Full Scale Testing Facilities. Stuart Herbert Business Development Manager, Engineering and Drive Train EWEC 2010

Transcription

1 Full Scale Testing Facilities Ensuring Reliability for Offshore Wind Stuart Herbert Business Development Manager, Engineering and Drive Train EWEC 2010

2 Narec UK operational locations Head Office Wind, Marine, Sub-Sea & PV Campus Blyth, Northumberland Electrical Networks Division High Voltage Laboratory Newcastle London Office Victoria, London

3 A world class research, development & demonstration centre Blade test facilities Wave test facilities O&M training facilities Drive train test facilities Narec offices Offshore Demonstration

4 Narec: At the Heart of Innovation Independent, Crossdisciplined R&D Platform. Mission: Enable energy industry to advance technology in order to reach sustainability. New breakthroughs in design, deployment and commercialisation of sustainable energy technologies.

5 The Move Offshore Larger turbines installed: E.g. 5MW machines from: RE Power Multibrid Bard Others in development. Minimises number of units to install. Maximises energy yield per unit installed. RE Power 5M at Beatrice. The Engineering Business s BOWTIS and Rambiz vessel.

6 Risks and Problems Difficulties in installing and operating turbines: Variable weather Extreme load cases Marine air / salt water Access for maintenance and repair not guaranteed. With large turbines financial losses from not generating become significant.

7 Need and Solution Need - improved reliability prior to deploying turbines offshore Reliability from enhanced and rigorous testing onshore Solution -Narec is developing a new, large drive train and full nacelle test-rig. Better testing -de-risks turbine deployment De-risking enhances investment attractiveness

8 Drive train / Full nacelle Test-rig 15MW drive system capable of testing the full nacelle of a 10MW turbine: with either gearbox or direct drive includes drive shafts, bearings, gearbox, generator, converter. Mechanical loads: ultimate fatigue. Electrical loads and grid faults.

9 Drive train load cases Mechanical full envelope including side loads: Fx Axial Force Fy Radial Force Fz Radial Force Mx Shaft Torque My Moment about y axis Mz Moment about z axis Max side loading 70,000kNm. Axial load continuous 4,000kN.

10 Full scale nacelle test-rig Existing route to turbine deployment field testing on a wind turbine test site. Limitation can test only with the loads provided by the wind at the test site. Test-rig all combinations of loads can be applied as needed. Result a comprehensive and thorough test of the turbine is conducted. Potential problems identified early before offshore deployment. The key prize a more rapid insertion into service, with increased revenue to manufacturer.

11 Example of Increase in Installation Rate 1200 MW install led Manufacturer - base installation rate Enhanced installation rate 5MW prototype deployed O4 O5 O6 O7 O8 O Year

12 Effect on Cumulative Installation Rate Cumulative MW installed Manufacturer - base installation rate Enhanced installation rate 1GW increase in deployed turbines O4 O5 O6 O7 O8 O Year

13 Narec s Future Facility Development

14 Drivetrain Test Facilities - Update 2 Bidders preparing final designs for project Fujin. Final design to be selected in May/ June Industry involvement discussions with Narec. Project Nautilus Procurement at an advanced stage

15 15MW Drive Train Test Stand Codename Fujin Estimated cost 30-40M $60 million Status Scheduled for commissioning 2011 Facility capability Continuous shaft input power Max torque operational Max torque instantaneous Shaft Speed at max power Speed range Max side loading Radial loading Axial load continuous FAS frequency response Heaviest lift (x2 cranes) Grid supply (loss make up) Grid voltage Supply Test bed 15MW 15000kNm 30000kNm rpm 0 30 rpm knm 8000 kn 4000 kn 2.5 Hz 450T 3MW 3.3kV 50Hz 30m x 10m Testing capability (Phase 1) Overload torque Dynamic fatigue Extreme static Side loading Dynamic fatigue Extreme static Brake emulation Unbalanced rotor Fouling Pitch error Complete nacelle testing and proving Condition monitoring evaluation Control system validation

16 3MW Marine Drive Test Stand (Wind turbine/ generator test possible) Codename Nautilus Estimated cost 15M / $23 million Status Scheduled for commissioning Q Facility capability Continuous shaft input power Max torque Shaft Speed at max power Speed range Max side loading Axial load continuous Heaviest lift Grid supply (loss make up) Grid voltage Supply Test bed DAQ 3MW 5000kNm 6 rpm 0 30 rpm knm 3000 kn 100T 0.9MW 3.3kV 50Hz 34m x 7m 512 channels Testing capability (Phase 1) Overload torque Side loading Dynamic fatigue Extreme static Brake emulation Unbalanced rotor Fouling Pitch error Complete nacelle testing and proving Condition monitoring evaluation Control system validation Immersion testing for cooling or seal validation

17 Basic System: Control and communications Overview of NaREC Testing, R&D, Consultancy Services August 2009 Siemens Brande Stuart Herbert, Business Development Manager Engineering and Drive Train Services

18 Additional Services 1. Strain gauging of ring gears 2. Data acquisition and processing 3. Gearbox assembly and disassembly 4. Analysis of gearbox vibration data 5. Review of component wear following tests. 6. Root cause analysis of failures during testing 7. Gearbox FMEA and test plan review 8. Critical review of gearbox failure modes in relation to proposed test plan 9. Design validation of gearbox or drivetrain 10. Analytical review of gearbox design, safety factors and component lives, leading to recommendations of suitable tests 11. Design of Optimised HALT tests and Interpretation of HALT results 12. Manipulating load cycling to correct errors in order of failures. 13. Drivetrain dynamic analysis and design of dynamic tests; complete with model verification. 14. In field failure mode replication plan; - detailed simulation of drivetrain and available load data to design tests that isolate and then replicate in service failure conditions on the test rig.

19 Narec Blade Test

20 100m Blade test facility (BTF2) Codename BTF2 Estimated cost 15M Status Scheduled for commissioning Q Facility capability Blade length Static winches Hub height (static test) Hub height (dynamic test) Heaviest lift Dynamic testing Maximum hub moment Static tip deflection Dynamic tip deflection Up to 100m Up to 8 winches 9m 14m 65T Hydraulic resonant mass 173 MNn Max 50m Max 24m all directions DAQ NI based with up to 512 strain gauge channels Testing capability Static blade testing Overload (130%, 160%, failure) Design validation Certification (GL, DNV) Stiffness calibration Dynamic blade testing Accelerated fatigue (1M, 5M cycles) Flap Edgewise Combined Pitch bearing testing

21 Offshore Wind Demonstration Zone (100MW 20 Turbines)

22 100 MW offshore wind research & demonstration site 30 60m water depths 20 turbine positions 5-10MW class turbines Novel foundations Electrical networks Operated under lease from TCE Permitting by end 2011 Construction to commence 2012 Codename Project 32 Infrastructure cost 18.5M Status Scheduled for consent 2011

23 Summary - Approved projects 2010 $ 50m -Offshore wind drive train test facility rated at 15MW (Project Fujin) $20m -Rotary drive train test facility rated at 3MW (Project Nautilus) $25m -wind turbine blade test facility with 100m capability $30m -100 MW offshore demonstration project Well over $100m of approved projects in planning/ procurement/ construction

24 Thank you and Questions?