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Competitive wind turbine drive trains
    through representative testing
    Dr. Stefan Lammens, Vice President – Chief Sales & Marketing Officer
    Wind Power Technology                                                  A brand of ZF




                                                                                           © ZF Friedrichshafen AG, 2012
1                      Presentation Title, Date
                       OWI-Lab, 27/09/2012                                 A brand of ZF
Combination of ZF and Hansen
                                                                                                               +




    Customers




    Products
                    2 MW                       1,5 MW to 6,15 MW




     Regions




                 Gainesville, USA                                                                        Gainesville, USA         Lommel, Belgium
    Production                                               Lommel, Belgium

    Locations




                                                                                                                                                                           © ZF Friedrichshafen AG, 2012
                                       Coimbatore, India      Tianjin, China                            Coimbatore, India         Tianjin, China


                                                           Source: ZF; Hansen Transmission Annual Report 2011, 31.03.11 and Annual Report 2010, 31.03.10


2                                   OWI-Lab, 27/09/2012                                                                                                    A brand of ZF
The Business Unit Wind Power Technology is
                     part of the Industrial Technology Division of ZF

    ZF Friedrichshafen AG               Shareholders: 93.8 % Zeppelin Foundation and 6.2 % Dr. Jürgen and Irmgard Ulderup Foundation


                               Division                 Division                  Division                  Division                    Joint Venture
                                                                                                                                        Steering Systems     4)
                               Powertrain               Chassis                   Commercial Vehicle        Industrial
                               Technology               Technology                Technology                Technology                  50 %
    CEO, Market

                               Transmissions            Chassis Systems           Truck & Van               Construction                Passenger Car
                                                                                  Driveline Technology      Machinery Systems           Steering Systems
    Finance,                   Axle Drives              Chassis
                                                        Components                Bus Driveline             Agricultural                Commercial Vehicle
    Controlling,
                               Powertrain Modules                                 Technology                Machinery Systems           Steering Systems
    IT, Process Management
                                                        Rubber & Plastics
                                                                                  CV Axle Systems           Material Handling           Passenger Car
    Human Resources                                                                                                                     Steering Columns
                                                        Suspension                                          Systems
                                                        Technology                CV Chassis Modules
                                                                                                            Test Systems                Global Aftermarket
                                                                                  CV Damper
    Materials Management                                                          Technology                Special Driveline
                                                                                                            Technology
                                                                                  CV Powertrain
                                                                                  Modules                   Electronic Systems
    Operations and
    Technology                                                                                              Marine Propulsion
                                                                                                            Systems

    Compliance 1)                                                                                           Aviation Technology

    Die Casting Technology2)                                                                                Wind Power
                                                                                                            Technology




                                                                                                                                                                     © ZF Friedrichshafen AG, 2012
    ZF Services 3)


       Board of Management        Organizational unit    1) linked to CEO                                4) ZF Lenksysteme GmbH is a joint venture between
                                                         2) linked to Materials Management domain           ZF Friedrichshafen AG and Robert Bosch GmbH.
       Integration of Hansen       Partial activities    3) linked to Market domain
       Transmissions               in wind power

3                                            OWI-Lab, 27/09/2012                                                                                     A brand of ZF
Key Figures
                         2011 Group
    The ZF Group – An Overview                                   2011    2011/2010

                          Sales                       € 15,509 million        20 %


                          Employees (end of year)              71,488         11 %


                          Capital expenditure          € 1,058 million        82 %


                          R&D expenditure                € 754 million        17 %


                          121 production companies in 27 countries


                          8 main development locations in 4 countries




                                                                                                © ZF Friedrichshafen AG, 2012
                          34 service companies and more than 650 service partners


4                        OWI-Lab, 27/09/2012                                    A brand of ZF
Wind Market Segments

                            Global Annual Market Installations (in GW)
60 GW
                                                 Onshore         Offshore                                        6.3
                                                                                                   5.6
50 GW
                                                                                       4.9
                                                           2.0                 3.9
                                               0.8                     2.9
40 GW                                 1.5
                           0.6

30 GW
                  0.2
                                                                                                  49.7          52.8
                                                       45.8                   43.4    46.0
20 GW      0.2                        37.9     40.5                   41.1
                          37.6
                  28.2
10 GW      19.8

    0 GW
           2007   2008    2009        2010    2011     2012e          2013e   2014e   2015e      2016e         2017e

 Offshore wind power technology is still in the emerging stage and larger, more efficient turbines
  along with optimization of the nascent supply chain have large potential for reducing Cost of Energy
  (CoE)
 Reducing CoE of offshore wind will help wind to become a base-load production for the grid in mid-




                                                                                                                                  © ZF Friedrichshafen AG, 2012
  long term
 Flemish stakeholders take a pioneering role in offshore innovations and developments
                                                                                         Source: ZF WPT Market Intelligence

5                                OWI-Lab, 27/09/2012                                                              A brand of ZF
CoE Reductions Critical to Competitiveness


    Wind competitive with fossil fuels                                 Cost of Energy (EUR/MWh)

                                                                        Cost of Energy (CoE) is defined as:




                                                                        Onshore
                                                                            A reduction of 10% in onshore wind CoE will
                                                                             make it directly competitive with natural gas at
                                                                             today’s lower energy prices



                                                                        Offshore
                                                                            As wind farms are installed at sites further from
                                                                             shore and in deeper water, the industry will have
                                                                             to work hard to decrease current levels of
                                                                             CAPEX per megawatt installed




                                                                                                                                                   © ZF Friedrichshafen AG, 2012
    Note: NG prices = USD 4.00-6.75/MMBTU, Coal = USD 1.60-
    1.70.MMBTU, onshore wind capacity factor = 30%, no CO2 costs for
    fossil technology, EUR = 1.45 USD.
    Source, MAKE, Lazard, others
                                                                                         Source: MAKE Consulting, ZF WPT Market Intelligence

6                                          OWI-Lab, 27/09/2012                                                                     A brand of ZF
Impact of gearboxes on CoE


    Offshore Wind Cost Drivers                         Offshore CAPEX structure

                                                                                          Others         Preparational
                                                            Management        Insurance    1%               Work
                                                                  2%             2%                           1%
                                                           Contingencies
                                                                  3%
                                                       Electrical Grid
                                                             6%
 CAPEX impact of a gearbox is limited within a
                                                       Substation                                        Foundations
  typical offshore project, however, turbine
                                                          6%                                                26%
  suppliers are continually looking for ways to
  reduce component weight and material
  usage
                                                                Installations Vessels
                                                                         18%
 Not the offshore environment is changing wind
                                                                                            Other Turbine
  turbine gearbox specifications, but the                                                   Components
  challenges in O&M are emphasizing the                                                         31%
  importance of reliability, with a direct impact on
  OPEX and AEP




                                                                                                                                        © ZF Friedrichshafen AG, 2012
                                                                    Gearbox
                                                                      4%


                                                                              Source: MAKE Consulting, ZF WPT Market Intelligence

7                              OWI-Lab, 27/09/2012                                                                      A brand of ZF
Our mission

       We reduce the kWh cost of renewable energy


 We develop competitive products with      proven reliability
     to lower costs of unplanned OPEX
     to guarantee AEP by increased availability




                                                                                 © ZF Friedrichshafen AG, 2012
8                     OWI-Lab, 27/09/2012                        A brand of ZF
Trends in drive train technology


    Diversity in solutions on the market
 Search for the lowest CoE yields various           Mechanical power transfer:
  industrial solutions for the drive train,               gearbox
  being a trade-off between all design
  drivers:                                                hydraulic converter

        reliability                                 Electrical generator
        weight and cost                                  gear driven or direct drive ?
        efficiency                                       high speed, medium speed, low speed ?
        serviceability                                   traditional or permanent magnet
                                                           generator ?
        grid compatibility
                                                     Power conversion / transfer
                                                          low, medium, high voltage ?
                                                          AC or DC ?




                                                                                                             © ZF Friedrichshafen AG, 2012
    All published solutions claim to be winners,
    but few are proven by test and experience
9                             OWI-Lab, 27/09/2012                                            A brand of ZF
Representative testing


 Representative testing is key to proof reliability of our competitive designs


Logistic complexity and uncontrolled              What ?
 environment of a wind turbine makes
 it a tough ‘test lab’


Short time-to-market requirements in
 new developments put time pressure
 on field validation campaign
                                                            Start the turbine !


Representative (lab) testing
 capabilities are a long-term key




                                                                                                  © ZF Friedrichshafen AG, 2012
 differentiator of ZF WP



10                     OWI-Lab, 27/09/2012                                        A brand of ZF
Representative testing




                             It is possible to
                             transform wind
                           turbine behaviour
                                into test rig
                               conditions…




                                                            © ZF Friedrichshafen AG, 2012
11   OWI-Lab, 27/09/2012                    A brand of ZF
Hansen Transmissions International
                  Evolution of wind turbines and testing procedures

                                                                       ZF WP Capability       ZF WP DORoTe

                                                                                     Dynamic Testing @
                                                                                     ZF WP 13.2 MW Test Bench

                                             Industry Standard   Overload Prototype Testing

100% Serial testing, first at partial, later at full load

1970                           1980                1990             2000                        2010                2020




                                                                                                                             © ZF Friedrichshafen AG, 2012
     ZF WP is continuously improving its testing procedures by implementing ZF WP
                           specific dynamic testing methods
* Indicative Numbers & years
12                                    OWI-Lab, 27/09/2012                                                    A brand of ZF
Design verification proving reliability

                                          Technology/
                                            Materials
                                           Verification




                                                          Reliable Designs
                                        Component and
            State-of-the-art
                                        Sub-assembly
             Design Tools



                                         Verification



                                           Gearbox
                                          Verification




                                              Field




                                                                             © ZF Friedrichshafen AG, 2012
                                           Verification


13                             OWI-Lab, 27/09/2012          A brand of ZF
Component and Sub-assembly Verification

 ZF WP’s dynamic bearing
  system test rig
      testing real size bearings
      in their actual arrangement
       as built in the gearbox
      under representative wind
       turbine loading and
       operational conditions




                                                                                               © ZF Friedrichshafen AG, 2012
      This pro-active testing method contributes largely to the design of robust
                  bearing arrangements for new reliable gearboxes


14                        OWI-Lab, 27/09/2012                                  A brand of ZF
Gearbox Verification




                                 Motor       GB1     GB2 Generator

                    ZF WP’s 13.2 MW / 16.8 MW Dynamic Test Rig
     -   13.2 MW rated power        -    1500 RPM nom speed     -    1000 tons of steel
     -   16.8 MW peak power         -    2600 RPM max speed     -    1000 tons of concrete




                                                                                                        © ZF Friedrichshafen AG, 2012
     -   Investment                 -    80 kNm at motors       -    35m x 10m
         > 10 M EUR                                             -    100% Availability (24/7)

15                             OWI-Lab, 27/09/2012                                      A brand of ZF
Next steps in representative testing

 From gearbox verification to complete drive train / wind turbine testing

Need for more large scale test infrastructure and
 prototype field testing
Research topics
     •   make tests even more representative by correlation
         between field and test rig conditions
     •   increase acceleration factor for life testing on test rigs




New conditions require dedicated testing
     •   cold / hot climate          OWI climate chamber
     •   offshore                    e.g. corrosion testing




                                                                                        © ZF Friedrichshafen AG, 2012
     •   grid codes                  e.g. grid compatibility testing



16                              OWI-Lab, 27/09/2012                     A brand of ZF
Additional leverage to reduce CoE


 Minimise OPEX and optimise availability in our service offering




                                                                                   © ZF Friedrichshafen AG, 2012
17                       OWI-Lab, 27/09/2012                       A brand of ZF
Additional leverage to reduce CoE


 Minimise OPEX and optimise availability in our service offering



O&M business is evolving rapidly
ZF has a global footprint for offering service solutions for wind turbine
 gearboxes
 Our unique gearbox know-how and large installed gearbox base will enable
     intelligent preventive maintenance



 Research challenge: innovation in performance and condition monitoring
       create wind turbine data sets (SCADA, CMS, …)
       develop intelligent processing algorithms




                                                                                             © ZF Friedrichshafen AG, 2012
       merge measurements and algorithms into added value for O&M



18                            OWI-Lab, 27/09/2012                            A brand of ZF
Conclusions


 ZF contributes to further proof competitive wind energy technology

 Wind energy has grown significantly during last decades
 Further CoE reduction will support wind to gain share in future energy mix, where
  offshore wind is still emerging
 Proven reliability contributes to lower OPEX and higher AEP
     •   Representative testing is key
     •   ZF WP emphasizes this with large test capabilities
     •   Next steps to focus on further improvement and expansion of test infrastructure


 Additional leverage to reduce CoE by using intelligent preventive maintenance as
  part of our service solution


 More and larger scale testing is better affordable in public test infrastructure (e.g.
  OWI), where governmental support increases regional competitiveness and
  contributes globally to stimulate renewable energy




                                                                                                           © ZF Friedrichshafen AG, 2012
19                            OWI-Lab, 27/09/2012                                          A brand of ZF
Thank you very much for your attention!




                                                        © ZF Friedrichshafen AG, 2012
20   Presentation Title, Date
     OWI-Lab, 27/09/2012                A brand of ZF

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2012 09-27 opening-owi-lab-zf

  • 1. Competitive wind turbine drive trains through representative testing Dr. Stefan Lammens, Vice President – Chief Sales & Marketing Officer Wind Power Technology A brand of ZF © ZF Friedrichshafen AG, 2012 1 Presentation Title, Date OWI-Lab, 27/09/2012 A brand of ZF
  • 2. Combination of ZF and Hansen + Customers Products 2 MW 1,5 MW to 6,15 MW Regions Gainesville, USA Gainesville, USA Lommel, Belgium Production Lommel, Belgium Locations © ZF Friedrichshafen AG, 2012 Coimbatore, India Tianjin, China Coimbatore, India Tianjin, China Source: ZF; Hansen Transmission Annual Report 2011, 31.03.11 and Annual Report 2010, 31.03.10 2 OWI-Lab, 27/09/2012 A brand of ZF
  • 3. The Business Unit Wind Power Technology is part of the Industrial Technology Division of ZF ZF Friedrichshafen AG Shareholders: 93.8 % Zeppelin Foundation and 6.2 % Dr. Jürgen and Irmgard Ulderup Foundation Division Division Division Division Joint Venture Steering Systems 4) Powertrain Chassis Commercial Vehicle Industrial Technology Technology Technology Technology 50 % CEO, Market Transmissions Chassis Systems Truck & Van Construction Passenger Car Driveline Technology Machinery Systems Steering Systems Finance, Axle Drives Chassis Components Bus Driveline Agricultural Commercial Vehicle Controlling, Powertrain Modules Technology Machinery Systems Steering Systems IT, Process Management Rubber & Plastics CV Axle Systems Material Handling Passenger Car Human Resources Steering Columns Suspension Systems Technology CV Chassis Modules Test Systems Global Aftermarket CV Damper Materials Management Technology Special Driveline Technology CV Powertrain Modules Electronic Systems Operations and Technology Marine Propulsion Systems Compliance 1) Aviation Technology Die Casting Technology2) Wind Power Technology © ZF Friedrichshafen AG, 2012 ZF Services 3) Board of Management Organizational unit 1) linked to CEO 4) ZF Lenksysteme GmbH is a joint venture between 2) linked to Materials Management domain ZF Friedrichshafen AG and Robert Bosch GmbH. Integration of Hansen Partial activities 3) linked to Market domain Transmissions in wind power 3 OWI-Lab, 27/09/2012 A brand of ZF
  • 4. Key Figures 2011 Group The ZF Group – An Overview 2011 2011/2010 Sales € 15,509 million 20 % Employees (end of year) 71,488 11 % Capital expenditure € 1,058 million 82 % R&D expenditure € 754 million 17 % 121 production companies in 27 countries 8 main development locations in 4 countries © ZF Friedrichshafen AG, 2012 34 service companies and more than 650 service partners 4 OWI-Lab, 27/09/2012 A brand of ZF
  • 5. Wind Market Segments Global Annual Market Installations (in GW) 60 GW Onshore Offshore 6.3 5.6 50 GW 4.9 2.0 3.9 0.8 2.9 40 GW 1.5 0.6 30 GW 0.2 49.7 52.8 45.8 43.4 46.0 20 GW 0.2 37.9 40.5 41.1 37.6 28.2 10 GW 19.8 0 GW 2007 2008 2009 2010 2011 2012e 2013e 2014e 2015e 2016e 2017e  Offshore wind power technology is still in the emerging stage and larger, more efficient turbines along with optimization of the nascent supply chain have large potential for reducing Cost of Energy (CoE)  Reducing CoE of offshore wind will help wind to become a base-load production for the grid in mid- © ZF Friedrichshafen AG, 2012 long term  Flemish stakeholders take a pioneering role in offshore innovations and developments Source: ZF WPT Market Intelligence 5 OWI-Lab, 27/09/2012 A brand of ZF
  • 6. CoE Reductions Critical to Competitiveness Wind competitive with fossil fuels Cost of Energy (EUR/MWh)  Cost of Energy (CoE) is defined as:  Onshore  A reduction of 10% in onshore wind CoE will make it directly competitive with natural gas at today’s lower energy prices  Offshore  As wind farms are installed at sites further from shore and in deeper water, the industry will have to work hard to decrease current levels of CAPEX per megawatt installed © ZF Friedrichshafen AG, 2012 Note: NG prices = USD 4.00-6.75/MMBTU, Coal = USD 1.60- 1.70.MMBTU, onshore wind capacity factor = 30%, no CO2 costs for fossil technology, EUR = 1.45 USD. Source, MAKE, Lazard, others Source: MAKE Consulting, ZF WPT Market Intelligence 6 OWI-Lab, 27/09/2012 A brand of ZF
  • 7. Impact of gearboxes on CoE Offshore Wind Cost Drivers Offshore CAPEX structure Others Preparational Management Insurance 1% Work 2% 2% 1% Contingencies 3% Electrical Grid 6%  CAPEX impact of a gearbox is limited within a Substation Foundations typical offshore project, however, turbine 6% 26% suppliers are continually looking for ways to reduce component weight and material usage Installations Vessels 18%  Not the offshore environment is changing wind Other Turbine turbine gearbox specifications, but the Components challenges in O&M are emphasizing the 31% importance of reliability, with a direct impact on OPEX and AEP © ZF Friedrichshafen AG, 2012 Gearbox 4% Source: MAKE Consulting, ZF WPT Market Intelligence 7 OWI-Lab, 27/09/2012 A brand of ZF
  • 8. Our mission We reduce the kWh cost of renewable energy  We develop competitive products with proven reliability  to lower costs of unplanned OPEX  to guarantee AEP by increased availability © ZF Friedrichshafen AG, 2012 8 OWI-Lab, 27/09/2012 A brand of ZF
  • 9. Trends in drive train technology Diversity in solutions on the market  Search for the lowest CoE yields various  Mechanical power transfer: industrial solutions for the drive train,  gearbox being a trade-off between all design drivers:  hydraulic converter  reliability  Electrical generator  weight and cost  gear driven or direct drive ?  efficiency  high speed, medium speed, low speed ?  serviceability  traditional or permanent magnet generator ?  grid compatibility  Power conversion / transfer  low, medium, high voltage ?  AC or DC ? © ZF Friedrichshafen AG, 2012 All published solutions claim to be winners, but few are proven by test and experience 9 OWI-Lab, 27/09/2012 A brand of ZF
  • 10. Representative testing Representative testing is key to proof reliability of our competitive designs Logistic complexity and uncontrolled What ? environment of a wind turbine makes it a tough ‘test lab’ Short time-to-market requirements in new developments put time pressure on field validation campaign Start the turbine ! Representative (lab) testing capabilities are a long-term key © ZF Friedrichshafen AG, 2012 differentiator of ZF WP 10 OWI-Lab, 27/09/2012 A brand of ZF
  • 11. Representative testing It is possible to transform wind turbine behaviour into test rig conditions… © ZF Friedrichshafen AG, 2012 11 OWI-Lab, 27/09/2012 A brand of ZF
  • 12. Hansen Transmissions International Evolution of wind turbines and testing procedures ZF WP Capability ZF WP DORoTe Dynamic Testing @ ZF WP 13.2 MW Test Bench Industry Standard Overload Prototype Testing 100% Serial testing, first at partial, later at full load 1970 1980 1990 2000 2010 2020 © ZF Friedrichshafen AG, 2012 ZF WP is continuously improving its testing procedures by implementing ZF WP specific dynamic testing methods * Indicative Numbers & years 12 OWI-Lab, 27/09/2012 A brand of ZF
  • 13. Design verification proving reliability Technology/ Materials Verification Reliable Designs Component and State-of-the-art Sub-assembly Design Tools Verification Gearbox Verification Field © ZF Friedrichshafen AG, 2012 Verification 13 OWI-Lab, 27/09/2012 A brand of ZF
  • 14. Component and Sub-assembly Verification  ZF WP’s dynamic bearing system test rig  testing real size bearings  in their actual arrangement as built in the gearbox  under representative wind turbine loading and operational conditions © ZF Friedrichshafen AG, 2012 This pro-active testing method contributes largely to the design of robust bearing arrangements for new reliable gearboxes 14 OWI-Lab, 27/09/2012 A brand of ZF
  • 15. Gearbox Verification Motor GB1 GB2 Generator ZF WP’s 13.2 MW / 16.8 MW Dynamic Test Rig - 13.2 MW rated power - 1500 RPM nom speed - 1000 tons of steel - 16.8 MW peak power - 2600 RPM max speed - 1000 tons of concrete © ZF Friedrichshafen AG, 2012 - Investment - 80 kNm at motors - 35m x 10m > 10 M EUR - 100% Availability (24/7) 15 OWI-Lab, 27/09/2012 A brand of ZF
  • 16. Next steps in representative testing From gearbox verification to complete drive train / wind turbine testing Need for more large scale test infrastructure and prototype field testing Research topics • make tests even more representative by correlation between field and test rig conditions • increase acceleration factor for life testing on test rigs New conditions require dedicated testing • cold / hot climate OWI climate chamber • offshore e.g. corrosion testing © ZF Friedrichshafen AG, 2012 • grid codes e.g. grid compatibility testing 16 OWI-Lab, 27/09/2012 A brand of ZF
  • 17. Additional leverage to reduce CoE Minimise OPEX and optimise availability in our service offering © ZF Friedrichshafen AG, 2012 17 OWI-Lab, 27/09/2012 A brand of ZF
  • 18. Additional leverage to reduce CoE Minimise OPEX and optimise availability in our service offering O&M business is evolving rapidly ZF has a global footprint for offering service solutions for wind turbine gearboxes  Our unique gearbox know-how and large installed gearbox base will enable intelligent preventive maintenance  Research challenge: innovation in performance and condition monitoring  create wind turbine data sets (SCADA, CMS, …)  develop intelligent processing algorithms © ZF Friedrichshafen AG, 2012  merge measurements and algorithms into added value for O&M 18 OWI-Lab, 27/09/2012 A brand of ZF
  • 19. Conclusions ZF contributes to further proof competitive wind energy technology  Wind energy has grown significantly during last decades  Further CoE reduction will support wind to gain share in future energy mix, where offshore wind is still emerging  Proven reliability contributes to lower OPEX and higher AEP • Representative testing is key • ZF WP emphasizes this with large test capabilities • Next steps to focus on further improvement and expansion of test infrastructure  Additional leverage to reduce CoE by using intelligent preventive maintenance as part of our service solution  More and larger scale testing is better affordable in public test infrastructure (e.g. OWI), where governmental support increases regional competitiveness and contributes globally to stimulate renewable energy © ZF Friedrichshafen AG, 2012 19 OWI-Lab, 27/09/2012 A brand of ZF
  • 20. Thank you very much for your attention! © ZF Friedrichshafen AG, 2012 20 Presentation Title, Date OWI-Lab, 27/09/2012 A brand of ZF