Introduction of the Sway Turbine ST10
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1 IQPC 3 rd International Conference Drivetrain Concepts for Wind Turbines October 2012 Swissôtel Bremen, Germany Introduction of the Sway Turbine ST10 Eystein Borgen CTO Sway Turbine AS 1
2 To be presented: Sway Turbine s new large diameter generator technology with ironless stator core Generator and blade rotor integration Weight and cost advantages Cost of energy prospects compared to state of the art DD turbines 2
3 Who are we? Sway AS founded in Norway 2000 (floating foundations for wind turbines) De-merged into two independent companies in 2010: Sway AS (development of floating foundations for wind turbines) Sway Turbine AS (10MW wind turbine development, for fixed and floating foundations) Sway Turbine AS is a technology company Commercialization of the technology with preferred industrial partner(s)
4 The challenge High Balance of Plant cost per unit related to: Installation In-field transmission (connection by submerged cable) Operation & Maintenance (O&M) Less units, i.e. larger turbines, may reduce the above costs BUT: The cost per MW of the wind turbine itself increases by size (cube-square law) 10MW turbine development with ironless generator stator initiated by Sway Turbine in 2005 to overcome this challenge Approximately 70 engineers have been involved 20 million spent on the development and design phase
5 Top Head Mass comparison Top Head Mass of 5MW-115m diameter rotor Mass conventional DD turbine (te) Sway Turbine scaled to 5MW (te) Comment / 185* *Blade supports in composite (-34%) Top Head Mass of 10MW-164m diameter rotor Mass conventional DD turbine (te) Sway Turbine ST10 (te) Comment Prototype mass (-19%) 570 Expected mass after optimalisation (-26%) 530 Blade supports in composite (-31%)
6 ST10 specification Power regulation: Pitch regulated with variable speed Rated power: 10MW Cut-in wind speed: 4 m/s Cut-out wind speed 28 m/s Nominal rotor speed 12 rpm (tip speed 103m/s) Operational temperature range : deg C (North sea) Extreme temperature range: degc Wind class IEC: IEC S Annual average wind speed: 10,0 m/s Turbulence intensity: IEC B Structural design lifetime: 20 years Main bearings design life time: 40 years + Rotor diameter: 164 m Blade length: 67 m Generator type: PM synchronous axial flux with ironless stator windings Nominal generator voltage: 3.5kV Converter type: Full 4Q converter
7 Why ironless stator core? Ironless stator core No attracting forces. No cogging, forgiving to large air gap variations, flexible generator structure possible More usage of magnets on same dimensions, stator is a part of the air gap Large generator diameter reduces the magnet usage. Iron core Large forces between rotor and stator in case off centered, High stiffness and production tolerances needed. Less magnet usage on same dimensions, due to small air gap Air gap integrety brings on a lot of mass for larger diameters (T ~ k*d^2*l). Large diameter difficult to realize No laminated iron in either the stator or rotor Generator structure lighter
8 Permanent Magnets in Generator Low cost magnets can be used (35-40% lower price) The total cost of PM is equivalent to a conventional PM machine. There is no laminated iron in either the stator or rotor, saving considerable cost relative to conventional direct drive generators The generator structure in the ST10 is 55-60% lighter than in an equivalent size conventional DD PM generator Total cost saving of generator of approx. 20%
9 Optimizing the generator Parametrizized model OD, L, f,ag, and current loading varied machines investigated Sensitivity curves used as design input for the overall design Electro magnetic calc s calibrated with 50kW. scaled prototype
10 Main Features, Generator - Segmented 25m diameter generator Passive air cooling through open air gap Both stator segments and rotor magnets totally encapsulated to resist the offshore environment
11 Generator stator De-moulding of full scale stator segments
12 Generator and blade rotor integration 10MW -164m rotor diameter: Generator mass: Conv. PM DD:373te ST10: 162te 6% less turbine costs Blade mass (3 off) Conv. :133te ST10: 71te 10%-4%= 6% less turbine costs 2 small main bearings on fixed shaft Several suppliers identified for each of the large components Main bearing masses: Conventional PM DD:18te ST10: 2x4te 6% less turbine costs
13 Generator and blade rotor integration - Special direct coupling between blade rotor and generator short torque loop saves weight +air-gap in generator not affected by the rotor blade loads Generator rotor yoke has double function; carries both magnetic flux and edgewise gravity loads between the blades
14 - Generator and blade rotor integration Generator rotor and stator included in global dynamic analysis (air gap clearances and forces) Inertial loads Short circuit Thermal expansion Vibration sources: No gear box No generator cogging Bearings only vibration source
15 Maintenance All components except blades, main structural steel, main bearings and yaw bearing can be replaced by onboard crane and special tools
16 weight (te)) weight (te)) Weight and cost advantages 800,00 700,00 600,00 500,00 400,00 300,00 200,00 100,00 0, , ,00 800,00 600,00 Top head Weight comparison, medium rotor size Conventional PM DD Turbine weight (480W/m2) Sway Turbine weight (480W/m2) Top head Weight comparison, Large rotor size Conventional PM DD Turbine weight (331W/m2) Sway Turbine weight (331W/m2) Size (MW) Issue to keep in mind: Extensive thrust clipping (latest 6-7MW conventional designs) reduces weight of turbine but also reduces annual energy production The ST10 uses only limited thrust clipping The overall Sway Turbine solution should result into 20-30% lower weight and 15-20% lower turbine cost 400,00 200,00 0, Size (MW)
17 Cost of Energy (CoE) input assumptions 490MW wind farm 40km from shore, 30m water depth (fixed) and 120m water depth (floating). IRR of 10.9% on the total wind farm CAPEX Manufacturing costs are based on European costs levels 3 different generator to rotor area ratios; medium (480W/m2), medium to large (405W/m2) and large (331W/m2) The Cost of Energy calculations includes: Electrical grid connection to shore + onshore grid reinforcement 33% additional costs of wind turbine due to offshore application (additional corrosion protection, landing platforms, market factor, warranty risk etc) 10% contingency on total farm Capex and 10% profit to the OEM.
18 Cost of Energy ( cent/kwh) CoE fixed foundations, 10m/s 18 COE - Conventional DD PM turbines versus Sway Turbine (ST), both on fixed foundations, 10m/s site, 10.9%IRR, Foundation and installation calibrated with wind farm operator s cost model. Conventional Turbine DD PM Medium rotor diam. 480W/m2 on fixed foundation Conventional Turbine DD PM Medium to large rotor diam. 405W/m2 on fixed foundation 17 Conventional Turbine DD PM Large rotor diam. 331W/m2 on fixed foundation Sway Turbine (ST) Medium rotor diam 480w/m2 on fixed foundation 16 Sway Turbine (ST) Medium to large rotor diam. 405W/m2 on fixed foundation Sway Turbine (ST) Large rotor diam. 331W/m2 on fixed foundation ST Turbine size (MW)
19 Cost of Energy ( cent/kwh) CoE fixed foundations, 9m/s 20 COE - Conventional DD PM turbines versus Sway Turbine (ST), both on fixed foundations, 9m/s site, 10.9%IRR, Foundation and installation calibrated with wind farm operator s cost model. Conventional Turbine DD PM Medium rotor diam. 480W/m2 on fixed foundation 19 Conventional Turbine DD PM Medium to large rotor diam. 405W/m2 on fixed foundation Conventional Turbine DD PM Large rotor diam. 331W/m2 on fixed foundation 18 Sway Turbine (ST) Medium rotor diam 480w/m2 on fixed foundation Sway Turbine (ST) Medium to large rotor diam. 405W/m2 on fixed foundation 17 Sway Turbine (ST) Large rotor diam. 331W/m2 on fixed foundation ST Turbine size (MW)
20 Cost of Energy ( cent/kwh) CoE floating, 10m/s COE - Conventional DD PM turbine versus Sway Turbine, both on Sway foundations, 10m/s site, 10.9%IRR Conventional Turbine DD PM Medium rotor diam. 480W/m2- on Sway floating foundation Conventional Turbine DD PM Medium to large rotor diam. 405W/m2- on Sway floating foundation Conventional Turbine DD PM Large rotor diam. 331W/m2- on Sway floating foundation 18 Sway Turbine (ST) Medium rotor diam. 480W/m2- on Sway floating foundation Sway Turbine (ST) Medium to large rotor diam. 405W/m2- on Sway floating foundation 17 Sway Turbine (ST) Large rotor diam. 331W/m2- on Sway floating foundation Turbine size (MW)
21 Summary: (apple to apple 10MW-164m rotor diam.) Generator -6% turbine cost Blades -6% turbine cost Main bearing -6% turbine cost Misc. -4% turbine cost Fewer units. Less balance of plant costs.
22 Thank you!
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