Simplified Design as Secret to higher Performance: Siemens Direct Drive Technology

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1 Simplified Design as Secret to higher Performance: Siemens Direct Drive Technology Formatvorlage Gunnar Liehr, Head des Untertitelmasters of Sales Wind Power durch Region Klicken Central bearbeiten siemens.at/future-of-energy

2 Agenda Evolution DD Plattform Design & Holistic Portfolio Outlook Page 2

3 The Direct Drive Technology Project : Selection : Design 2008: Component Testing : Field Testing Choice of preferred generator technology determined First prototype generators designed and manufactured by sub-supplier Initial component testing in preparation first installed proof-of-concept turbine Proof-of-concept turbines installed in Tim, Denmark in 2008 and 2009 Patent on a segmented generator design granted to Siemens Wind Power Siemens DD Generator Stator segment. The generators are built by sup-suppliers Siemens DD generator test bed. In addition, the main bearing test program was initiated in st of two DD Proof-of-concept turbine installed in Tim (DK). Installed in 2008 Page 3

4 Proven technology through field testing: today, +900 Siemens D3 turbines installed or ordered Selection Design Testing Field testing Prototypes Pre-Series Serial production 146 x SWT * 1st prototype (3.0) (Drantum) Prototypes and Pre-series Arctic Circle (Havøygavlen) 2 nd multi WTG project (Vester Barde) 2 nd prototype (2.3) (Høvsøre) 1 st prototype (3MW) SWT x SWT * Arctic Circle SWT st multi WTG pjct SWT nd multi WTG pjct SWT st prototype (2.3MW) SWT nd prototype (2.3MW) SWT Total grid connected DD Prototypes 12 1 st multi WTG project (Lejbølle) 1 st prototype (2.3) (ECN) Under installation:* SWT : 82 SWT : 136 SWT : 77 Signed orders* Page D3 turbines * As of March 2013.

5 Siemens Wind Power test facilities; 150 mill. Euro invested in Aalborg and Brande Test center Brande (DK): Back-2-Back test (1) Main bearing test (2) Blade bearing test (3) Performance test Low Load test Vibration test Yaw test Climate test Misc. tests Brande Test centre 1 Test center Aalborg (DK): Static testing Dynamic testing Flap wise testing Edgewise testing Material testing Page 5 Aalborg Blade factory and Test centre

6 Testing at R&D facilities running in parallel with operating prototypes Preparation of dynamic testing of the B75 blade at the test stand in Aalborg, Denmark Back-to-Back testing of the SWT-6.0 drive train, at the R&D center in Brande, Denmark Low load testing of the SWT-6.0 electricals at the R&D center in Brande, Denmark Page 6

7 SWT MW Direct Drive turbine with 154 m rotor Technical data SWT-6.0 IEC class: IA Nominal power: 6,000 kw Rotor diameter: 154 m Blade length: 75 m Swept area: 18,600 m 2 Hub height: Site specific Tower head mass: < 360 t Power regulation: Pitch regulation, variable speed Prototype installed: 2011 (SWT ) 2012 (SWT ) Pre-series release: Serial production/installation: 2013/2014 Page 7

8 Agenda Evolution DD Plattform Design & Holistic Portfolio Outlook Page 8

9 Key direct drive design decision results in weight and dimension advantages Generator designs Outer rotor design High stiffness of stator structure Segmented concept feasible without excessive structural reinforcements Simple cooling arrangement Classical inner rotor topology Innovative outer rotor topology Outer diameter: Weight: 5.0 m 60 tons Outer diameter: Weight: 4.2 m 50 tons Page 9 SWT-3.0: nacelle transportation

10 Wind turbine designed to bring down the cost of energy Increased efficiency due to minimum losses in drive train, generator and cooling system Passive cooling radiator Reduction in number of wearing parts due to the simplified drive train Direct Drive generator Compact and light weight design (nacelle Ø = 4.2m nacelle weight = 78 t) SWT-3.0: nacelle Page 10

11 Patented IntegralBlade manufacturing, ensuring blade robustness Integral blade manufacturing IntegralBlade technology; manufacturing process invented by Siemens One-shot process eliminating the presence of glue joints for increased robustness Process based on vacuum-assisted resin transfer molding No gel coating as part of the manufacturing process allows for visually inspection. Siemens blade manufacturing Page 11

12 New blade design for improved performance and reduced loads Root section Tip section Chord B49 blade SWT meters B53 blade SWT meters B55 blade SWT meters Blade innovations Optimized Maximum Chord Flat back root design Pre-Bent tip design B53: Aero Elastically Tailored Blade design Page 12

13 Bolted Steel Shell tower - An innovation allowing for higher hub heights Bolted steel shell tower Description Tower type for m m hub height Competitive for IEC II and III sites Bolted solution only limited weldings Advantages Optimized transport standard trucks Automated production method Cost optimized for high hub heights Bolted Steel Shell Tower Page 13

14 A complete re-interpretation of the tower design, bypassing conventional constraints Automated production and painting for increased consistency and process control Optimized transport solution requiring only standard trucks and trailers Onsite assembly and installation, allowing for increased bottom diameter Intelligent service solution: No additional requirement of bolt tensioning Page 14

15 Onshore small DD Portfolio IEC I and II product portfolio, based on one core technology SWT SWT SWT IEC class: IEC IA IEC IA IEC IIA Nominal Power: 3000 kw 3000 kw 3000 kw Core Technology Nacelle weight: 78 t 78 t 78 t Transport weight: 75 t 75 t 75 t Rotor diameter: 101 m 108 m 113 m Blade Innovations Rotor weight: 60 t 60 t 67 t Blade length: 49 m 53 m 55 m Swept area: 8,000 m 2 9,150 m 2 10,000 m 2 Hub height: Tower concepts Tower Concept: Tubular steel Tubular steel Tubular steel and Bolted Steel Shell Page 15

16 Agenda Evolution DD Plattform Design & Holistic Portfolio Outlook Page 16

17 Evolution of Windpower technology over the last 30 years - From 30 Kilowatt to 6 Megawatt m 157 m m m 100 m m 22 m 35 m m m 60 m Generation KW 1993 / Generation KW 1996 / Generation KW 2002 / Generation KW Kölner Dom heute 5. Generation KW Siemens AG 2013 All rights reserved. Seite März 2013

18 and from 11 meter to more than 150 rotor diameter 6 MW 79,8 Meter 11 Meter 35 Meter 154 Meter 30 kw 450 kw Siemens AG 2013 All rights reserved. Seite März 2013

19 SWT : Installation of the world s largest operating wind turbine, summer 2012 Transportation of the first B75 blades, from blade factory in Aalborg, Denmark to test centre Oesterild Transportation of SWT-6.0 Nacelle from factory in Brande, Denmark to test centre Oesterild Installation of the 154 meter rotor on the SWT-6.0 prototype at test centre Oesterild, August 2012 Page 19

20 All necessary cost engineering levers are known Onshore wind is on a good way to achieve grid parity soon Levelized Cost of Electricity (LCoE) Global LCoE Comparison LCoE 2020 Technologie Cost optimization products Prozessoptimisation Partnering Service Gas- und Dampfturbinenkraftwerke Kohlekraftwerke CAPEX (inkl. BoP) + OPEX + FUEL Kernkraftwerke 5 7 LCoE = Wind Onshore 3 7 Lifetime Electricity Production Wind Offshore <10 Technology Solar PV EUR ct / kwh Siemens AG 2013 All rights reserved. Seite März 2013

21 Summary: The Siemens D3 Platform, building blocks to suit any site Core technology Blade innovations Tower concepts One nacelle Applicable across the entire Siemens D3 product portfolio Three rotors variants Allowing for application in all IEC conditions, without compromising structural loading Two tower concepts For improved performance and optimized transportation Siemens AG 2013 All rights reserved.

22 Thank you for your attention! Gunnar Liehr Vicepresident Head Central & Eastern Europe Siemens AG Energy Sector Wind Power Division Europe, Middle East and Africa E W EMEA ON S2 Lindenplatz Hamburg, Germany Phone: Fax: siemens.at/future-of-energy Page 22

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