Copyright by DOOSAN Heavy Industries & Construction Co All Rights Reserved. Development of 3MW Class Offshore Wind Turbine(WinDS3000 TM )

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Korea-Denmark Energy Conference September 7, 2009 Copyright by DOOSAN Heavy Industries & Construction Co.

1 Development of Doosan 3MW Offshore Wind Turbine System Do-Gyoon Kim, Staff R&PD Engineer Wind Power Engineering Team Power Plant Doosan Heavy Industries & Construction Co. Ltd. Korea-Denmark Energy Conference September 7, 2009 Copyright by DOOSAN Heavy Industries & Construction Co All Rights Reserved. Contents Company Introduction Status of Korean Wind Energy Market & Policy Development of 3MW Class Offshore Wind Turbine(WinDS3000 TM ) Blueprint of Korea-Denmark Wind Energy Cooperation 2 2 1

I. Company Introduction Location Global Leader in Power and Water Seoul Changwon Head Quarter : Changwon, Korea Foundation year : 1962 No. of Employee : 5,000 Sales : 3,200 mil.

2 I. Company Introduction Location Global Leader in Power and Water Seoul Changwon Head Quarter : Changwon, Korea Foundation year : 1962 No. of Employee : 5,000 Sales : 3,200 mil. EUR in 2008 Organization : 5 Business groups and 5 Departments 3 3 I. Company Introduction Global Networks Asia Beijing Taipei Kuala Lumpur Tokyo CHICO(Sri Lanka ) Shanghai New Delhi Hanoi Bangkok Mumbai HANVICO(Vietnam) :Power & Industrial Plant HPL(Papua New Guinea) Doosan E&S(India) Europe Frankfurt DOOSAN IMGB(Rumania) : Steel Manu./ Casting&Forging Doosan Bobcock Energy Middle East Dubai, Abu Dhabi (UAE) Kuwait Riyadh (Saudi Arabia) Tripoli Branch (19) Corporation (4) Subsidiary (9) North America New Jersey (US) Schenectady (US) Pittsburgh (US) Windsor (US) Pittsburgh 4 2

II. Status of Korean Wind Energy Market & Policy Korean Wind Resource Source : KIER (Korea Institute of Energy Research) Korean Wind Resource Theoretical Available Onshore: 186.5 18.

3 II. Status of Korean Wind Energy Market & Policy Korean Wind Resource Source : KIER (Korea Institute of Energy Research) Korean Wind Resource Theoretical Available Onshore: TWh/yr Offshore: TWh/yr Source : A Renewable Energy Whiter Paper 2005, Ministry of Knowledge Economy, Korea Korean Wind Capacity Forecast Year Cumulative Capacity Installed (MW) Growth rate (%) 63 % 48 % 54 % 42 % 40 % 35 % Source : BTM Consult ApS March II. Status of Korean Wind Energy Market & Policy Korean Local Manufacturer Model Rated Power Rotor Dia. Class Description DOOSAN WinDS3000 3,000 kw 91.6 m IEC IA 06.09~ (Oct, 09, prototype test HYOSUNG HS-48 HS kw 2,000 kw 48 m 90.6 m IEC IA IEC IIA scheduled) ~ (DEWI-OCC type cert.) UNISON U-50/54/57 U-88/ kw 2,000 kw 50/54/57 m 88/93 m IEC I/II/IIIA IEC II/IIIA ~ (DEWI-OCC type cert.) ~ (DEWI-OCC type cert.) HANJIN HJWT1500 1,500 kw 70 m IEC IIA ~ (Prototype testing) SAMSUNG SAMSUNG 2,500 kw 90 m IEC IIA ~ (DEWI-OCC type cert.) HYUNDAE HQ1650/ kw 2000 kw 77 m 76/86/93 m IEC IA IEC I/II/IIIA Developing Developing HYUNDAE ROTEM HR-D86 2,000 kw 86 m IEC IIA Developing ~ (Developing) 6 6 3

II. Status of Korean Wind Energy Market & Policy 2030 Vision & Target of Korea Wind Industry Korea Wind Industry

Target 10% (7.5 GW) 2030 Global market 158 GW Target 20% (31.

Zealand Ireland Finland Austria Germany Spain Korea Denmark Czech Rep.

Cumulative Cumulative RPS (Renewabl e Portfolio Standard) 2011 Top 20 2020 Top 5 2030 Top 1 Source : Ministry of

4 II. Status of Korean Wind Energy Market & Policy 2030 Vision & Target of Korea Wind Industry Korea Wind Industry Support Policy PTC (Product Tax Credit) USA 2011 Global market 33 GW Target 2% (660 MW) 2020 Global market 75 GW Target 10% (7.5 GW) 2030 Global market 158 GW Target 20% (31.6 GW) 2030 Global wind market leader Green Certificate New USA* Italy England Australia Belgium Norway Japan New Zealand Ireland Finland Austria Germany Spain Korea Denmark Czech Rep. France Portugal Greece Swiss Canada Holland Hungary FIT (Feed In Tariff) Korea Wind Energy Supply Trend New Cumulative Cumulative RPS (Renewabl e Portfolio Standard) 2011 Top Top Top 1 Source : Ministry of Knowledge Economy, Renewable Energy RD&D Strategy 2030 Source : Korea Power Exchange ( 7 Design Requirements of WinDS3000 TM Component & System Design Concepts: High RAMS + Low COEMulti-Body Dynamics Analysis Integrated Drive Train Enhanced Blade Design Advanced Control System PMG + Full Power Converter Simulation-Driven Hub & Mainframe Design Innovative Gearbox Design SCADA & CMS High RAMS & Low COE High Reliability Maximized Availability Reduced O&M Cost 8 8 4

Specifications of WinDS3000 TM Power regulation Pitch regulated Electrical with variable speed Grid frequency 50/60 Hz Operating data Converter type Full power conver Rated power 3,000 kw Generator

5 Specifications of WinDS3000 TM Power regulation Pitch regulated Electrical with variable speed Grid frequency 50/60 Hz Operating data Converter type Full power conver Rated power 3,000 kw Generator type Synchronous PM Wind class - IEC Ia Voltage 690 V Cut-in wind speed 4 m/s Rated wind speed 13 m/s Main dimension Cut-out wind speed 25 m/s Blade length 44 m Operational temperature range -20/50 o C Max. chord 4.15 m Sound power level at 11.5 m/s db Nacelle dimension (height x width x length) 5.5 x 4.5 x 12.6 m Rotor Number of blade 3 Rotor diameter 91.3 m Swept area 6,539 m2 Rotor speed (rated) 8 ~ 20.4 (15.71) rpm Gearbox Type 2 planetary + 1 parallel Gear ratio Tower Type Height Tubular steel tower m 9 9 Blade Design & Manufacturing EU (basic model) Enhanced Blade Design Improvement Aerodynamic load reduction - Slim blade has been applied for load reduction Material & manufacturing process changes - OCF111A(GFRP) SE1500 (GFRP) - Hand lay-up Vacuum infusion Structural design and analysis - Optimized internal structure for weight reduction ton (basic model) 9.9 ton (design model) Length Weight Specifications : 44 m : 10.3 tons (incl. T-Bolt & Nut & Platform)

Efficiency, % 10-09-2009 Innovative Gear Box Design for Light Weight and

92 Rotating housing Flexible pin Differential gear Compact Size

Generator with Full Power Converter System Efficiency - Windpower 2007,

20 Wind Speed PMG Excellent efficiency in partial load Increased annual

region Full Power Converter No direct connection between grid &

6 Efficiency, % Innovative Gear Box Design for Light Weight and High Reliability 2 Planetary / 1 Parallel Transmission ratio: Rotating housing Flexible pin Differential gear Compact Size Multi-planet Light Weight High Reliability Permanent Magnet Generator with Full Power Converter System Efficiency - Windpower 2007, GE 100 G/B PMG AC/DC DC/AC 50 PMG DFIG Full Power Converter Wind Speed PMG Excellent efficiency in partial load Increased annual energy production - General : 2% more AEP - Superior AEP in low speed region Full Power Converter No direct connection between grid & generator Easy 50/60Hz grid frequency conversion System protection from grid impact Grid-friendly system

7 Control System Torque Control Maximizing power production below rated wind speed Drive Train Damper Reducing gearbox torque vibration - by active control of generator torque Power Control Limiting power production above rated wind speed Tower Control Reducing tower vibration and load Individual Pitch Control Reducing load fluctuation due to wind shear - increase fatigue life of blade & drive train Condition Monitoring System (CMS) & SCADA TCS Sensors (Turbine Control System) Key phaser MASTER SCADA Accelerometer Pressure CMS Server Temperature Fiber strain Wind Turbine CMS Field Access Configuration S/W Direct data access & analysis Client PC Configuration S/W Display S/W

Cooling System Gearbox cooling system - Air to oil cooler -

cooler with shaft integrated fan - Pump number : 2 EA Heating

number : 2 EA : 1 EA for each inverter (master/slave) Nacelle

Aspirator/Ventilation Duct Thermal Exchange 15 15 III.

Internal Maintenance Crane : Concept Conventional O&M System

8 Cooling System Gearbox cooling system - Air to oil cooler - Pump number : 2 EA Generator cooling system - Water to air cooler with shaft integrated fan - Pump number : 2 EA Heating Air Inlet Inverter cooling system - Air to water cooler - Pump number : 2 EA : 1 EA for each inverter (master/slave) Nacelle cooling system -Air to air heat exchanger Cooled Air Vent Aspirator/Ventilation Duct Thermal Exchange III. Development of 3MW Class Offshore Win Turbine (WinDS3000 TM ) Internal Maintenance Crane : Concept Conventional O&M System Doosan Way Large Jack-up Barge + Crawl Crane Small Jack-up Barge + Winch Pulley System

Advanced Design Feature Enhanced blade design & manufacturing Weight reduction due to Integrated drive train Innovative

system Advanced control system Condition monitoring system Offshore Application Isolated nacelle system Easy maintenance

17 Back to Back Test for Gearbox Back to Back Test Load Test No Load (step 1) Full Load (step 10) Test Setup Low Temp.

9 Advanced Design Feature Enhanced blade design & manufacturing Weight reduction due to Integrated drive train Innovative gearbox concept (rotating housing, differential gear, flexible pin) Permanent magnet generator with full power converter system Advanced control system Condition monitoring system Offshore Application Isolated nacelle system Easy maintenance crane concept Anti-corrosion surface coating against salinity and humidity WinDS3000 high RAMS and low COE requirements Back to Back Test for Gearbox Back to Back Test Load Test No Load (step 1) Full Load (step 10) Test Setup Low Temp. Test Simulated condition at -15 VG1000 instead of VG320 5 Operating Temp. Certification Test with witness Inspection Completed

distribution by 2 whiffle tree sets Procedure Flapwise max

Procedure Flapwise & Edgewise direction 1 st & 2 nd Natural

Generator Back to Back Test Guideline IEC 61400-1 Rotor

Inspection Dielectric Test & No Load Test Phase Rotation

Test Temperature Rising Test Test Setup 2009.

10 Full-Scale Blade Static Test Test Loads Static Test According to GL Guideline Load distribution by 2 whiffle tree sets Procedure Flapwise max & min (2 Steps) Edgewise max & min (2 Steps) Modal Test Procedure Flapwise & Edgewise direction 1 st & 2 nd Natural Frequencies with Accelerometer Back to Back Test for Generator Back to Back Test Guideline IEC Rotor AssemblyRotor Balancing test Stator Wiring Test Visual Inspection Dielectric Test & No Load Test Phase Rotation Test Over Speed Test Demagnetization Test Load & Efficiency Test Temperature Rising Test Test Setup Measure Winding & Insulation Resistance Vibration, Sound Level, THD* *THD: Total harmonic distortion

11 Acquisition of C-Design Assessment Installation Procedure Finished & Scheduled Foundation Construction Tower Transportation Erection Prototype Test ( ) ( ) Blade Transportation Nacelle Transportation ( ~) ( ) ( ) ( )

3MW Onshore Prototype Test Schedul e Project Scope PJT Term : 09. 05 ~ 11.

Test Operation Power Curve Assessment Load Assessment Noise Assessment Type Certification 23 23 3MW Offshore Prototype Test Schedul e Project Scope PJT Term : 09. 05 ~ 12.

12 3MW Onshore Prototype Test Schedul e Project Scope PJT Term : ~ (24 months) Site : Kimnyeong, Jeju Prototype WinDS3000 Installation Operating tests and Measurements Type Certification 1/ /4 3/4 4/4 1/4 2/4 3/4 4/4 11 1/4 2/4 Foundation Erection & Test Operation Power Curve Assessment Load Assessment Noise Assessment Type Certification MW Offshore Prototype Test Schedul e Project Scope PJT Term : ~ (36 months) Site : Offshore near Woljeong, Jeju WinDS Unit manufacture Offshore foundation manufacture and installation Offshore windfarm operation and maintenance /4 2/4 3/4 4/4 1/4 2/4 3/4 4/4 1/4 2/4 3/4 4/4 1/4 2/4 3/4 4/4 2/4 12 WinDS3000 Manufacture Foundation Design Foundation Manufacture Erection O&M

Doosan Vision for Wind Energy Business World Best

Crank Shaft 8 th World Best Product Offshore Wind

Blueprint of Korea-Denmark Wind Energy Cooperation

contract Employing Vestas s retired and senior

Korean wind power manufacturers and related agencies

technology and quality Including prominent Korean

Including leading Danish component makers as Korean

13 Doosan Vision for Wind Energy Business World Best Products Desalination Plant Work Roll HRSG Mould Steel Crank Shaft 8 th World Best Product Offshore Wind Turbine Cast Steel 25 IV. Blueprint of Korea-Denmark Wind Energy Cooperation Reliable market approach and extension by licensing contract Employing Vestas s retired and senior technical engineers as managers and consultants of Korean wind power manufacturers and related agencies Utilizing Korea as new Asian service hub to consider technology and quality Including prominent Korean component makers as Vestas s major supply chain Including leading Danish component makers as Korean major supply chain Mutual patent cross-licensing Foundation of collaborative research center Mutual investment, etc 26 13

14 Thanks for Your Attention!! 27 I. Company Introduction History

II. Status of Korean Wind Energy Market & Technologies What is

Energy converting system from wind to electrical power Theoretical

3% The efficiency limited to 20~50 % due to aerodynamic,

Grid 6 Rotation Energy Increase Speed Electric Energy AD to DC or

Status of Korean Wind Energy Market & Technologies Global Wind

15 II. Status of Korean Wind Energy Market & Technologies What is Wind Energy? Energy converting system from wind to electrical power Theoretical maximum energy efficiency can be reached up to 59.3% The efficiency limited to 20~50 % due to aerodynamic, mechanical, electrical losses Rotor Gear Box Generator Electronics Grid 6 Rotation Energy Increase Speed Electric Energy AD to DC or DC to AC Electric Energy II. Status of Korean Wind Energy Market & Technologies Global Wind Energy Market Forecast Global Market Growth Rate 29%: 121GW in 2008 to 190GW in 2010 USA and Asia catch up Europe: New installations Source: World Wind Energy Report 2008, WWEA

Height (m) 10-09-2009 Design Issues for Offshore Salinity & Humidity - Isolation design - Anti-corrosion coating Easy Approach Ocean Wind High RAMS Offshore Condition Load Condition by Offshore Wind

16 Height (m) Design Issues for Offshore Salinity & Humidity - Isolation design - Anti-corrosion coating Easy Approach Ocean Wind High RAMS Offshore Condition Load Condition by Offshore Wind Onshore Offshore Difference of Design Load Between Onshore & Offshore Wind Velocity Wind Profile Onshore Wind turbine class I II III V ref V ave V gust50 * V gust1 ** Power factor 0.2 Wind Offshore Unit: m/s Wind turbine class I II III V ref V ave V gust50 * V gust1 ** Power factor 0.14 *Average max. wind speed during 3sec. with recurrence period of 50 years ** Average max. wind speed during 3sec. with recurrence period of 1 year Onshore Offshore Wind speed 10m/s at Hub height 80m Wind vel. (m/s)

required maintenance cost during 20 years

17 Internal Maintenance Crane : Innovation for Maintenance Saving Cost (per 1 Unit) Immediate Action Annual failure ratio : 10% - Average required maintenance cost during 20 years of design lifetime (unit : mil. $) Small Jack-up Barge Lent dramatic maintenance time 0.92 GEN Cost Save : 1.3 mil. $ Cost Reduction Ratio : 72 % 60 days 12 days 0.52 Conventional Doosan Way 0.92 G/B Conventional 0.23 GEN 0.23 G/B 0.06 Initial Cost Doosan Way Innovative Customer Value Creation for maintenance * 1 $ = 1275 Won Nacelle Assembly & Nacelle Functional Test (May ~ August, 2009)

II. Status of Korean Wind Energy Market & Policy Large Wind Farms in Korea Site location Wind

39.6 MW 96,680 MWh/year NM82 (V82) IEC IIB 24 x 1.

3 : start operation Site location Wind park capacity Estimated AEP WTG model WTG type class

0 MW Weibull parameter Shape factor (A) : 7.95 Scale factor (k) : 1.61 Project status 06.

18 II. Status of Korean Wind Energy Market & Policy Large Wind Farms in Korea Site location Wind park capacity Estimated AEP WTG model WTG type class Number of WTG units Youngdeok, Gyeongbuk 39.6 MW 96,680 MWh/year NM82 (V82) IEC IIB 24 x 1.65 MW Weibull parameter Shape factor (A) : 7.8 Scale factor (k) : 1.98 Project status 05.3 : start operation Site location Wind park capacity Estimated AEP WTG model WTG type class Number of WTG units Daegwanryung, Gangwon 98 MW 244,400 MWh/year V80 IEC IA & IIA 49 x 2.0 MW Weibull parameter Shape factor (A) : 7.95 Scale factor (k) : 1.61 Project status : start operation II. Status of Korean Wind Energy Market & Policy Korean Wind Farm Status ( ) Already installed To be installed

19 Cumulative installed capacity (MW) by end of in 2008 Installed capacity (MW) in 2008 Installed capacity between Cumulative installed capacity (MW) by end of II. Status of Korean Wind Energy Market & Policy Global Wind Energy Forecast Forecast (incl. Offshore) Sum Accu. Total Americas 28,918 9,527 7,650 10,450 12,450 16,200 18,300 65,050 93,968 Total Europe 65,971 9,179 11,580 13,505 15,900 18,080 20,150 79, ,186 Total South & East Asia 22,174 8,201 9,650 10,300 12,400 13,400 15,300 61,050 83,224 Total OECD-Pacific 4,256 1,051 1,100 1,350 1,600 1,900 2,250 8,200 12,456 Total other areas ,035 1,470 1,810 2,520 7,480 8,320 Total MW new capacity every year: 28,190 30,625 36,640 43,820 51,390 58, , ,153 Accu. capacity (MW) 122, , , , , ,153 Source: BTM Consult ApS - March Development of Doosan 3MW Offshore Wind Turbine System Do-Gyoon Kim, Staff R&PD Engineer Wind Power Engineering Team Power Plant Doosan Heavy Industries & Construction Co. Ltd. Korea-Denmark Energy Conference September 7, 2009 Copyright by DOOSAN Heavy Industries & Construction Co All Rights Reserved. 19

Vestas Product Offering V MW at a Glance. Renato Loureiro Gonçalves Wind & Site Engineer

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