ) Yaw motor right ( ) 55. Rotor head (Hub) The hub is the connection from machine house to the blades. Including axle pin, Generator, The picture right showing the axel pin (blue) with bearings (red) and the support of the stator (part of the generator). 55 From foundation to rotor blades 56. Rotor head (Hub) Enercon is using an direct driven Generator weight 55 to for E 70 Enercon E70 55 Picture showing the assembled generator with cooling ducts. 56 From foundation to rotor blades 57. Rotor head (Hub) Rotorhub is put on the front of axle pin, to fix the blades to the WTG. It contains also entire equipment for pitch etc. Picture showing pitch engine fixed on rotorhub. 57 From foundation to rotor blades 58. Rotor head (Hub) Picture is showing the complete assembled rotor hub including cover. 58 From foundation to rotor blades 59. From foundation to rotor blades Unloading hub Transportation generator 59 60. 60 From foundation to rotor blades Generator (hub) Generator (nacelle) 61. 61 From foundation to rotor blades Hub (pitch on top) Preassembled hub 62. 62 From foundation to rotor blades Generator (view from nacelle) Generator (view from hub) 63. 63 From foundation to rotor blades Checking pitch Noise sensor 64. From foundation to rotor blades Blades Enerocn blades made of GFK. Enercon 64 65. From foundation to rotor blades Blades Blades are important for lightening protection so the contain a tip to collect the litheining. Conductor to transport the flash to the hub and further to the tower to ground. 65 66. Blades Enercon special is the spoiler to get the wind close to the center of the nacelle. Enercon Due to the new designed blades the Enercon WTG has an better air flow (reduced noise) Enercon 66 From foundation to rotor blades 67. 67 Blade transport in the harbour Blade transport to site From foundation to rotor blades 68. 68 From foundation to rotor blades Unloading blades on site Blades fixed to hub 69. 69 From foundation to rotor blades Preassembled blades Maintenance work inside blades 70. 70 From foundation to rotor blades 71. 71 From foundation to rotor blades 72. 72 From foundation to rotor blades 73. 73 From foundation to rotor blades 74. 74 From foundation to rotor blades 75. Thank you! Q & A 75 76. 2002 332MW ( ) 40 400 CO2 77. 2011 311 11 ( ) open house! !! . .