INTRODUCTION
IMPSA is a w orld leader in the provision of integrated solutions for renew able energy projects through the production of capital goods and investment in energy projects. IMPSAs success and renow n are based on its broad experience in infrastructure projects in markets w orldw ide:
Almost 100 years of experience in the provision of high-tech capital goods
Over 15,000 MW of installed capacity in turbines and generators for hydroelectric pow er plants
More than 150 hydroelectric projects in 30 countries in North A merica, Central America, South A merica, Africa, Asia, Europe and the Middle East
Processes certif ied to stringent quality standards
Ow n state-of-the-art technology for clean energy production from renew able sources.
3
Wind Energy
Rising environmental and economic costs associated w ith the use of fossil fuels for energy production have led to the explosive growth of clean renew able sources. Wind energy among them occupies a relevant position because of its advanced technological and industrial development.
The w ind generator manufacturing industry has grown by more than 25% over the past decade second only to the cell phone industry. Now adays, the equipment market represents more than USD 10 billion a year. With over 50,000 MW installed around the w orld, more than 360,000 MWh are produced every day, which represents USD 8 billion a year.
In the past, Europe and North America concentrated more than 90% of the w orlds wind generation, but in the last few years Asia and Oceania have experienced a remarkable grow th. Despite its great potential for w ind generation, South America has not managed to develop it signif icantly mostly due to a lack of regional companies capable of meeting the markets peculiar conditions.
Having detected a great opportunity in this market, IMPSA accepted the challenge to play an active role in the development of w ind energy based on two of its greatest strengths: development of eff icient and competitive cutting-edge technology, and successful execution of integrated projects.
IMPSA Wind is a new business unit w hose mission is to provide comprehensive solutions in the f ield of w ind generation w ith an optimum combination of variables critical to the success of a project. To this end, IMPSA develops the necessary know-how to participate in all the links in the value chain for an adequate control of each of the factors that are critical to the success of an undertaking:
4
Technological development - UNIPOWER
Equipment manufacture and provision
Development of generation projects o Assessment of w ind resources
o Micrositing and energy calculations
o Economic and f inancial evaluation
Construction of w ind farms under the EPC mode
o Civil w orks (access roads and foundations) o Equipment assembly and startup
o Grid connection systems
Operation and maintenance
Through IMPSA Energy its investment arm IMPSA promotes and invests in w ind generation projects.
TECHNOLOGICAL DEV ELOPMENT
The vision of providing comprehensive, competitive and innovative solutions has led to the development of a new concept in wind generation equipment that stands out from other products currently available in w orld markets.
OBJECTIVES OF WIND GENERATOR DESIGN
- Maximize eff iciency in capturing and converting the kinetic energy of the air
- Minimize maintenance time and costs
- Maximize local value added (project siting) - Develop, design and manufacture equipment that meets the strictest and highest
international standards.
Adherence to the above objectives has led to a new concept in w ind generation equipment: IWP - UNIPOWER .
The equipment in its tw o versions 1,5 MW pow er class 1S, and 1.5 MW pow er class 2 will be commercially available at the beginning of 2008.
5
MANUFACTURE
By the end of the next 5 years, the Company expects to rank among the top 10 w orld producers with 5% of the world market, w hich would represent sales for more that USD 500 billion. To this end, industrial plants w ill be set up at geographically strategic points to meet the demands of its target markets.
SUPPLY UNDER EPC CONTRA CTS
IMPSAs vast experience in infrastructure projects allow s it to offer integrated solutions and to assume responsibility for the entire project. By combining its ow n know -how and a number of strategic alliances, IMPSA is in a posit ion to undertake the optimum design and construction of a w ind farm from the technical and economic points of view, optimizing customers investment and ensuring the return on investments.
COMPREHENSIV E PROJECT DEV ELOPMENT
Together w ith IMPSA Energy, IMPSA develops, executes and operates wind generation projects based on its risk management, f inance raising and executive capacity. IMPSA contributes to sustainable grow th by developing renew able energy and promoting its use in the global energy matrix.
6
WIND GENERATORS
Machines that convert the kinetic energy of the w ind into electrical energy are called w ind generators or aerogenerators, subdivided into low -power wind generators and high-pow er wind generators. The former are low capacity, light and simple machines that produce from a few hundred W to some tens of kW and are used to feed small units outside the electric grid system. On the other hand, high-pow er wind generators because of their pow er, which ranges from a few hundred kW to several MW can be connected to grids feeding important consumption centers.
There are tw o main stages in the energy conversion chain of a w ind turbine:
a) A f irst stage, consisting of a device know n as turbine, w hich converts the kinetic energy of the w ind into mechanical energy.
b) A second stage, know n as generator, w hich converts mechanical energy (captured by the turbine) into electrical energy.
Both stages are physically linked by means of a shaft that transmits the torque from the turbine to the generator either directly or, if necessary, through a gearbox that raises the rotational speed.
According to the type of generator, there are tw o main design concepts:
1. Turbines w ith fast generators: Usually asynchronous, they are small high-speed machines, with a limited number of f ield poles, coupled onto the turbine through a multistage gearbox. The gearbox is a complex and expensive component that reduces the assemblys overall yield and considerably increases shutdow n times for maintenance operations.
2. Turbines w ith slow mult i-pole generators: Usually synchronous, these machines are directly coupled onto the turbine and reach the minimum generation frequency w ith a large number of f ield poles. They do not require a gearbox, but they are bigger and heavier than their fast counterparts.
7
In any of the above designs there is a clear difference between the tw o stages turbine and generator , and some kind of structure or shaft that transmits the torque betw een them either directly or indirectly.
IMPSA WIND GENERATOR
IWP-UNIPOWER means state-of-the-art w ind power generation.
This new concept breaks many of the industrys traditional paradigms as a large number of mobile components are eliminated: as the equipment does not require a gearbox, the number of individual rotating components is reduced.
The technologies and innovations used in the design of this machine make it possible to reduce its size with respect to the conventional turbinemulti-pole generator assemblies. This is accomplished through a special arrangement of the generators active components and, in given sizes, through the use of permanent magnets, eliminating pow er-transmission rotating devices for inductor excitation.
Thus, the IWPUNIPOWER w ind generator overcomes the main draw backs of directly-coupled mult i-pole generators size and w eight but keeps their main advantage: no gearbox.
As stated above, w ithout additional devices to increase speed, the machine requires less maintenance (in tw enty years operation, the IWPUNIPOWER rotates few er times than a fast generator in three months). In turn, the peculiar layout of its various components minimizes the loads on the tow er structure, reducing stresses and prolonging the useful life of the main bearings and active tow er components such as the bearing of the orientation system.
Thus, substantial improvement is achieved in terms of eff iciency, availability, reliability, as w ell as of operation and maintenance costs.
8
COMPREHENSIV E TECHNOLOGICAL APPROACH
Designing a w ind generator is a long and complex process that requires the participation of a multidisciplinary team w ith professionals from all branches of engineering. The entire process must conform to the strictest international standards in order to ensure product quality.
It is at this stage that the machines conceptual design, layout and operating principle are established.
IEC WT01 IEC 61400 IEC 17025
Detail Engineering & Manufacturing
R&D Structural & Mechanical
Design Mechatronics
Manuf acturing & Testing
9
Our specialists use the most modern computational tools for the aerodynamic, aero-elastic and structural design of each component and many of those tools w ere especially developed by IMPSA.
Sophisticated tools used in simulations of the aerodynamic behavior of blades and fairings make it possible to perform fluid numerical simulations to determine:
- Stripping of the boundary layer
- Aerodynamic performance
- Optimization of blade profile
- Generation of vortices and induced vibrations
- Fluid velocity and energy transfer
Numerical simulation of air f lows w ith highly complex software CFX-TASCflow (ANSYS Inc.) makes it possible to optimize aerodynamic designs.
With ARGEN-PROGEN, a program especially designed by IMPSA professionals, it is possible to study the magnetic, electric, and thermal behavior of synchronous generators by simulating normal operating conditions and extreme events such as short circuiting.
10
This program w as also used to design a generator particularly suited to this type of pow er generation and to optimize the size, w eight and pow er ratio.
11
STRUCTURAL AND M ECHANICAL DESIGN
The data on f luid behavior derived from numerical simulations are used to perform structural studies of all components.
IMPSA maximizes local value added by employing locally produced raw materials and components as much as possible. Development and characterization of such materials have been performed jointly w ith renow ned national and international laboratories.
FEM (Finite Element Model) simulations are carried out w ith the most modern NASTRAN calculation programs developed by NASA for this type of analysis. MSC/NASTRAN (NASA STRUCTURAL ANALYSIS) is the most advanced tool in f inite element calculations for static and dynamic requirements, thermal analysis, aero elasticity, etc.
Some of the behaviors analyzed include:
- Frequencies and natural vibration modes
- Deformations
- Stresses and distribution of mechanical tensions
Detail Engineering
Basic Design
Structural & Mechanical
Design
Mechatronics Manuf acturing &
Testing
12
The complete structural analysis model is the most complex analysis performed in Argentina and involves the simultaneous resolution of 2,500,000 variables.
13
MECHATRONICS
The eff icient and safe operation of this type of equipment requires the precise operation of all mechanical and control components as w ell as a correct strategy for maximum energy production w hich, combined w ith safe operating condit ions, ensure a prolonged useful life w ith minimum maintenance.
Development of its ow n control system has allow ed IMPSA to gain a deep understanding of equipment restrictions and possibilities, and thus optimize energy production and safe operation. The control system operates on a PLC platform and performs all primary control, supervisory control and frequency conversion functions.
Detail Engineering
Basic Design
Structural & Mechanical
Design
Mechatronics Manuf acturing &
Testing
-1200
-1000
-800
-600
-400
-200
0
200
400
600
800
1000
1200
20 30 40 50 60 70 80 90 100 110 120
Time
0,00
2,50
5,00
7,50
10,00
12,50
15,00
17,50
20,00
22,50
25,00
27,50
30,00
Spee
d
RotPwr (kW) YawBrMzn (kNm) RotSpeed
14
DETAIL ENGINEERING AND MANUFACTURING
Producing competitive equipment requires that the design of every component contribute to optimized manufacturing and eff icient operation of the machine as a whole. To this end, tools such as animation, multiple-view visualization, rotation, interfaces with calculation programs, simultaneous connection between workstations, and f iber optics connection to factory (CNC machines) are used.
Detail Engineering
Bas ic D es ign
Struc tural & Mechanical
D es ign
Mechatronics Manuf acturing &
Tes t ing
15
MANUFACTURING
Manufacturing the different w ind generator components requires intensive labor of different type and qualif ications.
16
TESTING
The response of the w hole machine is analyzed before it is put into operation. Static and dynamic simulations are carried out to study the general behavior of structures working together and to establish the best control strategies.
The rotor-hub and stator-beam assembly is mounted on a test bench for rigorous operation tests to verify, among others, voltage, generated current and heating.
17
CERTIFICATION
IMPSA is w orking on equipment certif ication together w ith top-level international consultants
The 1,5 MW-Class 1S generator is being certif ied by TV the renow ned international agency w ith the most modern and stringent international standards.
Main characteristics of the IWP-UNIPOWER wind generator
- Compact and mobile
- Does not absorb reactive pow er from the grid (improves the pow er factor) - Can generate pow er at different frequencies and pow er factors
- High eff iciency (due to less losses in the generator and mechanical components) - Minimum maintenance (no gearbox, no slip rings, few er mobile parts)
18
TECHNICAL DATA IWP-UNIPOWER
Technical Data IWP-70 (Class 1S)
Rated pow er 1500 kW
Pow er regulation Blade pitch control w ith emergency pow er supply
Cut in w ind speed 3.5 m/s
Rated w ind speed 12 m/s
Cut out w ind speed 25 m/s
Survival w ind speed 77 m/s
Design standards IEC 61400-1; IEC WT01
Class 1S
Rotor
Diameter 70 m
Sw ept area 3848 m2
Speed Variable, 6 rpm to 19 rpm
Type Unipow er, horizontal axis
Rotation direction Clockw ise
Blades
Number 3
Manufacturer IMPSA Wind
Blade material Fiberglass and resin w ith integral lightning protection
Generator
Type DDPM (direct drive permanent magnet)
Rated frequency 50 Hz / 60 Hz
19
Cooling Air
Braking system
Aerodynamic brake 3 independent pitch-control systems w ith emergency supply
Mechanical brake Disk, w ith 2 fail-safe actuators
Mechanical lock Hydraulic, for maintenance tasks
Orientation system
Type Active, with ring gear bearing
Actuators Four motor-reducers (electrical motor + planetary gear box)
Tower
Type Steel tubing, different foundations
Hub height 71.8 m
Anti-corrosive protection Paint
20
IWP - 70
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
viento m/s
Cp y
Ct
Cp salida (-) Ct (-)
IWP - 70
0
200
400
600
800
1000
1200
1400
1600
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
viento m/s
Pote
nci
a
Potencia (kW)
21
TECHNICAL DATA IWP-77 (Class 2)
Rated pow er 1500 kW
Pow er regulation Blade pitch control w ith emergency pow er supply
Cut in w ind speed 3 m/s
Rated w ind speed 11.5 m/s
Cut out w ind speed 25 m/s
Survival w ind speed 59.5 m/s
Design standards IEC 61400-1; IEC WT01
Class II
Rotor
Diameter 77 m
Sw ept area 4654 m2
Speed Variable, 6 rpm to 19 rpm
Type Unipow er, horizontal axis
Rotation direction Clockw ise
Blades
Number 3
Manufacturer IMPSA Wind
Blade material Fiberglass and resin w ith integral lightning protection
Generator
Type DDPM (direct drive permanent magnet)
Rated frequency 50 Hz / 60 Hz
22
Cooling Air
Braking system
Aerodynamic brake 3 independent pitch-control systems w ith emergency supply
Mechanical brake Disk, w ith 2 fail-safe actuators
Mechanical lock Hydraulic, for maintenance tasks
Orientation system
Type Active, with ring gear bearing
Actuators Four motor-reducers (electrical motor + planetary gear box)
Tower
Type Steel tubing, different foundations
Hub height 77 m
Anti-corrosive protection Double-coat epoxi paint
23
IWP - 77
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25viento (m/s)
Cp y
Ct
Cp (-) Ct (-)
IWP - 77
0
200
400
600
800
1000
1200
1400
1600
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
viento (m/s)
Pote
ncia
Potencia (Kw)
24
MANUFACTURING INFRASTRUCTURE
IMPSA Wind manufactures equipment at designated shops at IMPSAs industrial plant in Mendoza (Argentina) laminates, structure manufacturing, and f inal assembly. It shares machining and surface treatment facilit ies, and the manufacturing plant for the generators active components w ith the IMPSA products.
View of the generator manufacturing plant in Mendoza
25
Stator manufacturing process at the Mendoza plant
Assembly of the UNIPOWER generator at the Mendoza plant
26
Structure shop
Laminate shop
Automatic welding machine
27
Ladders and cable trays Tower IWP-70
As the current manufacturing structure does not make it possible to meet regional market demands, IMPSA is planning to install several custom-made plants for serial production of the main components of w ind generators.
An ambitious investment plan w ill result in the installat ion of production plants at points that offer an optimum combination of labor, logistics and procurement costs, w ith emphasis on job creation at natural markets for this type of technology.
The infrastructure is expected to have an initial production capacity of 250 MW p/a and is scheduled to begin production at the beginning of 2008 along w ith commercial equipment.
The infrastructure required to produce w ind generators includes:
. A manufacturing plant of composite material structures, blades and fairings
. The UNIPOWER generator plant
28
. A f inal assembly plant
Where possible, IMPSA plans to subcontract locally the construction of towers and structures with a view to minimizing logistics and transportation problems and to maximizing the posit ive impact of projects on regional economies.
29
PROJECTED INFRASTRUCTURE
In order to comply w ith the orders from its immediate markets, IMPSA Wind is planning to install industrial plants in Argentina and Brazil:
Generators and generator structures
Structures Argentina and Brazil
Blades and fairings Argentina and Brazil
Final assembly Argentina and Brazil
30
SUPPLIERS
Fifty percent of the wind generator components are commercial products manufactured by specialized suppliers. The most important commercial components include:
Main bearings
Bearings (orientation) Blade bearings
Forgings
Frequency converter
Control equipment
Transformers
Most of these components can be purchased at the local market. IMPSA has already approached different suppliers with a view to entering supply contracts so as to maximize the local added value of the equipment manufactured, as w ell as to comply w ith the requirements of FINAME and of the National Argentine Strategic Plan.
Top Related