1 Turbina Sapiens in its natural habitat Siemens 6.0 MW Offshore Wind Turbine
2 Turbina Sapiens A different breed of wind turbine The Siemens 6.0 MW offshore wind turbine redefines the wind industry standards for leanness, robustness and lifecycle profitability. Based on Siemens Direct Drive technology, the 6.0 MW turbine has 50% fewer moving parts than comparable geared machines and a towerhead mass of less than 350 tons. This unique combination of robustness and low weight significantly reduces infrastructure, installation and servicing costs, and boosts lifetime energy output. its design criteria irrespective of the conditions. Its advanced diagnostics system provides comprehensive real-time performance data and service requirements and will keep track of lifetime use and its overall asset condition. Even its user interface is clear and intuitive. It is no coincidence that a product of this simple beauty and intelligence has been created by Siemens. We are world leaders in offshore wind power, with over 20 years of experience. Incorporating the aggregate intelligence of Siemens, the 6.0 MW offshore wind turbine thinks for itself. It constantly manages its own operating load helping it remain within
3 Lean, robust and reliable technology Lean The Siemens 6.0 MW turbine is based on proven Siemens direct drive technology, offering the simplest and most straightforward wind turbine design. Replacing the main shaft, gearbox and high-speed generator with only a low-speed generator eliminates two-thirds of the conventional drive train arrangement. As a result, the number of rotating and wear-prone parts is vastly reduced, and a Siemens direct drive wind turbine has 50% fewer parts than a comparable geared machine. Crucially important in offshore applications, of course, is that maintenance requirements drop accordingly. As a rule, the weight of large wind turbines has grown disproportionately to increases in power rating. The Siemens 6.0 MW wind turbine has conclusively broken the trend: with a towerhead mass of less than 60 tons per MW the 6.0 MW wind turbine is genuinely lean. This new low-weight standard for offshore wind turbines offers significant cost benefits in terms of substructure requirements, shipping and installation, all made possible by the use of Siemens tried and tested direct drive technology.
4 Robust Benefiting from our unique offshore experience, the 6.0 MW direct drive wind turbine is designed to exploit the broadest range of offshore environmental conditions. Designed to IEC 1 Standards, the 6.0 MW turbine can be deployed in any known offshore location. The structural capacity of all components is verified by full-scale testing, and Highly Accelerated Lifetime Tests on all main components and the complete nacelle demonstrate their robustness. The entire turbine design is dedicated to offshore application. All external surfaces and systems feature offshore-grade corrosion protection, and the completely enclosed nacelle is fitted with internal climate control. Reliable The Siemens 6.0 MW wind turbine is designed not merely to continue, but to enhance, the legendary reliability of Siemens wind turbines. Simple and robust, the direct drive technology offers the best possible basis for high reliability. The rotor blades combine both lightness and strength through single-cast Siemens IntegralBlade production. The nacelle, housing every part of the power system, forms a self-contained unit delivering medium voltage power to the wind farm grid. As a result the turbine can be fully pre-commissioned onshore, leaving only final connection to be performed after installation. Finally, with the extra nacelle space repurposed as an on-site workshop complete with crane and coffee machine, the maintenance process has been reinvented too.
5 Mould for the B75 Quantum Blade A choice of blades 120m rotor for tip height restricted locations The 120 m rotor, standard equipment with the Siemens 3.6 MW offshore workhorse, also allows the 6.0 MW turbine to be installed in locations where air traffic regulations make it difficult or impossible to exceed a maximum tip height of 150 m. 154m rotor for maximum energy yield The 154m rotor, designed specifically for the Siemens 6.0 MW turbine, has a swept rotor area of 18,600m 2. It therefore maximizes energy yield at offshore locations, from inland waters with moderate wind resources to the most exposed offshore sites. IntegralBlade technology Both the 120m and 154m rotors use blades manufactured with Siemens unique, patented IntegralBlade technology. Instead of glueing the blades together from a number of spars and shells, they are cast in a single process. This not only enables both low weight and enormous strength, there are no glue joins which could potentially expose the blades to cracking and lightning damage. The aerodynamic and structural design of the blade for the 154m rotor is based on Siemens Quantum Blade technology, incorporating unique airfoil profiles and redesigned tip and root sections. The root section uses Siemens flatback profiles to minimize root leakage and provide higher lift. The tip has also undergone a fine-tuning process to enhance lift. As a result, Quantum Blades offer superior performance in a wide range of wind speeds.
6 SWT for maximum output Swept area 18,600m 2 Rated power at a wider range of wind speeds Quantum blade technology SWT for maximum versatility Swept area 11,500m 2 Can be applied to the same foundation as the SWT Suitable for environments where maximum tip height restrictions apply, even onshore
7 To know To learn The Siemens 6.0 MW wind turbine represents all the brainpower of the world s most experienced offshore wind turbine supplier and more. The overall 6.0 MW turbine design is based on highlyproven technology. All the classical virtues of Siemens turbines have been retained ample dimensioning of main components, redundant safety systems, and details designed with the best engineering practices. The ground-breaking IntegralBlade and direct drive technologies have been deployed in the field for years, and many core components are directly linked to turbines produced in large volumes. The main elements of the generator are scaled-up versions of their 3MW forebears. The converters are identical: the bigger machine simply uses two 3MW converters side by side. Adding to the combined knowledge gained from fieldtesting a vast fleet of multi-megawatt offshore wind turbines, Siemens continually strives to acquire in-depth understanding of every element in the wind turbine system. Fundamental to this process is rigorous testing of components and complete systems. At our R&D headquarters in Brande, Denmark, our test facility makes it possible to verify the structural capacity of every component. The facility even enables Highly Accelerated Lifetime Tests on the complete nacelle, simulating 25 years of real life through 3-6 months of overload operation. This process ensures that Siemens legendary quality runs through every component of our wind turbines. Utilizing Siemens standard marinisation technologies, most of which were developed for the world s first offshore wind farm at Vindeby, Denmark, in 1991, the turbine s environmental protection makes it eminently suited to the most severe offshore conditions
8 To sense On top of its knowledge-based and robust technology foundation, the 6.0 MW turbine cleverly exploits an extensive list of proven and new Siemens innovations, including: Superior grid compliance As more wind power enters the grid, there is a greater onus on wind turbine manufacturers to meet stringent grid stability requirements. The Siemens NetConverter system used by the 6.0 MW is designed for maximum flexibility in each wind turbine s response to voltage and frequency variations, fault ride-through capability, and output adjustment. The grid compatibility of Siemens turbines sets the benchmark for the wind industry, and the advanced wind farm control system provides stateof-the-art fleet management. Siemens WebWPS SCADA system The 6.0 MW is equipped with the Siemens WebWPS SCADA system. Via a standard web browser, the system provides a variety of status views of electrical and mechanical data, operation and fault status, meteorological and grid station data. Turbine Load Control (TLC) The Turbine Load Control system continuously monitors the structural loading on the wind turbine. In case the loads exceed normal values, e.g. as the consequence of extreme meteorological conditions, the turbine automatically regulates operation to bring loads back within the design envelope. In addition, the TLC system monitors the accumulated fatigue loading on the turbine, thereby providing key input for fact-based asset management. High Wind Ride Through (HWRT) Wind turbines are normally programmed to shut down if the 10-minute mean wind speed exceeds 25 m/s. This may lead to severe challenges for the grid system if the turbines in large offshore wind farms are shut down more or less simultaneously, e.g. at the passage of a gust front. The Siemens 6.0 MW turbine enhances grid stability with its High Wind Ride Through system, which replaces the fixed-threshold high wind shutdown with an intelligent load-based reduction in output power at very high wind speeds. Turbine Condition Monitoring (TCM ) Siemens unique Turbine Condition Monitoring system compares the vibration levels of the main nacelle components with a set of established reference spectra and instantly detects deviations from normal operating conditions. This allows Siemens to proactively plan the service and maintenance of the wind turbines, as any unusual event can be categorized and prioritized based on severity.
9 Added efficiencies in logistics, pre-commissioning and installation Wind turbine design evolution is affecting far more than just the design itself. The Siemens 6.0 MW turbine s manufacturing, assembly and installation processes are prepared with genuine industrialization in mind, creating a scalable production model that will reduce both delivery times and costs throughout the value chain. A modular nacelle arrangement will reduce onshore port assembly requirements dramatically. And with the entire electrical system including the medium voltage system and the full converter included in the nacelle, pre-commissioning testing can be carried out at quayside, reducing offshore work to a minimum.
10 Further improvements in safety Safety is at the heart of all Siemens operations. From production, through installation, operation, and service, Siemens strives to set the standard. Onshore pre-commissioning and testing significantly reduce the amount of work that needs to be done in riskier offshore conditions. While the simplified direct drive concept in itself reduces service requirements, offshore maintenance has been completely rethought. Service technicians can enter the turbine via the helihoist platform or via conventional tower access, where a new gangway system enables safer access at rough sea conditions. The spacious nacelle, housing far fewer parts than usual, provides technicians with safe and easy access to all key components.
11 The world s first wind farm at Vindeby, Denmark. Installed by Siemens in The turbines in this project are still running today Siemens Wind Power the offshore leader The world is seeing a dramatic increase in the nature and scope of offshore wind power plants. As larger projects head farther out to sea, the reliability of the wind turbine is paramount. Given the logistical challenges of offshore projects, where even the smallest issue can amplify costs, having technology that performs to order under some of the harshest operating conditions on the planet is crucial. With good reason, Siemens is the obvious first choice for assured delivery of high-performing technology. From the very beginning, the company has been the undisputed leader in offshore wind power, and remains so today. Landmark projects include the world s first offshore wind farm at Vindeby, Denmark. Installed in 1991, the 11 turbines in this project are still operating today. The first offshore wind farm using multi-megawatt turbines was also delivered by Siemens. Installed in 2000 in a single arc off Copenhagen, the 20 turbines of the Middelgrunden project remain the iconic symbol of the offshore wind industry. For many years the 165MW Nysted offshore wind farm, installed in 2003, held the record as the world s largest offshore project, a record only broken in 2009 by our 200MW Horns Rev II project. The 1GW London Array project, currently being developed, will once again redefine the capabilities of offshore wind power and pave the way for green energy to become the cornerstone of the global energy mix. Not surprisingly, all of these projects are delivered by Siemens. With over 2GW of installed offshore capacity, the Siemens offshore organisation has deservedly earned the reputation for having the deepest experience and world class project management capabilities. No wonder, then, that despite the immense challenges of installing and commissioning offshore wind farms, every offshore project undertaken so far by Siemens Wind Power has been delivered on time and within budget. Our infrastructure capabilities are no less proven. Siemens has a wealth of experience of building and integrating substations for national grids and is the only company to have designed, built and delivered offshore substations of up to 500 MW. And with our dynamic modelling of wind turbine arrays and grid connections through our Power Technologies International (PTI) teams, we lead in dealing with unknowns at the beginning of a project, rather than during it.
12 The installation of a 6.0MW wind turbine onshore
13 Technical Specifications SWT Rotor Type 3-bladed, horizontal axis Position Upwind Diameter 154 m Swept area m² Speed range 5-11 rpm Power regulation Pitch regulation with variable speed Rotor tilt 6 degrees Blade Type Self-supporting Blade Length 75 m (B75) Aerodynamic profile Siemens proprietary airfoils, FFA-W3-XXX Material GRE Surface gloss Semi-gloss, <30 / ISO2813 Surface colour Light grey, RAL 7035 Aerodynamic brake Type Activation Load-Supporting Parts Hub Main shaft Nacelle bed plate Mechanical brake Type Canopy Full-span pitching Active, hydraulic Nodular cast iron Nodular cast iron Nodular cast iron Hydraulic disc brake Type Totally enclosed Surface gloss Semi-gloss, / ISO2813 Colour Light grey, RAL 7035 Material Fire retardant GFRP with integrated EMC shielding Generator Type Synchronous, PMG, Direct Drive Grid Terminals (LV) Nominal power 6000 kw Voltage 690 V Frequency 50 Hz Yaw system Type Active Yaw bearing Externally geared Yaw drive Electric gear motors Yaw brake Passive friction brake Controller Type Microprocessor SCADA system WPS Controller designation WTC 3.0 Tower Type Cylindrical and/or tapered tubular Hub height Site-specific Corrosion protection Painted Surface gloss Semi-gloss, / ISO2813 Colour Light grey, RAL 7035 Operational data Cut-in wind speed 3-5 m/s Nominal power at m/s Cut-out wind speed 25 m/s Maximum 3 s gust 70 m/s (IEC version) Weights (approximately) Towerhead mass 360,000 kg
14 Quantum Blade 3 Nacelle 2 Unique design and manufacturing process IntegralBlade one-piece moulding for maximum strength Optimized aerodynamics for medium to high wind conditions Increased length for higher energy yield Blade root designed for minimized root leakage and increased lift Direct drive generator Permanent magnet design Totally enclosed, easy to handle and lightweight design Optimum reliability and efficiency 4 Solid and lightweight structure Spacious, ergonomic design maximum serviceability 50% fewer parts compared to geared turbines Cooling Simple and robust LiquidLink water cooling system Top-mounted passive cooling radiators High-efficient two-stage cooling as function of power
15 Published by and copyright 2011: Siemens AG Energy Sector Freyeslebenstrasse Erlangen, Germany Siemens Wind Power A/S Borupvej Brande, Denmark For more information, please contact our Customer Support Center. Phone: Fax: (Charges depending on provider) Wind Power Division Order No. E50001-G310-A186-X-7600 Printed in Germany Dispo c4bs No MCS Printed on elementary chlorine-free bleached paper. All rights reserved. Trademarks mentioned in this document are the property of Siemens AG, its affiliates, or their respective owners. Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.
16 Oceans of opportunities Complete solutions for the entire life cycle of offshore wind farms Answers for energy.
17 Sustainable profit Offshore wind power firmly established as a viable source of renewable energy 2
18 Due to higher, more consistent wind speeds at sea, offshore wind turbines can generate substantially more energy than onshore wind turbines. Offshore wind farms may reach capacity factors in the range of 50%. Even considering the planning constraints relating to shipping lanes, fishing, bird migration, and the like, the world has abundant space for offshore projects. Offshore wind power has its challenges, however. Conditions during installation, operation, and maintenance may be harsh, and the product requirements are high. It takes a special supplier to provide stable, long-term offshore partnerships. When it comes to offshore wind power, no supplier can match Siemens in terms of experience and reliability. Siemens has a proven track record for delivering offshore projects on budget. From the world s first offshore wind farm more than 20 years ago to today s largest offshore wind farms, all projects have been delivered on time and on budget. All projects operate with high availability. Optimized processes across the complete project life cycle make Siemens a stable, reliable, and trustworthy business partner. 3
19 Siemens offers integrated solutions and services that perfectly meet the high demands along the entire wind energy conversion chain Number one in offshore Grown from experience Siemens has developed a broad realm of experience and excellent skills in delivering offshore projects. From the outset Siemens has played a key role in founding the offshore wind industry by installing the world s first offshore wind farm in Vindeby, Denmark, in The 11 turbines installed in this pioneering project are still in excellent condition. The turbines have consistently operated at high availability, reflecting the unique combination of product quality and dedicated offshore modifications. Now, amidst the current boom in offshore projects, Siemens still leads the world in offshore technology. With an installed offshore capacity of more than 2 GW and a high order intake, the company remains the preferred supplier of wind turbines to offshore projects. Furthermore, unlike any other offshore wind turbine supplier, Siemens offers equipment for the entire energy value chain, from the wind turbine to net conversion, efficient feed-in to smart energy grids, and power distribution. Making history, over and over again The trend in offshore wind farms is towards larger and more complex projects, located further from shore, in deeper waters, which are exposed to severe sea and wind conditions. Utilizing the knowledge gained from more than two decades of experience in the offshore environment, Siemens is equipped to handle the challenges of this unique environment. Siemens has not only supplied the world s first, but also the world s largest offshore projects. For several years, the 165-MW Nysted offshore wind farm held the record as the largest offshore project. In September 2009, that record was broken by the 200-MW Horns Rev II project. The 500-MW Greater Gabbard project, currently under instal lation, will raise the bar again. And the world s first 1-GW project, London Array, will represent yet another stride towards large-scale, green energy supply. All record projects and all feature Siemens wind turbines. 4
20 Siemens can also supply turnkey grid connections for wind farms, including construction of the offshore transformer station Delivering on a promise Delivering projects on time and within budget is one of Siemens major strengths. Since the offshore industry was established in 1991, and despite the logistical challenges associated with offshore installation works, every Siemens offshore project has been completed within budget and on time. This unique track record was not established by chance. It requires deep respect for the challenging conditions, detailed planning, and superior and consistent project management skills required during the execution phase. All of which are key elements of the Siemens offshore model. The Siemens offshore model has been proven to deliver results. Everywhere, every time. Providing the best technology When access conditions are difficult and when high wind resources make every hour count, reliability is the key to profitability. Over the years, Siemens turbines have set the standard for robustness and re liability. Designed with offshore applications in mind, the turbines have a rugged, conservative structural design, automatic lubrication systems with ample supplies, climate control of the internal environment, and a simple generator system without slip rings. These and many other high-quality design features provide exceptional reliability with long service intervals. Siemens turbines are built to last. 5
21 Maximized potential across the board A well-proven and robust installation process Components delivery to port Siemens transports all components, parts and equipment to a harbor site close to the proposed wind farm. The site serves as the assembly and embarkation station for the project. Pre-assembly of components Once all necessary components have been delivered, pre - assembly commences. Siemens designs, plans, and executes all work processes to minimize the amount of work required offshore. Storage of rotor blades Specialists place rotor blades in the storage area, ready for shipment to the site. The blades are stored in special transport fixtures used on the installation vessel. In some cases, blades are shipped as completed rotors. Load out Service technicians load all components onto the transport vessel in accordance with the project plan. Siemens proprietary fixtures and sea fastenings are used for safe transport and working procedures. 6
22 Experience counts in installation Drawing on more than two decades of experience in successfully delivering offshore projects on time and within budget, Siemens knows exactly what it takes. Over the years, a large number of aspects of installation methodology have been tested and analyzed. Gradually, best practices have been established, and even though the process often needs to be adjusted to fit projectspecific re quirements, the fundamental approach remains the same. By thoroughly understanding the complexity and challenges associated with implementing an offshore project, and by establishing optimized installation processes, Siemens maximizes the value of each link in the chain, providing minimum costs and optimum predictability in project delivery. Installation scope The Siemens installation scope is tailored to the needs of individual customers. One classical approach is an all-in equipment supply where Siemens provides the installation vessels. In another approach, the customer provides the installation vessels and Siemens carries out the work. Further alternatives are possible, depending on the customer s skills and objectives and a joint evaluation of the most optimal solutions. Irrespective of the installation scope, Siemens customers will always benefit from the reliability and robustness of a proven installation process. Transport A transportation vessel takes the components to the site. Transportation time can vary from site to site based on many factors, including the vessel type, the distance from the port of origin to the site, and weather conditions. Installation The transport vessel arrives onsite. The tower is lifted onto the foundation. Service technicians then lift the nacelle onto the tower and the rotor is mounted on the nacelle, either as a completed unit or in single-blade installation. Commissioning Once the turbine is mechanically completed and energized, it is thoroughly tested for commissioning. Some tests are auto matically performed by the turbine computer controller, while others are performed by the service crew. Service and maintenance Siemens provides service and maintenance during the warranty period. Long-term service and maintenance contracts are also available from Siemens to ensure years of trouble-free operation. 7
23 Blades on a service vessel before mounting The inside of an SWT-3.6 Simply the best The fundamental pillars the best turbines and the best service Turbine types offered Two Siemens turbine types are offered for offshore projects, the SWT-2.3 and the SWT-3.6. Both types offer the same key features. Rotor The rotor blades for Siemens offshore turbines are made of fiberglass-reinforced epoxy, manufactured using the proprietary Siemens IntegralBlade process. Unlike conventional wind turbine blades, the Integral- Blades are cast in one piece in a closed process. This process leaves no weak points at glue joints and provides optimum quality. The aerodynamic design represents state-of-the-art wind turbine technology, offering maximum energy extraction from any available wind resource, and the structural design lives up to the usual Siemens safety factors in addition to all industry codes and standards. The blades are mounted on double-row pitch bearings fitted to a large rotor hub. The pitch actuation system is hydraulic, offering maximum robustness and safety. Like the turbine itself, the blades are designed to last. Nacelle The nacelles of the Siemens offshore turbine types are ideally suited for severe offshore operating conditions. Major components such as the main shaft, the gearbox, and the yaw system are all of particularly heavy dimensions. The automatic lubrication systems have redundant lubricant reserves to enable continued operation even if scheduled maintenance is severely delayed by weather. The nacelle canopy is metallic to provide optimum lightning and fire protection. All safety systems are fail-safe and have layers of redundancy. Fully integrated climate control and comprehensive offshore-grade surface protection contribute to long service life. Overall performance is well-proven and all details are designed using market-leading engineering practices. Tower Siemens offshore turbines are normally mounted on tubular steel towers fitted with internal personnel hoists. A prefabricated power module is located at the bottom of the tower and provides the platform for the power converter, the turbine transformer, and the medium-voltage switchgear. 8
24 Blades being transported before mounting Service technicians at work on an SWT Grid performance Grid stability requirements grow as more wind power is fed into the grid. Siemens also sets the standard in the field of grid compliance. Power conversion is implemented with Siemens unique NetConverter system. This system uses full conversion of the power generated, efficiently decoupling generator and turbine dynamics from the grid. The NetConverter system offers maximum flexibility in the turbine response to voltage and frequency control, fault ride-through, and output ad justment. As a result, Siemens turbines comply with all relevant grid codes. Service and maintenance Reliable and competent service and maintenance is almost as important for profitable offshore wind power projects as selecting the right turbine equipment. Due to sea and wind conditions, access may be restricted for long periods, and the losses resulting from trivial errors could be substantial. Siemens is known as the most experienced and reliable offshore service provider, with an unmatched track record for maintaining optimum availability. Central demand planning, excellent diagnostics capabilities, and competent field service teams offer fast response times and wellplanned service operations. The service offering can be adjusted to match the owner s skill sets, objectives, and interest in participation. Irrespective of the service scope, Siemens support enables owners to maximize revenue and earnings throughout the project lifetime. Monitoring Siemens offshore turbines are equipped with the unique Siemens WebWPS SCADA system. This system offers remote control and a variety of status views and useful reports from a standard Internet browser. The status views present information such as electrical and mechanical data, operation and fault status, meteorological data, and grid station data. Voltage and frequency control, and other grid-related adjustments, can be implemented by the integrated park pilot utility in the WebWPS SCADA system. In addition to this WebWPS SCADA system, the turbine is equipped with a web-based turbine condition monitoring (TCM ) system. The TCM system con tinuously carries out precise condition diagnostics on main turbine components and gives early warning of possible component problems in real time. Based on the TCM system, Siemens can detect and correct any problems at the earliest possible stage, thereby reducing maintenance costs, optimizing availability, and maximizing energy output. New turbine technology Siemens has installed the first prototype of its next generation offshore wind turbine at the Høvsøre test site in Denmark and has initiated the first trial operation. The new SWT wind turbine, with a power rating of 6.0 megawatts and a rotor diameter of 121 meters, uses Siemens innovative direct drive technology and the well-proven B58 blade. The wind turbine will also be available with a rotor diameter larger than 150 meters. Serial production is planned for