Renewable Energy Club Summer Event 26 June 2014 - SKF by Stefan Lammens, head of Business Unit...

SKF, the Power ofKnowledge Engineering inRenewable Energy

Presented to REC Summer Event, June 26th 2014Presented by Stefan Lammens

SKF, a Truly Global Company

© SKF Group 20 June 2014Slide4

SKF – a truly global company

• Established 1907• Sales 2012 SEK 64,575 million• Employees 46,775• Production sites around 140 in 28 countries• SKF presence in over 130 countries• Distributors/dealers 15,000 locations• Global certificates ISO 14001

OHSAS 18001 certification


Western Europe

Middle East and Africa

Eastern Europe

Asia /Pacific

North AmericaLatin America

Net sales by geographic areas 2012


Net sales by customer segment 2012

Aerospace

Railway

Off-highway

Trucks

Two-wheelersand Electrical

Industrial,general

Cars andlight trucks

Industrial, heavyand special

Vehicle ServiceMarket

Industrialdistribution

Energy

Commercialtransport

Industrial business


Energy• Renewable• Traditional

CommercialTransport• Aerospace• Railways• Off-highway

SpecialIndustrialMachinery• Food & Beverage• Machine tools• Marine• Healthcare• Medical• Printing• Textile

Heavy Industry• Metal-working• Mining• Pulp & Paper

General Industry• Industrial gearboxes• Fluid power• Material handling• Industrial Electrical

• Cars and light trucks• Trucks, trailers

and buses• Two wheelers• Vehicle aftermarket• Home appliances

& Portable powertools

Automotive

Industry specialist and partner to many industries

© SKF Group 20 June 2014Slide8Slide 8

October 30, 2007 © SKF Group Slide 8

To equip the worldwith SKF knowledge

SKF Group Vision


What is SKF knowledge?

Renewable Energy,a Strategic Market for SKF

© SKF Group 20 June, 2014Slide11

Facts Renewable Business Unit 2013

Sales 2013: 7.899 Mio. SEK (ca. 895 Mio. €)Sales Renewable: 1.826 Mio. SEK (ca. 207 Mio. €)Business areas: Renewable Energy, LSB, SRBEmployees: 3.740Production sites: 10 in 6 countriesSales Units: 8


SKF Focus on Renewable Energy

Wind turbine Wind gearbox Wind generator

Wind aftermarket

Wave Energy Tidal Energy

PV Solar ConcentratorsConcentrators CPV Solar

Other Renewables;(Hydropower, Bioenergy)

Wind EnergyWind Energy Ocean EnergyOcean Energy Solar EnergySolar Energy

SKF Renewable Energy


SKF Renewable Business Unit - A holistic business responsibility

Marketing

Sales

DevelopmentEngineering

Manufacturing

Sourcing

HR Controlling Quality DC

Full life cycle Responsible for all functions

GlobalAll sub-segments

Major turbine & gearbox OEM market

Major t urbine OEM marketMajor gearbox OEM market

Smaller/emerging turbine OEM market

Emerging/potential turbine OEM market

Major turbine & gearbox OEM market

Major t urbine OEM marketMajor gearbox OEM market

Smaller/emerging turbine OEM market

Emerging/potential turbine OEM market

; SKF-Wind manufacturing unit*; SKF-Wind sales & engineering center

; SKF-Wind R&D and technical center

*

**

* *** *

*

*

l

* *l

l

l

l

l


-30%

-20%

-10%

0%

10%

20%

30%

40%

50%

2013 2014 2015 2016

Bloomberg Sept 2013

MAKE Sept 2013

BTM April 2013

Average 3 analysts

State of the wind energy industryRecovering from a challenging period – a bumpy road ahead

Average price on new windturbines (€M/MW)

0.881.011.11 1.10

1.211.20

1.06 1.02 0.990.94 0.94 0.92 0.91 0.90

0.90

0.83

0.91

H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1

2008 2009 2010 2011 2012 2013 2014 2015

Previous Index (H2 2012) Current Index (H1 2013)

© SKF Group 20 June 2014Slide15Slide 15

Some major trends in Wind Energy market

• Reduce LCOE to reach grid parity• Strong globalization of an emerging industry, and massive

growth by leading Asian turbine manufacturers• Challenging environments; Deserts, Arctic, Offshore, Low wind• Expanding turbine sizes, MMW-class gaining importance• Direct drive turbines expansion versus gearbox-equipped• Major expansion and maturing of wind O&M• Increasingly automotive mindset on quality, delivery and cost• An industry driven (and limited) by political decisions

© SKF Group

SKF Life cycle management for improved LCOE

20 June 2014Slide 16

CAPEX•Design for reliability•Design for performance•Design for simplifiedmaintenance

•Cost vs. value•Reduce turbine weight•Simplify productionprocess

Reduce LCOE by maintaininghigh operational reliability and

turbine availability

OPEX•Windfarm management•Extend maintenanceintervals

•Easy & quickcomponentreplacements

•Spare partsmanagement

•Condition monitoring

© SKF Group 20 June, 2014Slide 17

Levelized Cost Of Electricity, Q2 2013 ($/MWh)

0 50 100 150 200 250 300 350 400 450 500

Coal firedNatural gas CCGT

CHPNuclear

Small hydroLarge hydro

Biomass - anaerobic digestionLandfill gas

Geothermal - flash plantBiomass - incinerationMunicipal solid waste

Wind - onshoreGeothermal - binary plant

PV - c-SiBiomass - gasification

PV - c-Si trackingPV - thin film

STEG - tower & heliostat…STEG - parabolic trough

Wind - offshoreFuel cells

STEG - parabolic trough + storageSTEG - tower & heliostat

STEG - LFRMarine - tidal

Marine - wave

Global LCOE range Regional scenarios Q1 2013 central Q2 2013 central

1059861

531

STEG is the term used by Bloomberg New Energy Finance forwhat is also referred to as Concentrated Solar Power (CSP).

© SKF Group

Downtimes of wind turbines often not only caused bylarge components

• Component quality/reliability a key driver of downtime• Rotor, Gearbox and Generator are within top 4 in terms of downtime• Large portion of downtime also caused by smaller and more frequent failure

of electrical system and electronic control• Overall increased component quality reduces downtime expectations

significantly

Source: German wind turbine park, 2008

Electrical system

Electronic control

Sensors

Hydraulic system

Yaw system

Rotor hub

Mechanical brake

Rotor blades

Gearbox

Generator

Support/Housing

Drive train

Failure frequency p.a. Downtime per failure (days)

0.96

0.72

0.40

0.35

0.48

0.76

0.45

0.40

0.73

0.71

0.44

0.42

Downtime expectation p.a. (days)

0.07

0.11

0.12

0.12

0.13

0.15

0.2

0.2

0.25

0.25

0.4

0.6

3,1

6,1

5,9

4

6

3,8

2,4

1,4

1,6

1,8

1,6

3

Maintenance Practice

“Breakdown”

Daily

100% or Call Availability

Periodic (Routine 3 to 6 months)

Predictive (CMS)

Preventive (Inspection)

“As Required” Service

© SKF Group 20 June 2014Slide 19

SKF active involvement in life cycle for LCOE-reduction

OPEX

CAPEX

Reduce LCOEHigh operational reliabilityand availability

© SKF Group

SKF contribution to wind turbine life cycle

Pitch bearings

Yaw bearingMainshaft housingsand locknutsCouplings

Automatic distributedlubrication system

Monitoring anddiagnosticsservices

Mechanical repairs &refurbishment

Sealing solutionsNew re-inforcedrubber seals

Bolt tensioning toolsTower alignment services

EngineeringConsultancyServices

Plain bearings

Maintenance toolsand grease

Generator bearingsDGBB quiet running/Insocoat/Hybrid

Mainshaft bearing(s)SRB/CARB/TRB/CRB/Nautilus

Gearbox bearingsTRB/CRB/SRB/CARB/DRTRB/HC-CRB family

Condition MonitoringWindCon/WebCon


Turbine concepts & Main shaft bearing arrangements

2-point suspension 3-pointsusp.

Moment bearing(no shaft)

2 sep.housings

1 jointhousing

1 brg ingearbox separate Integrated

in gearbox

2-pointsuspension

Moment bearing(no shaft)

1 joint housing Full / semiintegrated

2-pointsuspension

Momentbearing

Commonhub No axis

Turbines with gearbox Hybrid Turbine Direct Drive

NautilusNautilus Nautilus DRTRB+CRBTRB+TRB

NautilusCRB+DRTRBTRB+TRB

CRB+DRTRBTRB+TRB

SKF have capability to supply all mainshaft bearing arrangement solutions

SRB+CARBSRB+SRB

SRBNautilus + Nautilus + Nautilus + Nautilus +


The SKF Nautilus™ wind-mainshaft unit

Patented segmentedPEEK cage developed bySKF.

SKF Nautilus is a Robust, Stiff,and Compact solution developedspecifically for wind mainshafts

Nautilus ™ key features;• Designed for heavy, complex loads.• Only pure torque load is being

transmitted to the drivetrain.• Segmented cage for improved

performance also undermisalignment.• Extremely low friction coefficient.• Can be either oil or grease lubricated• Available for cold-climate locations

Asset Life Cycle Management:Specification to Maintain & Repair


Specification

The world‘s need for energy and the drive for lower costs per kWh is steadily increasing. SKF has been a developing partner forwind turbine manufacturers for nearly 20 years and this experience is used when specifying requirements for turbines with highercapacity and demanding environments. The experience gained in the other phases of the life cycle management will alsoinfluence the specification, with the end user benefiting from it as well.

Specification


Design and Develop

SKF application engineers and SKF Engineering Consultancy Service are working globally, with professional calculation anddesign programs, to translate turbine specifications and requirements into a solution.

Engineering Consultancy Service

• Advanced calculations

• Dynamic simulations

• Lubrication engineering/tribology

• Material analysis

• Design for Six Sigma

Advanced calculation toolslike SKF Bearing Beacon andFinite Element Analysis (FEM)to decrease kWh/€.

• Increase turbine reliability by validating– the bearing requirements– the operational conditions

of the bearing– the design/dimensions of

surrounding components• Optimize performance to increase

electrical and mechanical efficiency

Design and develop

© SKF Group20 June 2014Slide 26

Manufacture and test


Generator

Gearbox

Main shaftMain shaft

Pitch and yaw

Main shaft incl. generator

Pitch and yaw

With factories in all major wind markets, SKF can provide solutions for pitch,main shaft, gearbox, generator as well as yaw.This includes testing components in prototypes and supplying for large scalewind turbine serial production.


Manufacture and test – Main shaft

With factories in all major wind markets, SKF can provide solutions for pitch, main shaft, gearbox, generator as well as yaw.This includes testing components in prototypes and supplying for large scale wind turbine serial production.

• SKF Nautilus bearing solutions

• SKF spherical roller bearings

• SKF spherical roller bearing andCARB® bearing arrangements

• Lubrication systems

• Grease

• Sealing solutions

• HMS Lock nuts

• Friction Disc

• Housings

• Couplings

• Reduce the cost of energy

• Increase reliability and operational safety

• Simplify mounting, dismounting andreplacement

• Extend maintenance intervals

• Improve serviceability

• Decrease nacelle weight



Operate and monitor

With monitoring tools and services, SKF helps wind farm operators to improve operational efficiency and reduce plannedand unplanned downtime. This can lead to higher profitability of the wind farm.

• SKF Remote Diagnostic Centres

• SKF WindCon

• SKF Thermal Imagers

• SKF Microlog data collectors

• Baker AWA-IV static motor/generator analyzer

• Baker DX static motor/generatoranalyzer

• SKF training

• Reduced risk of unplanned shutdowns• Preventing lost energy production due

to breakdowns• Predicting remaining service life per

turbine• Reduced wind turbine operating

costs and cost per kWh produced• Lower investments• Increased data integrity• Expert SKF analysis and

recommendations• Global, 24/7 access to reports and data• GL certified remote monitoring centre

Operate and monitor


SKFThe Knowledge Engineering Company

Thank you for your attention !

Renewable Energy Club Summer Event 26 June 2014 - SKF by Stefan Lammens, head of Business Unit...

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Transcript of Renewable Energy Club Summer Event 26 June 2014 - SKF by Stefan Lammens, head of Business Unit...