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Luca Peretti - ABB Corporate Research, 2012-04-04




“Clean“ wind power generation
Electric/mechatronic aspects and
trends
Overview

          Presentations

          The wind energy sector – a bird’s eye view

          What is ”clean” wind energy?

          Mechatronic aspects of wind turbines

          Control aspects of wind turbines

          Reflections

          Soft conclusion



© ABB Group
April 4th, 2012   | Slide 2
Presentations



© ABB Group
April 4th, 2012   | Slide 3
Some about myself….
                             Born in Udine, Italy, in 1980



                             M.Sc. In Electronic Engineering, University of Udine (Italy), 2005



                             Ph.D. in Mechatronics and Industrial Systems, University of Padova in
                              Vicenza (Italy), 2009



                             Post-doc, University of Padova in Vicenza (Italy), 2009-2010



                             Scientist, ABB Corporate Research, Västerås (Sweden), 2010-today



                             Member of the technical steering committee in the SWPTC

                             Member of reference group for Vindforsk projects

                             Member of the IET

© ABB Group
April 4th, 2012   | Slide 4
ABB – a multinational corporation
 Power and automation technologies

                                  ~133,600 employees in about 100 countries


                                  2011 revenue: $ 38 billion


                                  Formed in 1988, merger of Swiss and Swedish
                                   engineering companies


                                  Predecessors founded in 1883 (ASEA) and
                                   1891 (Brown Boveri)


                                  Publicly owned company with head office in
                                   Switzerland


© ABB Group



 April 4th, 2012   | Slide 5
ABB offers
Divisional structure and portfolio



                                                                     Discrete
                                              Power Systems                                Low Voltage             Process
                  Power Products                                  Automation and
                                                                                            Products              Automation
                                                                      Motion
                        $9.9 billion            $7.6 billion            $8.0 billion       $4.9 billion           $7.6 billion


                 ultrahigh, high and        electricals,          •    machines         contactors           control systems
                  medium voltage              automation and        •    motors           instrumentation       and application-
                  products (switchgear,       control for power     •    drives           panels                specific
                  capacitors, …);             generation            •    robotics         softstarters          automation
                 distribution               transmission                                                       solutions for
                  automation;                 systems and                                                        process
                 transformers                substations                                                        industries
                                             network
                                              management



               Based on 2011 revenues



© ABB Group
April 4th, 2012      | Slide 6
Innovation: key to ABB’s competitiveness
Consistent R&D investment




                                  More than $1 billion invested annually in R&D*

                                  Approx. 6,000 scientists and engineers

                                  Collaboration with approx. 70 universities

                                         MIT (US), Tsinghua (China), KTH Royal Institute of Technology (Sweden), Indian
                                          Institute of Science (Bangalore), ETH (Switzerland), Karlsruhe (Germany), …


                              * Comprises non-order related R&D and order-related development

© ABB Group
April 4th, 2012   | Slide 7
ABB Corporate R&D – globally distributed




                                                                         SECRC - Västerås (Oslo)
                                                                         CHCRC - Baden-Dättwil
                                                                         DECRC - Ladenburg
                                                                         PLCRC - Krakow
                                                                         USCRC - Raleigh
                                                                         INCRC - Bangalore
                                                                         CNCRC - Beijing and Shanghai




                              Power Technologies   Automation Technologies

© ABB Group
April 4th, 2012   | Slide 8
ABB Corporate Research, Västerås
Resources: brains and muscles
                 Approx. 260 Employees
                          240 Scientists and engineers
                          135 Ph.D.
                 Power Technologies labs
                          High Voltage
                          High Power
                          Motor/machines test benches
                          Power electronics test benches
                                                              c
                          Insulation systems and materials
                 Automation Technologies labs
                          Mechatronics
                          Communications
                 Technology Support labs
                          Chemistry
                          Mechanics




© ABB Group
April 4th, 2012       | Slide 9
Wind energy sector
                               A bird’s eye view on the market and (ABB’s) technologies




© ABB Group
April 4th, 2012   | Slide 10
Wind energy sector
Growing… ?




                                       From: http://www.wwindea.org/home/index.php?option=com_content&task=view&id=345&Itemid=43




                     China number 1, and growing
                     Very politically-driven market (financial crisis has a big impact)
                     Germany’s very ambitious plans are interesting… (but already behind schedule)
                      (http://www.thenational.ae/thenationalconversation/industry-insights/energy/german-
                      wind-energy-plans-in-the-doldrums)
© ABB Group
April 4th, 2012       | Slide 11
Offshore wind
Mainly a European challenge so far




                               From [1]
© ABB Group
April 4th, 2012   | Slide 12
Offshore wind in Europe




                                              From [1]




                                                         From [1]

      Lot of plans, few installations done
      Offshore is still a small percentage
      Technological reasons behind it?


© ABB Group
April 4th, 2012   | Slide 13
ABB contribution to renewable energy
Component supplier for wind power
                                       Offering to wind       turbine
                                       manufacturers:
                                          Generators and motors
                                          LV and MV converters
                                          LV and MV switchgears
                                          Transformers
                                          Control and protections
                                          Low voltage products
                                          Full life cycle management
                                           to all products delivered



                                       Sales to wind farm owners,
                                       operators or developers:
                                          Sub-stations
                                          Transformers
                                          Grid connections
                                          AC and HVDC underground
                                           and sea
                                          Cables
                                          System studies
                                          Full life cycle management
                                           to all products delivered



© ABB Group
April 4th, 2012   | Slide 14
Generators for different drive train concepts
A complete coverage
                        Doubly-fed induction machine (±30% speed)              Squirrel-cage induction machine (0-100% speed)




                     Permanent magnet machine (0-100% speed)                   Permanent magnet DD machine (0-100% speed)




© ABB Group                                                         From [6]
April 4th, 2012   | Slide 15
Induction generators
                                                     Fixed-speed generators
                                  Generator directly coupled to the grid
                                  From single- to two-speed, air- and water-cooling, cast iron and welded housings
                                  Typical rated speed 1000 – 1500 rpm, 4 – 6 poles
                                  Normally powers from 1 MW to 2 MW




                                                           Doubly-fed generators
                                  Direct on-line stator and a wound rotor connected to the grid using a frequency
                                   converter, torque and speed ranges limited by the converter power rating
                                  Typical rated speed 1000 – 1500 rpm, 4 – 6 poles
                                  Normally powers from 1,5 MW to 5 MW




                                                           Full-speed generators
                                    Welded modular construction
                                    Fully controlled with variable speed, reactive power supply
                                    High power quality and efficiency for the end user
                                    Typical rated speed 1000 – 1500 rpm, 4 - 6 poles
                                    Normally powers from 2 MW to 5 MW



© ABB Group                                     From [7]
April 4th, 2012   | Slide 16
Synchronous (PM) generators
                                            Low-speed generators
                                  Integration of turbine and generator.
                                  Simple and robust low speed rotor design with no separate excitation or cooling system
                                  High efficiency, simple and robust, lowest maintenance demand, maximum reliability
                                  Typical rated speed 14 – 30 rpm, multi-pole
                                  Normally powers from 1,5 MW to 3 MW



                                          Medium-speed generators
                                  Slow speed system, single-stage gearbox.
                                  Same simple and robust low speed rotor design with no separate excitation or cooling system
                                  High power with small space requirement
                                  High efficiency, simple and robust, low maintenance demand
                                  Typical rated speed 120 – 450 rpm, multi-pole
                                  Normally powers from 1 MW to 7 MW


                                              High-speed generators
                                  Mechanically similar to the doubly-fed type with smaller space requirements
                                  Highest power density with well-proven, high speed gear solution
                                  High efficiency, no slip rings, low maintenance demand
                                  Typical rated speed 1000 – 2000 rpm, 4 to 8 poles
                                  Normally powers from 2 MW to 5 MW


© ABB Group                                           From [7]
April 4th, 2012   | Slide 17
Low-voltage (<1 kV) drives: ABB ACS800 family




                  ACS800-77LC - 0,6 to 3,3 MW         ACS800-87LC - 1, 5 to 6 MW                     ACS800-67LC - 1,7 to 3,8 MW
                     Robust grid code compliance        Robust grid code compliance                   Small and light weight
                     Nacelle or tower installation      Compact size, back-to-back configuration      Lowest harmonics and        highest
                                                                                                         efficiency at rated point
                     Redundant configuration            Optimized for tower base installation
                      available at higher ratings




© ABB Group                                                               From [6]
April 4th, 2012       | Slide 18
Medium voltage (~3 kV) drives: ABB PCS6000 family




                              2011-08-23: first order from Global Tech I project (400 MW offshore wind farm, 110km
                               north-west of Cuxhaven, Germany)

                              80 wind turbines (Multibrid) of 5 MW each - provided by AREVA

                              $ 30 millions from AREVA Wind to provide 5MW-MV drives

© ABB Group                                                          From [6,8]
April 4th, 2012   | Slide 19
What is “clean” wind
                              energy?
                               ...or the “behind the scene” aspect




© ABB Group
April 4th, 2012   | Slide 20
“Clean” energy
Is it this...?




           From: http://www.cbc.ca/news/pointofview/WindTurbine.jpg




                                                                                                           From: http://www.greenpeace.org/eu-unit/Global/eu-
                                                                                                           unit/image/2011%20pix/December%202011/turbine%20on%20the%20beach.jpg




             From: http://www.bettergeneration.co.uk/images/stories/blog/wind-eolic-turbine-in-hands.jpg


© ABB Group
April 4th, 2012    | Slide 21
“Clean” energy
...or this?




           From: http://graphics8.nytimes.com/images/2010/11/08/opinion/08rfd-image1/08rfd-
           image1-custom2.jpg




                                                                                                From: http://andysrant.typepad.com/.a/6a01538f1adeb1970b0154361c515e970c-500wi




    From: http://www.cbc.ca/gfx/images/news/photos/2011/07/07/li-rare-earth-mine-620rtxu1.jpg

© ABB Group
April 4th, 2012   | Slide 22
Mechatronics aspects
                     ...or wind turbines from the view of a power electronics engineer


                                        (no grid aspects included)




© ABB Group
April 4th, 2012   | Slide 23
Wind turbines structures
How did we get here




                               Picture from [2]


© ABB Group
April 4th, 2012   | Slide 24
Growing and growing…
Foreseen problems?




                               Picture from [2]
© ABB Group
April 4th, 2012   | Slide 25
Inside a wind turbine
The real mechatronic application




                                                                             Picture from [2]



           The turbine rotor rotates at low speed – approx. 5 rpm nominal

           Depending on the drive train concept, the generator rotates either at low (15 rpm), medium-(300-
            400 rpm) or high (1000-1800 rpm) speed

© ABB Group
April 4th, 2012   | Slide 26
A true mechatronic vision is needed
                                                                                                           Material
                               Electrics           Electronics        Mechanics             Civil
                                                                                                           science




                                                      Maximum
                                                      efficiency
                                                       control
                    Light-weight                                          Foundations
                     materials                                            for offshore
                                                                                                       Results in each field stimulate
                                                      Flexible
                                                   blades design                                        and benefit all other fields
                   Design of
                                                                                  Grid-fault
                    larger
                  generators
                                                                                compensation           Interdisciplinary exchange
                                                                                   control
                                                                                                        and circulation of ideas is
                                                                                  New                   essential
                                      Reliable                                  generator
                                      electrical                                concepts
                                      contacts


                                                                   Mechanical
                                   Vibration                        vibration
                                   damping                          damping
                                  algorithms

© ABB Group
April 4th, 2012   | Slide 27
Let’s start: cost breakdown of a wind turbine




                                                    Picture from [2]

                 Generator and power converter do not account for much of the cost… (so far)
                 The gearbox is indeed quite a big part of it
© ABB Group
April 4th, 2012    | Slide 28
The gearbox
One of the most unknown things ever (for electrical guys)




                   From: http://www.designnews.com/document.asp?doc_id=230485   From: http://eetweb.com/wind/gearbox-failure-fig1.jpg



                 Mature product trying to enter a new market
                 One or more stages between the turbine rotor and the electric generator (epicyclical or
                  parallel axis type)
                 Mechanical multi-body simulations are performed by suppliers (but not available)
                 Source of noise (and failures)
                 Today, closer interaction with turbine manufacturers
© ABB Group
April 4th, 2012    | Slide 29
Noise from the gearbox
             There might be some vibrations (mesh frequency and maybe others)
             What happens during normal operation? And during a fault?




                  From: S. Li, D. Jiang, M. Zhao, "Experimental investigation and analysis for gearbox fault", Proc. of the World
                  Non-Grid-Connected Wind Power and Energy Conference (WNWEC), Nanjing, China, Nov. 5th-7th, 2010.



© ABB Group
April 4th, 2012     | Slide 30
The mechanical drive train
       A classic mechanical engineering work
       Quite different structures for different concepts (direct-drive, gearbox-based)
       Surprisingly (or not?), few information available for high-frequency behaviour (above 100 Hz)
       There might be some resonances... what happens when they are hit?




                   𝑑𝜔 𝑟𝑜𝑡     1                          𝑑𝜙
                          =         𝜏 𝑟𝑜𝑡 − 𝜙𝐾 𝑠𝑕𝑎𝑓𝑡 −      𝐵
                    𝑑𝑡      𝐽 𝑟𝑜𝑡                        𝑑𝑡 𝑠𝑕𝑎𝑓𝑡

                  𝑑𝜔 𝑔𝑒𝑛     1            1                    𝑑𝜙
                         =       −𝜏 𝑔𝑒𝑛 +         𝜙𝐾 𝑠𝑕𝑎𝑓𝑡 +      𝐵
                   𝑑𝑡      𝐽 𝑔𝑒𝑛          𝑁                    𝑑𝑡 𝑠𝑕𝑎𝑓𝑡

                      𝑑𝜙           1
                         = 𝜔 𝑟𝑜𝑡 −   𝜔
                      𝑑𝑡           𝑁 𝑔𝑒𝑛

             From: J. D. Grunnet, M. Soltani, T. Knudsen, M.              From: J. Sopanen, V. Ruuskanen, J. Nerg, J.
             Kragelund, T. Bak, “Aeolus toolbox for dynamic wind          Pyrhönen, "Dynamic torque analysis of a wind
             farm model, simulation and control”, Proceedings of          turbine drive train including a direct-driven
             the European Wind Energy Conference and                      permanent magnet generator", IEEE Trans. Ind.
             Exhibition (EWEC) 2010, 20th-23rd April 2010,                El., vol. 58, no. 9, Sept. 2011.
             Warsaw, Poland.


© ABB Group
April 4th, 2012   | Slide 31
The (twisting) tower…
             Side-to-side and fore-aft oscillations: impact on power generation

  Side-to-side oscillations:

   The sideways oscillation of the tower causes an
   oscillating angular deflection of the nacelle and
   thereby superimposes an apparent oscillation in the
   rotating magnetic flux. This leads to a corresponding
   power fluctuation.


   From: T. Thiringer, J.-Å. Dahlberg, "Periodic pulsations from a three-bladed wind turbine", IEEE Trans. En. Conv., vol. 16, no. 2,
   Jun. 2001



   Fore-aft oscillations:
  Change of the equivalent wind speed over the rotor: change of torque
  contribution from the wind source.

                                                      1 𝑣3
                                                         𝑟𝑜𝑡
  Torque produced on the shaft:             𝜏 𝑟𝑜𝑡   =         𝜌𝐴 𝑟𝑜𝑡 𝐶 𝑝 𝜆, 𝛽
                                                      2 𝜔 𝑟𝑜𝑡




© ABB Group
April 4th, 2012   | Slide 32
The nature adds some wind effects
                                       Wind shear and tower shadow effects


  Variation of the wind field with the height                           Disturbance related to tower presence




       From: D. S. L. Dolan, P. W. Lehn, “Simulation Model of wind turbine 3p torque oscillations due to wind shear and tower
       shadow”, IEEE Trans. En. Conv., vol. 21, no. 3, Sept. 2006




        That’s what individual pitch control is used for!                                             http://www.geograph.
                                                                                                       org.uk/photo/754033




© ABB Group
April 4th, 2012   | Slide 33                                                   Pitch systems
Designing the best generator…the PMSG case

       Let’s not consider issues like size or weight or mounting procedures
       Cogging torque (for synchronous generators) could be an issue



                                                                          Q: number of slots
                                                                          p: pole pairs
                                                                                         +∞

                                                                          𝜏 𝑐𝑜𝑔 𝜗 𝑚 =          𝑇 𝑘 sin 𝑘𝑁 𝑝 𝑄𝜗 𝑚 + 𝜑 𝑘𝑁 𝑝
                                                                                         𝑘=1


                                                                                                                               2𝑝
                                                                                                                 𝑁𝑝 =
                                                                                                                            𝐻𝐶𝐹 𝑄, 2𝑝

        From: N. Bianchi, S. Bolognani, “Design Techniques for Reducing the Cogging Torque in Surface-Mounted PM Motors”, IEEE Trans. Ind. Appl.,
        vol. 38, no. 5, Sept./Oct. 2002, pp. 1259-1265.




© ABB Group
April 4th, 2012   | Slide 34
Designing the best generator…the PM case

                 Best design for cogging torque reduction,
                  but not elimination




       From: J. Sopanen, V. Ruuskanen, J. Nerg, J. Pyrhönen, "Dynamic torque analysis of a wind turbine drive train including a
       direct-driven permanent magnet generator", IEEE Trans. Ind. El., vol. 58, no. 9, Sept. 2011.
© ABB Group
April 4th, 2012    | Slide 35
The grid…why should it be perfect?
           Weak grids could introduce voltage asymmetries
           Issue for doubly-fed generators (a superimposed 2nd-harmonic torque is generated)




                           ± 2% voltage unbalance
                                                                                   ± 10,1% torque unbalance
                  ± 8,7% stator current unbalance
                                                                              ± 0,5% DC-bus voltage unbalance
             ±7,8% stator active power unbalance

             From: L. Xu, Y. Wang, "Dynamic modeling and control of DFIG-based wind turbines under unbalanced network
             conditions", IEEE Trans. Pow. Syst., vol. 22, no. 1, Feb. 2007


© ABB Group
April 4th, 2012   | Slide 36
Put it all together
     An engineering miracle that it actually works
     …but how do the components affect the turbine reliability?

     ReliaWind Project: http://www.reliawind.eu/




     EU funding within the frame of the European Union’s Seventh Framework Programme
      for RTD (FP7)
     450 wind-farm months’ worth of data
     350 onshore wind turbines operating for varying lengths of time
     35,000 downtime events
     ”old type” turbines (probably no direct-drive concepts)
© ABB Group
April 4th, 2012   | Slide 37
Reliability & maintenance aspects
ReliaWind project – turbine failure rate




                  From: http://www.reliawind.eu/files/file-inline/110502_Reliawind_Deliverable_D.1.3ReliabilityProfilesResults.pdf

© ABB Group
April 4th, 2012     | Slide 38
Reliability & maintenance aspects
Reliawind project - downtime




                  From: http://www.reliawind.eu/files/file-inline/110502_Reliawind_Deliverable_D.1.3ReliabilityProfilesResults.pdf

© ABB Group
April 4th, 2012     | Slide 39
Reliability & maintenance aspects
Previous studies




                  From: http://www.reliawind.eu/files/file-inline/110502_Reliawind_Deliverable_D.1.3ReliabilityProfilesResults.pdf


© ABB Group
April 4th, 2012     | Slide 40
Interpreting the reliability figures...

             Converters’ reliability should be improved

             Pitch control is also very sensitive

             Gearbox impact: to be further analysed (lot of effort from manufacturers
              reported)

             We should also don’t forget the scheduled maintenance (i.e. change of the oil
              in the gearbox)


                           Do we gain something by changing the drive train concept?


             High-speed, medium-speed or low-speed generators?

             With or without gearbox?



© ABB Group
April 4th, 2012   | Slide 41
Drive train concepts
The different approaches
                 Traditional concept: high-speed generator with gearbox
                                   low raw material and investment costs

                                   high full-load efficiency of the drive train

                                   higher failure rate for high-speed components
                                    (e.g. high-speed shaft and generator bearing)


                 Direct-drive concept: low-speed generator, no gearbox
                                   no fast rotating parts, maybe higher reliability

                                   higher partial load efficiency

                                   more raw materials



                 Medium-speed concept: medium-speed generator, reduced-stage gearbox
                                   Tries to combine the two above                     ?


© ABB Group
April 4th, 2012    | Slide 42
Magnets’ price variability
Up and downs – direct impact on generators’ price




   Picture from: http://aussiemagnets.com.au/pages/Rare-Earth-Magnet-Price-Increases.html   Picture from: http://www.metal-pages.com/metalprices/neodymium/




                                  Rare-earth materials’ price is going up and down
                                  China dominates the market
                                  Future?

© ABB Group
April 4th, 2012   | Slide 43
Control aspects
                               Mainly converter ones, not pitch control ones




© ABB Group
April 4th, 2012   | Slide 44
The general picture
Pitch control and generator control
                                                     Pitch control and torque control;

                                                     Pitch control: PLC level (turbine
                                                      manufacturer);

                                                     Torque control: frequency converter
                                                      (supplier)

                                                     Power references are accepted as
                                                      well for the torque control;

                                                     Speed-power-torque relationships
                                                      based on turbine and generator
                                                      characteristics;

                                                     There is one drawback from the
                                                      electric drive point of view. Where?

                               Picture from [2]
© ABB Group
April 4th, 2012   | Slide 45
The two cases: DFIG and PMSG

                                                      DFIG: converter connected to the rotor
                                                       windings, slip rings
                                                      Stator connected to the grid
                                                      Smaller converter size (roughly 30% of
                                                       the rated power)

                               Picture from [2]




                                                          PMSG: grid/generator interaction
                                                           only through the converter
                                                          Bigger size of the converter (rated
                                                           power)


                                Picture from [2]


© ABB Group
April 4th, 2012   | Slide 46
A conventional speed-power curve




                               Picture from [2]



© ABB Group
April 4th, 2012   | Slide 47
The importance of the limitations
The PMSG case




                                    Picture from [3]




© ABB Group
April 4th, 2012   | Slide 48
The importance of the limitations
The DFIG case




                               Picture from [4]




© ABB Group
April 4th, 2012   | Slide 49
Grid-codes compliance
  •          Static and dynamic requirements to be fulfilled by a wind power installation
  •          Static requirements: voltage and power control, power quality (THD, flicker)
  •          Dynamic requirements: dynamic behavior under grid disturbance (fault ride-
             through, FRT)




                                              Picture from [3]
© ABB Group
April 4th, 2012   | Slide 50
Fault ride-through capabilities
    Turbine connected during temporary faults. Requirements:
                 voltage dip length
                 behaviour with a balanced (symmetrical) dip
                 behaviour with an unbalanced (unsymmetrical) dip.
    Depending on the country, the wind turbine:
                 has to stay connected to the power system for a certain time
                 may not take power from the power system
                 must produce capacitive reactive current as much as required.




© ABB Group
April 4th, 2012      | Slide 51                              Picture from [3]
Reflections
                               (Technical) tendencies and expectations on the turbine side




© ABB Group
April 4th, 2012   | Slide 52
Challenge 1 – The scaling of generators
     Coping with: increased weight? Increased disturbances and vibrations? PM availability?
     It is not only a raw material problem; it is also a production capacity issue.

                                   Drive train
                                                  Concept comparisons (3MW reference) Speed Full
                                                    Low Speed Full
                                                                   Medium Speed Full High
                                                    Converter (LSFC) -
                                    concept                              Converter (MSFC)    Converter (HSFC)
                                                       Direct drive
                                                     Low Speed Full
                                    Drive train                          Medium Speed Full   High Speed Full
                                                    Converter (LSFC) -
                                   Typical size
                                     concept                             Converter (MSFC)    Converter (HSFC)
                                                       Direct drive
                                                        70 tons               20 tons            8 tons

                                     Relative
                                   Typical size
                                   Production           70 tons               20 tons            8 tons
                                     capacity              4,5                  1,5                 1
                                     Relative
                                       need
                                   Production            (450%)               (150%)             (100%)
                                     Per unit
                                     capacity              4,5                  1,5                 1
                                       need              (450%)               (150%)             (100%)
                                    Efficiency
                                     Per unit
                                    at nominal
                                                         95,1%                98,2%              97,7%
                                        load
                                    Efficiency
                                    at nominal
                                     Relative            95,1%                98,2%              97,7%
                                        load
                                     Magnet
                                      weight               10                   2,5                1
                                     Relative
                                     Magnet
                                      weight               10                   2,5                1




    © ABB Group
    April 4th, 2012   | Slide 53
Challenge 2: the offshore
   •          Harsher conditions in offshore
   •          Wind AND waves effects!
   •          Water depth, soil stiffness: significant effect on
              the fatigue load/bending
   •          Indirect effects on the drive train (vibrations)
   •          Control may have a bigger role




       From: J. Sheng, S. Chen, "Fatigue Load Simulation for Foundation Design of Offshore Wind Turbines Due to Combined
       Wind and Wave Loading“, Proc. of the Non-Grid-Connected Wind Power and energy Conference (WNWEC), Nanjing,
       China, Nov. 5th-7th,2010.
© ABB Group
April 4th, 2012   | Slide 54
Challenge 3: maintenance




http://www.flightglobal.com/blogs/aircraft-pictures/assets_c/2009/01/Eurocopter-EC135.html                http://images.pennnet.com/articles/pe/cap/cap_0705pe-dsc06925.jpg




                                                                                                Do we design with maintenance in mind?
                                                                                                What does the offshore challenge require?
                                                                                                How a different drive train topology affect
                                                                                                 maintenance?



                   http://www.rope-access-photos.com/picture/number395.asp
 © ABB Group
 April 4th, 2012       | Slide 55
Challenge 4 – Cold climate
       Research to enhance power production in cold regions
       Blades do play a big role
                     New materials, new concepts needed
                     Condition monitoring (not only for blades...)
       Converters, generators could be affected by altitude




  From: Ø. Byrkjedal - Kjeller Vindteknikk, “Detailed national mapping of icing”, Seminar on wind energy aerodynamics - icing
  and de-icing of WT blades, KTH, Sept. 5, 2011 - Chalmers, Sept. 6, 2011,
  https://document.chalmers.se/workspaces/chalmers/energi-och-miljo/vindkraftstekniskt/icing-de-icing/oyvind_byrkjedal
© ABB Group
April 4th, 2012       | Slide 56
Do not limit the fantasy
Airborne turbines?
                                     Savonius style                                                      Twind




                                                    http://en.wikipedia.org/wiki/Airborne_wind_turbine

                                        Aerogenerator X                                             KiteGen




© ABB Group
April 4th, 2012   | Slide 57
                               http://www.windpower.ltd.uk/index.html           http://kitegen.com/press/kiwicarusel_hd_logo.jpg
Soft conclusion
                               To ease the listeners before the discussion




© ABB Group
April 4th, 2012   | Slide 58
ABB support to academia
The right time for knowledge




                               From: http://www.chalmers.se/ee/swptc-en

© ABB Group
April 4th, 2012   | Slide 59
SWPTC partners

  Universities
           Chalmers University of Technology

  Industries
           ABB
           DIAB
           GE Wind
           Göteborgs Energi
           Marström Composite
           SKF Sweden
           Triventus Energiteknik
           WindVector

  Municipal/Regional/Government
           Region Västra Götaland
           Swedish Energy Agency




© ABB Group
April 4th, 2012   | Slide 60
SWPTC’s direct-drive wind turbine in Göteborg
Main technical data




                                                                                                                   Picture from Göteborg’s harbour




                               From: http://www.goteborgenergi.se/Foretag/Projekt_och_etableringar/Fornyelsebar_energi/Vindkraft/I_drift/Goteborg_Wind_Lab


© ABB Group
April 4th, 2012   | Slide 61
Time-lapse video




                                  http://www.youtube.com/watch?v=jHn1n2tdnRc
© ABB Group
April 4th, 2012   | Slide 62
Thank you!
      Picture from: http://blog.luciolepress.com/2010/08/05/funny-photo-a-sheep-a-wind-turbine-and-a-rainbow-in-germany.aspx


© ABB Group
April 4th, 2012   | Slide 63
References
      1.          “Wind in our Sails - The coming of Europe's offshore wind energy industry”, EWEA report, November 2011,
                  http://www.ewea.org/fileadmin/ewea_documents/documents/publications/reports/Offshore_report_web_01.pdf


      2.          ABB Technical application papers no. 13, ”Wind power plants”, ABB document 1SDC007112G0201 - 10/2011 - 4.000.


      3.          "ABB wind turbine converters - System description and start-up guide, ACS800-77LC wind turbine converters (840 to 3180
                  kW)", ABB document 3AFE68802237 Rev B EN 2010-10-25.


      4.          ABB wind turbine converters- System description and start-up guide, ACS800-67LC wind turbine converters, ABB document
                  3AUA0000059432 Rev A (EN) 2011-01-14


      5.          "ABB wind turbine converters - Firmware manual - Grid-side control program for ACS800 wind turbine converters", ABB
                  document 3AUA0000075077 Rev B EN 2011-05-26


      6.          “Products and services for wind turbines - Electrical drivetrain solutions and products for turbine subsystems”, ABB document
                  3AUA0000080942 REV A 18.5.2010 #14995


      7.          “Wind turbine generators - Reliable technology for all turbine applications”, ABB brochure 9AKK104735 EN 04-2009
                  Piirtek#14426


      8.          “Medium voltage for wind power PCS 6000 - full-scale converters up to 9 MVA”, ABB document 3BHS275725 E01




© ABB Group
April 4th, 2012     | Slide 64
Atti della Conferenza GENERAZIONE EOLICA “PULITA”: aspetti meccatronici/azionamentistici e trends

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Atti della Conferenza GENERAZIONE EOLICA “PULITA”: aspetti meccatronici/azionamentistici e trends

  • 1. Luca Peretti - ABB Corporate Research, 2012-04-04 “Clean“ wind power generation Electric/mechatronic aspects and trends
  • 2. Overview  Presentations  The wind energy sector – a bird’s eye view  What is ”clean” wind energy?  Mechatronic aspects of wind turbines  Control aspects of wind turbines  Reflections  Soft conclusion © ABB Group April 4th, 2012 | Slide 2
  • 3. Presentations © ABB Group April 4th, 2012 | Slide 3
  • 4. Some about myself….  Born in Udine, Italy, in 1980  M.Sc. In Electronic Engineering, University of Udine (Italy), 2005  Ph.D. in Mechatronics and Industrial Systems, University of Padova in Vicenza (Italy), 2009  Post-doc, University of Padova in Vicenza (Italy), 2009-2010  Scientist, ABB Corporate Research, Västerås (Sweden), 2010-today  Member of the technical steering committee in the SWPTC  Member of reference group for Vindforsk projects  Member of the IET © ABB Group April 4th, 2012 | Slide 4
  • 5. ABB – a multinational corporation Power and automation technologies  ~133,600 employees in about 100 countries  2011 revenue: $ 38 billion  Formed in 1988, merger of Swiss and Swedish engineering companies  Predecessors founded in 1883 (ASEA) and 1891 (Brown Boveri)  Publicly owned company with head office in Switzerland © ABB Group April 4th, 2012 | Slide 5
  • 6. ABB offers Divisional structure and portfolio Discrete Power Systems Low Voltage Process Power Products Automation and Products Automation Motion $9.9 billion $7.6 billion $8.0 billion $4.9 billion $7.6 billion  ultrahigh, high and  electricals, • machines  contactors  control systems medium voltage automation and • motors  instrumentation and application- products (switchgear, control for power • drives  panels specific capacitors, …); generation • robotics  softstarters automation  distribution  transmission solutions for automation; systems and process  transformers substations industries  network management Based on 2011 revenues © ABB Group April 4th, 2012 | Slide 6
  • 7. Innovation: key to ABB’s competitiveness Consistent R&D investment  More than $1 billion invested annually in R&D*  Approx. 6,000 scientists and engineers  Collaboration with approx. 70 universities  MIT (US), Tsinghua (China), KTH Royal Institute of Technology (Sweden), Indian Institute of Science (Bangalore), ETH (Switzerland), Karlsruhe (Germany), … * Comprises non-order related R&D and order-related development © ABB Group April 4th, 2012 | Slide 7
  • 8. ABB Corporate R&D – globally distributed SECRC - Västerås (Oslo) CHCRC - Baden-Dättwil DECRC - Ladenburg PLCRC - Krakow USCRC - Raleigh INCRC - Bangalore CNCRC - Beijing and Shanghai Power Technologies Automation Technologies © ABB Group April 4th, 2012 | Slide 8
  • 9. ABB Corporate Research, Västerås Resources: brains and muscles  Approx. 260 Employees  240 Scientists and engineers  135 Ph.D.  Power Technologies labs  High Voltage  High Power  Motor/machines test benches  Power electronics test benches c  Insulation systems and materials  Automation Technologies labs  Mechatronics  Communications  Technology Support labs  Chemistry  Mechanics © ABB Group April 4th, 2012 | Slide 9
  • 10. Wind energy sector A bird’s eye view on the market and (ABB’s) technologies © ABB Group April 4th, 2012 | Slide 10
  • 11. Wind energy sector Growing… ? From: http://www.wwindea.org/home/index.php?option=com_content&task=view&id=345&Itemid=43  China number 1, and growing  Very politically-driven market (financial crisis has a big impact)  Germany’s very ambitious plans are interesting… (but already behind schedule) (http://www.thenational.ae/thenationalconversation/industry-insights/energy/german- wind-energy-plans-in-the-doldrums) © ABB Group April 4th, 2012 | Slide 11
  • 12. Offshore wind Mainly a European challenge so far From [1] © ABB Group April 4th, 2012 | Slide 12
  • 13. Offshore wind in Europe From [1] From [1]  Lot of plans, few installations done  Offshore is still a small percentage  Technological reasons behind it? © ABB Group April 4th, 2012 | Slide 13
  • 14. ABB contribution to renewable energy Component supplier for wind power Offering to wind turbine manufacturers:  Generators and motors  LV and MV converters  LV and MV switchgears  Transformers  Control and protections  Low voltage products  Full life cycle management to all products delivered Sales to wind farm owners, operators or developers:  Sub-stations  Transformers  Grid connections  AC and HVDC underground and sea  Cables  System studies  Full life cycle management to all products delivered © ABB Group April 4th, 2012 | Slide 14
  • 15. Generators for different drive train concepts A complete coverage Doubly-fed induction machine (±30% speed) Squirrel-cage induction machine (0-100% speed) Permanent magnet machine (0-100% speed) Permanent magnet DD machine (0-100% speed) © ABB Group From [6] April 4th, 2012 | Slide 15
  • 16. Induction generators Fixed-speed generators  Generator directly coupled to the grid  From single- to two-speed, air- and water-cooling, cast iron and welded housings  Typical rated speed 1000 – 1500 rpm, 4 – 6 poles  Normally powers from 1 MW to 2 MW Doubly-fed generators  Direct on-line stator and a wound rotor connected to the grid using a frequency converter, torque and speed ranges limited by the converter power rating  Typical rated speed 1000 – 1500 rpm, 4 – 6 poles  Normally powers from 1,5 MW to 5 MW Full-speed generators  Welded modular construction  Fully controlled with variable speed, reactive power supply  High power quality and efficiency for the end user  Typical rated speed 1000 – 1500 rpm, 4 - 6 poles  Normally powers from 2 MW to 5 MW © ABB Group From [7] April 4th, 2012 | Slide 16
  • 17. Synchronous (PM) generators Low-speed generators  Integration of turbine and generator.  Simple and robust low speed rotor design with no separate excitation or cooling system  High efficiency, simple and robust, lowest maintenance demand, maximum reliability  Typical rated speed 14 – 30 rpm, multi-pole  Normally powers from 1,5 MW to 3 MW Medium-speed generators  Slow speed system, single-stage gearbox.  Same simple and robust low speed rotor design with no separate excitation or cooling system  High power with small space requirement  High efficiency, simple and robust, low maintenance demand  Typical rated speed 120 – 450 rpm, multi-pole  Normally powers from 1 MW to 7 MW High-speed generators  Mechanically similar to the doubly-fed type with smaller space requirements  Highest power density with well-proven, high speed gear solution  High efficiency, no slip rings, low maintenance demand  Typical rated speed 1000 – 2000 rpm, 4 to 8 poles  Normally powers from 2 MW to 5 MW © ABB Group From [7] April 4th, 2012 | Slide 17
  • 18. Low-voltage (<1 kV) drives: ABB ACS800 family ACS800-77LC - 0,6 to 3,3 MW ACS800-87LC - 1, 5 to 6 MW ACS800-67LC - 1,7 to 3,8 MW  Robust grid code compliance  Robust grid code compliance  Small and light weight  Nacelle or tower installation  Compact size, back-to-back configuration  Lowest harmonics and highest efficiency at rated point  Redundant configuration  Optimized for tower base installation available at higher ratings © ABB Group From [6] April 4th, 2012 | Slide 18
  • 19. Medium voltage (~3 kV) drives: ABB PCS6000 family  2011-08-23: first order from Global Tech I project (400 MW offshore wind farm, 110km north-west of Cuxhaven, Germany)  80 wind turbines (Multibrid) of 5 MW each - provided by AREVA  $ 30 millions from AREVA Wind to provide 5MW-MV drives © ABB Group From [6,8] April 4th, 2012 | Slide 19
  • 20. What is “clean” wind energy? ...or the “behind the scene” aspect © ABB Group April 4th, 2012 | Slide 20
  • 21. “Clean” energy Is it this...? From: http://www.cbc.ca/news/pointofview/WindTurbine.jpg From: http://www.greenpeace.org/eu-unit/Global/eu- unit/image/2011%20pix/December%202011/turbine%20on%20the%20beach.jpg From: http://www.bettergeneration.co.uk/images/stories/blog/wind-eolic-turbine-in-hands.jpg © ABB Group April 4th, 2012 | Slide 21
  • 22. “Clean” energy ...or this? From: http://graphics8.nytimes.com/images/2010/11/08/opinion/08rfd-image1/08rfd- image1-custom2.jpg From: http://andysrant.typepad.com/.a/6a01538f1adeb1970b0154361c515e970c-500wi From: http://www.cbc.ca/gfx/images/news/photos/2011/07/07/li-rare-earth-mine-620rtxu1.jpg © ABB Group April 4th, 2012 | Slide 22
  • 23. Mechatronics aspects ...or wind turbines from the view of a power electronics engineer (no grid aspects included) © ABB Group April 4th, 2012 | Slide 23
  • 24. Wind turbines structures How did we get here Picture from [2] © ABB Group April 4th, 2012 | Slide 24
  • 25. Growing and growing… Foreseen problems? Picture from [2] © ABB Group April 4th, 2012 | Slide 25
  • 26. Inside a wind turbine The real mechatronic application Picture from [2]  The turbine rotor rotates at low speed – approx. 5 rpm nominal  Depending on the drive train concept, the generator rotates either at low (15 rpm), medium-(300- 400 rpm) or high (1000-1800 rpm) speed © ABB Group April 4th, 2012 | Slide 26
  • 27. A true mechatronic vision is needed Material Electrics Electronics Mechanics Civil science Maximum efficiency control Light-weight Foundations materials for offshore  Results in each field stimulate Flexible blades design and benefit all other fields Design of Grid-fault larger generators compensation  Interdisciplinary exchange control and circulation of ideas is New essential Reliable generator electrical concepts contacts Mechanical Vibration vibration damping damping algorithms © ABB Group April 4th, 2012 | Slide 27
  • 28. Let’s start: cost breakdown of a wind turbine Picture from [2]  Generator and power converter do not account for much of the cost… (so far)  The gearbox is indeed quite a big part of it © ABB Group April 4th, 2012 | Slide 28
  • 29. The gearbox One of the most unknown things ever (for electrical guys) From: http://www.designnews.com/document.asp?doc_id=230485 From: http://eetweb.com/wind/gearbox-failure-fig1.jpg  Mature product trying to enter a new market  One or more stages between the turbine rotor and the electric generator (epicyclical or parallel axis type)  Mechanical multi-body simulations are performed by suppliers (but not available)  Source of noise (and failures)  Today, closer interaction with turbine manufacturers © ABB Group April 4th, 2012 | Slide 29
  • 30. Noise from the gearbox  There might be some vibrations (mesh frequency and maybe others)  What happens during normal operation? And during a fault? From: S. Li, D. Jiang, M. Zhao, "Experimental investigation and analysis for gearbox fault", Proc. of the World Non-Grid-Connected Wind Power and Energy Conference (WNWEC), Nanjing, China, Nov. 5th-7th, 2010. © ABB Group April 4th, 2012 | Slide 30
  • 31. The mechanical drive train  A classic mechanical engineering work  Quite different structures for different concepts (direct-drive, gearbox-based)  Surprisingly (or not?), few information available for high-frequency behaviour (above 100 Hz)  There might be some resonances... what happens when they are hit? 𝑑𝜔 𝑟𝑜𝑡 1 𝑑𝜙 = 𝜏 𝑟𝑜𝑡 − 𝜙𝐾 𝑠𝑕𝑎𝑓𝑡 − 𝐵 𝑑𝑡 𝐽 𝑟𝑜𝑡 𝑑𝑡 𝑠𝑕𝑎𝑓𝑡 𝑑𝜔 𝑔𝑒𝑛 1 1 𝑑𝜙 = −𝜏 𝑔𝑒𝑛 + 𝜙𝐾 𝑠𝑕𝑎𝑓𝑡 + 𝐵 𝑑𝑡 𝐽 𝑔𝑒𝑛 𝑁 𝑑𝑡 𝑠𝑕𝑎𝑓𝑡 𝑑𝜙 1 = 𝜔 𝑟𝑜𝑡 − 𝜔 𝑑𝑡 𝑁 𝑔𝑒𝑛 From: J. D. Grunnet, M. Soltani, T. Knudsen, M. From: J. Sopanen, V. Ruuskanen, J. Nerg, J. Kragelund, T. Bak, “Aeolus toolbox for dynamic wind Pyrhönen, "Dynamic torque analysis of a wind farm model, simulation and control”, Proceedings of turbine drive train including a direct-driven the European Wind Energy Conference and permanent magnet generator", IEEE Trans. Ind. Exhibition (EWEC) 2010, 20th-23rd April 2010, El., vol. 58, no. 9, Sept. 2011. Warsaw, Poland. © ABB Group April 4th, 2012 | Slide 31
  • 32. The (twisting) tower…  Side-to-side and fore-aft oscillations: impact on power generation Side-to-side oscillations: The sideways oscillation of the tower causes an oscillating angular deflection of the nacelle and thereby superimposes an apparent oscillation in the rotating magnetic flux. This leads to a corresponding power fluctuation. From: T. Thiringer, J.-Å. Dahlberg, "Periodic pulsations from a three-bladed wind turbine", IEEE Trans. En. Conv., vol. 16, no. 2, Jun. 2001 Fore-aft oscillations: Change of the equivalent wind speed over the rotor: change of torque contribution from the wind source. 1 𝑣3 𝑟𝑜𝑡 Torque produced on the shaft: 𝜏 𝑟𝑜𝑡 = 𝜌𝐴 𝑟𝑜𝑡 𝐶 𝑝 𝜆, 𝛽 2 𝜔 𝑟𝑜𝑡 © ABB Group April 4th, 2012 | Slide 32
  • 33. The nature adds some wind effects Wind shear and tower shadow effects Variation of the wind field with the height Disturbance related to tower presence From: D. S. L. Dolan, P. W. Lehn, “Simulation Model of wind turbine 3p torque oscillations due to wind shear and tower shadow”, IEEE Trans. En. Conv., vol. 21, no. 3, Sept. 2006  That’s what individual pitch control is used for! http://www.geograph. org.uk/photo/754033 © ABB Group April 4th, 2012 | Slide 33 Pitch systems
  • 34. Designing the best generator…the PMSG case  Let’s not consider issues like size or weight or mounting procedures  Cogging torque (for synchronous generators) could be an issue Q: number of slots p: pole pairs +∞ 𝜏 𝑐𝑜𝑔 𝜗 𝑚 = 𝑇 𝑘 sin 𝑘𝑁 𝑝 𝑄𝜗 𝑚 + 𝜑 𝑘𝑁 𝑝 𝑘=1 2𝑝 𝑁𝑝 = 𝐻𝐶𝐹 𝑄, 2𝑝 From: N. Bianchi, S. Bolognani, “Design Techniques for Reducing the Cogging Torque in Surface-Mounted PM Motors”, IEEE Trans. Ind. Appl., vol. 38, no. 5, Sept./Oct. 2002, pp. 1259-1265. © ABB Group April 4th, 2012 | Slide 34
  • 35. Designing the best generator…the PM case  Best design for cogging torque reduction, but not elimination From: J. Sopanen, V. Ruuskanen, J. Nerg, J. Pyrhönen, "Dynamic torque analysis of a wind turbine drive train including a direct-driven permanent magnet generator", IEEE Trans. Ind. El., vol. 58, no. 9, Sept. 2011. © ABB Group April 4th, 2012 | Slide 35
  • 36. The grid…why should it be perfect?  Weak grids could introduce voltage asymmetries  Issue for doubly-fed generators (a superimposed 2nd-harmonic torque is generated) ± 2% voltage unbalance ± 10,1% torque unbalance ± 8,7% stator current unbalance ± 0,5% DC-bus voltage unbalance ±7,8% stator active power unbalance From: L. Xu, Y. Wang, "Dynamic modeling and control of DFIG-based wind turbines under unbalanced network conditions", IEEE Trans. Pow. Syst., vol. 22, no. 1, Feb. 2007 © ABB Group April 4th, 2012 | Slide 36
  • 37. Put it all together  An engineering miracle that it actually works  …but how do the components affect the turbine reliability?  ReliaWind Project: http://www.reliawind.eu/  EU funding within the frame of the European Union’s Seventh Framework Programme for RTD (FP7)  450 wind-farm months’ worth of data  350 onshore wind turbines operating for varying lengths of time  35,000 downtime events  ”old type” turbines (probably no direct-drive concepts) © ABB Group April 4th, 2012 | Slide 37
  • 38. Reliability & maintenance aspects ReliaWind project – turbine failure rate From: http://www.reliawind.eu/files/file-inline/110502_Reliawind_Deliverable_D.1.3ReliabilityProfilesResults.pdf © ABB Group April 4th, 2012 | Slide 38
  • 39. Reliability & maintenance aspects Reliawind project - downtime From: http://www.reliawind.eu/files/file-inline/110502_Reliawind_Deliverable_D.1.3ReliabilityProfilesResults.pdf © ABB Group April 4th, 2012 | Slide 39
  • 40. Reliability & maintenance aspects Previous studies From: http://www.reliawind.eu/files/file-inline/110502_Reliawind_Deliverable_D.1.3ReliabilityProfilesResults.pdf © ABB Group April 4th, 2012 | Slide 40
  • 41. Interpreting the reliability figures...  Converters’ reliability should be improved  Pitch control is also very sensitive  Gearbox impact: to be further analysed (lot of effort from manufacturers reported)  We should also don’t forget the scheduled maintenance (i.e. change of the oil in the gearbox) Do we gain something by changing the drive train concept?  High-speed, medium-speed or low-speed generators?  With or without gearbox? © ABB Group April 4th, 2012 | Slide 41
  • 42. Drive train concepts The different approaches  Traditional concept: high-speed generator with gearbox  low raw material and investment costs  high full-load efficiency of the drive train  higher failure rate for high-speed components (e.g. high-speed shaft and generator bearing)  Direct-drive concept: low-speed generator, no gearbox  no fast rotating parts, maybe higher reliability  higher partial load efficiency  more raw materials  Medium-speed concept: medium-speed generator, reduced-stage gearbox  Tries to combine the two above ? © ABB Group April 4th, 2012 | Slide 42
  • 43. Magnets’ price variability Up and downs – direct impact on generators’ price Picture from: http://aussiemagnets.com.au/pages/Rare-Earth-Magnet-Price-Increases.html Picture from: http://www.metal-pages.com/metalprices/neodymium/  Rare-earth materials’ price is going up and down  China dominates the market  Future? © ABB Group April 4th, 2012 | Slide 43
  • 44. Control aspects Mainly converter ones, not pitch control ones © ABB Group April 4th, 2012 | Slide 44
  • 45. The general picture Pitch control and generator control  Pitch control and torque control;  Pitch control: PLC level (turbine manufacturer);  Torque control: frequency converter (supplier)  Power references are accepted as well for the torque control;  Speed-power-torque relationships based on turbine and generator characteristics;  There is one drawback from the electric drive point of view. Where? Picture from [2] © ABB Group April 4th, 2012 | Slide 45
  • 46. The two cases: DFIG and PMSG  DFIG: converter connected to the rotor windings, slip rings  Stator connected to the grid  Smaller converter size (roughly 30% of the rated power) Picture from [2]  PMSG: grid/generator interaction only through the converter  Bigger size of the converter (rated power) Picture from [2] © ABB Group April 4th, 2012 | Slide 46
  • 47. A conventional speed-power curve Picture from [2] © ABB Group April 4th, 2012 | Slide 47
  • 48. The importance of the limitations The PMSG case Picture from [3] © ABB Group April 4th, 2012 | Slide 48
  • 49. The importance of the limitations The DFIG case Picture from [4] © ABB Group April 4th, 2012 | Slide 49
  • 50. Grid-codes compliance • Static and dynamic requirements to be fulfilled by a wind power installation • Static requirements: voltage and power control, power quality (THD, flicker) • Dynamic requirements: dynamic behavior under grid disturbance (fault ride- through, FRT) Picture from [3] © ABB Group April 4th, 2012 | Slide 50
  • 51. Fault ride-through capabilities Turbine connected during temporary faults. Requirements:  voltage dip length  behaviour with a balanced (symmetrical) dip  behaviour with an unbalanced (unsymmetrical) dip. Depending on the country, the wind turbine:  has to stay connected to the power system for a certain time  may not take power from the power system  must produce capacitive reactive current as much as required. © ABB Group April 4th, 2012 | Slide 51 Picture from [3]
  • 52. Reflections (Technical) tendencies and expectations on the turbine side © ABB Group April 4th, 2012 | Slide 52
  • 53. Challenge 1 – The scaling of generators  Coping with: increased weight? Increased disturbances and vibrations? PM availability?  It is not only a raw material problem; it is also a production capacity issue. Drive train Concept comparisons (3MW reference) Speed Full Low Speed Full Medium Speed Full High Converter (LSFC) - concept Converter (MSFC) Converter (HSFC) Direct drive Low Speed Full Drive train Medium Speed Full High Speed Full Converter (LSFC) - Typical size concept Converter (MSFC) Converter (HSFC) Direct drive 70 tons 20 tons 8 tons Relative Typical size Production 70 tons 20 tons 8 tons capacity 4,5 1,5 1 Relative need Production (450%) (150%) (100%) Per unit capacity 4,5 1,5 1 need (450%) (150%) (100%) Efficiency Per unit at nominal 95,1% 98,2% 97,7% load Efficiency at nominal Relative 95,1% 98,2% 97,7% load Magnet weight 10 2,5 1 Relative Magnet weight 10 2,5 1 © ABB Group April 4th, 2012 | Slide 53
  • 54. Challenge 2: the offshore • Harsher conditions in offshore • Wind AND waves effects! • Water depth, soil stiffness: significant effect on the fatigue load/bending • Indirect effects on the drive train (vibrations) • Control may have a bigger role From: J. Sheng, S. Chen, "Fatigue Load Simulation for Foundation Design of Offshore Wind Turbines Due to Combined Wind and Wave Loading“, Proc. of the Non-Grid-Connected Wind Power and energy Conference (WNWEC), Nanjing, China, Nov. 5th-7th,2010. © ABB Group April 4th, 2012 | Slide 54
  • 55. Challenge 3: maintenance http://www.flightglobal.com/blogs/aircraft-pictures/assets_c/2009/01/Eurocopter-EC135.html http://images.pennnet.com/articles/pe/cap/cap_0705pe-dsc06925.jpg  Do we design with maintenance in mind?  What does the offshore challenge require?  How a different drive train topology affect maintenance? http://www.rope-access-photos.com/picture/number395.asp © ABB Group April 4th, 2012 | Slide 55
  • 56. Challenge 4 – Cold climate  Research to enhance power production in cold regions  Blades do play a big role  New materials, new concepts needed  Condition monitoring (not only for blades...)  Converters, generators could be affected by altitude From: Ø. Byrkjedal - Kjeller Vindteknikk, “Detailed national mapping of icing”, Seminar on wind energy aerodynamics - icing and de-icing of WT blades, KTH, Sept. 5, 2011 - Chalmers, Sept. 6, 2011, https://document.chalmers.se/workspaces/chalmers/energi-och-miljo/vindkraftstekniskt/icing-de-icing/oyvind_byrkjedal © ABB Group April 4th, 2012 | Slide 56
  • 57. Do not limit the fantasy Airborne turbines? Savonius style Twind http://en.wikipedia.org/wiki/Airborne_wind_turbine Aerogenerator X KiteGen © ABB Group April 4th, 2012 | Slide 57 http://www.windpower.ltd.uk/index.html http://kitegen.com/press/kiwicarusel_hd_logo.jpg
  • 58. Soft conclusion To ease the listeners before the discussion © ABB Group April 4th, 2012 | Slide 58
  • 59. ABB support to academia The right time for knowledge From: http://www.chalmers.se/ee/swptc-en © ABB Group April 4th, 2012 | Slide 59
  • 60. SWPTC partners Universities  Chalmers University of Technology Industries  ABB  DIAB  GE Wind  Göteborgs Energi  Marström Composite  SKF Sweden  Triventus Energiteknik  WindVector Municipal/Regional/Government  Region Västra Götaland  Swedish Energy Agency © ABB Group April 4th, 2012 | Slide 60
  • 61. SWPTC’s direct-drive wind turbine in Göteborg Main technical data Picture from Göteborg’s harbour From: http://www.goteborgenergi.se/Foretag/Projekt_och_etableringar/Fornyelsebar_energi/Vindkraft/I_drift/Goteborg_Wind_Lab © ABB Group April 4th, 2012 | Slide 61
  • 62. Time-lapse video  http://www.youtube.com/watch?v=jHn1n2tdnRc © ABB Group April 4th, 2012 | Slide 62
  • 63. Thank you! Picture from: http://blog.luciolepress.com/2010/08/05/funny-photo-a-sheep-a-wind-turbine-and-a-rainbow-in-germany.aspx © ABB Group April 4th, 2012 | Slide 63
  • 64. References 1. “Wind in our Sails - The coming of Europe's offshore wind energy industry”, EWEA report, November 2011, http://www.ewea.org/fileadmin/ewea_documents/documents/publications/reports/Offshore_report_web_01.pdf 2. ABB Technical application papers no. 13, ”Wind power plants”, ABB document 1SDC007112G0201 - 10/2011 - 4.000. 3. "ABB wind turbine converters - System description and start-up guide, ACS800-77LC wind turbine converters (840 to 3180 kW)", ABB document 3AFE68802237 Rev B EN 2010-10-25. 4. ABB wind turbine converters- System description and start-up guide, ACS800-67LC wind turbine converters, ABB document 3AUA0000059432 Rev A (EN) 2011-01-14 5. "ABB wind turbine converters - Firmware manual - Grid-side control program for ACS800 wind turbine converters", ABB document 3AUA0000075077 Rev B EN 2011-05-26 6. “Products and services for wind turbines - Electrical drivetrain solutions and products for turbine subsystems”, ABB document 3AUA0000080942 REV A 18.5.2010 #14995 7. “Wind turbine generators - Reliable technology for all turbine applications”, ABB brochure 9AKK104735 EN 04-2009 Piirtek#14426 8. “Medium voltage for wind power PCS 6000 - full-scale converters up to 9 MVA”, ABB document 3BHS275725 E01 © ABB Group April 4th, 2012 | Slide 64