GARUDA WIND ELECTRIC GENERATOR

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1 GARUDA WIND ELECTRIC GENERATOR GARUDA VAAYU SHAKTHI LIMITED CORPORATE OFFICE: 5D,5th Floor, P.M.Tower, No.37, Greams Road, Thousand Lights, Chennai India. Tel.: , 41, 42 & 43 FACTORY: No.79/ 6, Tindivanam Main Road, Kiliyanur Post, Kiliyanur By Pass, Vanur TK, Villupuram Dist., Tamil Nadu India. Tel.: Website: All copy rights reserved by GVSL 2014 Catalogue: GVSL/700.54/JAN 2014

GARUDA - Offers Renewable Energy Solutions for Next Generation Garuda Vaayu Shakthi Limited, headquartered in Chennai was formed by

technology development and implementation, setting up of manufacturing facilities and operations, sale of power, concept to

, The team is also adept at offering provision of infrastructure facilities, building companies with excellent teams with system

2 GARUDA - Offers Renewable Energy Solutions for Next Generation Garuda Vaayu Shakthi Limited, headquartered in Chennai was formed by a group of renowned Engineering & Finance professionals with a combined experience of over 6 decades in technology sourcing, technology development and implementation, setting up of manufacturing facilities and operations, sale of power, concept to commissioning of green field power plants like Wind, Bio mass, Hydel etc., The team is also adept at offering provision of infrastructure facilities, building companies with excellent teams with system and processes, raising of capital and debt and management of multiple investors and banks. Garuda offers comprehensive solutions in all aspects of renewable energy business from concept to commissioning. 3

The Garuda Edge R&D WEG Design Assembly Project Development & Execution Garuda is an integrated wind energy company focused on design, assembly, marketing and servicing of world class Wind Electric

Garuda's strengths are in the key area of its business World class design & engineering capabilities, global supply chain management skills and vast operation and maintenance experience.

Garuda owns Intellectual Property (IP) rights for all its wind turbine models to enable Garuda to export its turbines around the Globe.

7 MW Wind Electric Generator (WEG) suitable for IEC Class IIIA with 54m rotor diameter and 73m hub height for the Indian and Global market. Besides 0.

SCM Sales & Marketing Comprehensive O&M The different platform strategy devised by Garuda enables its products to meet the specific requirements of the environment in different parts of the world

3 The Garuda Edge R&D WEG Design Assembly Project Development & Execution Garuda is an integrated wind energy company focused on design, assembly, marketing and servicing of world class Wind Electric Generator (WEG) to cater to the requirements of global markets. The technology has been developed with the assistance of German Consultant S&G Engineering, GmbH. Garuda's strengths are in the key area of its business World class design & engineering capabilities, global supply chain management skills and vast operation and maintenance experience. Garuda has end-to-end design capability from components to wind turbine systems. Garuda owns Intellectual Property (IP) rights for all its wind turbine models to enable Garuda to export its turbines around the Globe. Garuda has an aggressive and detailed plan to emerge as a leading provider of wind electric products and services for the global markets. Garuda has developed a 0.7 MW Wind Electric Generator (WEG) suitable for IEC Class IIIA with 54m rotor diameter and 73m hub height for the Indian and Global market. Besides 0.7 MW, Garuda has also designed and in the process of developing its 1.7 MW WEG with 84m rotor dia and 80m hub height suitable for IEC Class IIIA Wind regime. SCM Sales & Marketing Comprehensive O&M The different platform strategy devised by Garuda enables its products to meet the specific requirements of the environment in different parts of the world with maximum adaptability. Garuda's products are specifically designed for the low and moderate wind regimes to ensure investments made in the wind electric products remain an economically attractive proposition for its customers Generator 2. Generator Cooler Fan 3. Control System 4. Service Crane 5. Down holder 6. Integrated Gearbox 7. Pitch Control System 8. High Speed Shaft - Guard 9. Compressor for Central Lubrication System 10. Main Frame 11. Yaw Rim 12. Yaw Drive 13. Oil Circulating Pump 14. Pitch Pinion 15. Blade bearing 16. Cycloidal Servo Drive 17. Ultra Sonic Wind Sensor Garuda's World-class Gearo-synch Technology The Garuda's Gearo-Synch Technology is a unique hybrid concept which combines the advantages of high speed permanent magnet synchronous generator and integrated gearbox for optimum energy output. Garuda's wind electric generators are state-of-the art, three-bladed, upwind, horizontal-axis, pitch regulated, variable speed to easily fulfill all modern grid code requirements and harsh climate conditions

KEY COMPONENTS Tubular Tower The Conical tubular steel tower is designed as per international standards and has been equipped with ladders, platforms, cable supports, light fittings, cables and a

4 KEY COMPONENTS Tubular Tower The Conical tubular steel tower is designed as per international standards and has been equipped with ladders, platforms, cable supports, light fittings, cables and a Lift / Climb assist (optional). The tower base has all grounding cables interconnected and in turn connected to the grounding system incorporated in the tower base. The tubular steel tower has multiple layers of corrosion protective coating as per relevant standards. Full Power Converter Full power converters (FPC) combined with high speed permanent magnet synchronous generator; represent the newest technology in wind power market. The advanced Insulated Gate Bipolar Transistor (IGBT) ensures low switching and transient losses. With the advanced Water cooling system, the operating life time of the power electronics are substantially increased. The converter with inbuilt Low Voltage Ride Through (LVRT) and High Voltage Ride Through (HVRT) capabilities meets the stringent grid code requirements. The Advanced Direct Torque Control (DTC) feature minimizes the torque fluctuation caused by dynamic changes in wind speed and absorbs the load variance from gust or turbulence, resulting in improved life time and power quality. Control System The Advanced Wind Turbine Controller (AWC) is based on a modular rack concept, which provides compact, flexible and service-friendly solutions - right from simple plug-andplay rack modules to the cables fitted with pluggable connectors. The robust AWC has high performance processor for an improved operational safety and reliability. High Speed Permanent Magnet Synchronous Generator Garuda's WEGs are with high speed Permanent Magnet Synchronous Generator (PMSG) wherein the rotor windings are replaced with permanent magnets. PMSG does not require separate excitation, thus minimizes reactive power & eliminates stray current which increases the bearing life time. By using the permanent magnet technology highest efficiency is achieved at nominal load as well as in partial load operation. The PMSG yields higher generation in comparison with the traditional induction generators and also offers advantages: Maximum energy at lowest life time cost. More reliable and very low maintenance. The AWC control system offers following advantages: In-built grid monitoring module. Fail-Safe feedback system and secondary safety system that ensures better fault diagnosis and safe operation of WEG Periodic data storage and monitoring the operation of WEG Accessibility to the controller from anywhere in the world Mainframe & Yaw System The fabricated steel main frame transfers the loads from the integral drive train to the yaw system and holds the generator and control cabinet over the bolted cantilever. The yaw system consists of an external ring gear which is bolted to the top flange of the tower with sliding pad system. The maintenance-free sliding pads are located at the connection of slewing ring, glide and mainframe; the lateral suspender in conjunction with these pads helps the nacelle implement a smooth rotary motion relative to the tower. The yaw system is driven by three converter-fed electrical motors with cycloidal gearbox. The yaw actuators also keep the nacelle in a fixed position, even at high eccentric wind loads. Ultrasonic Wind Sensor To measure wind speed and direction accurately traditional mechanical type sensors are found unreliable in some cases. The ultrasonic sensor is able to measure variable gusts of weather. The ultrasonic sensor is best suited for wind turbines in terms of: Excellent error accuracy & No moving parts Easy interface/ connection to existing systems. (Digital / Analog) 6 7

Unique Integrated Drive Train The rotor shaft is integrated into the gear and is connected directly to the rotor. The rotor shaft is pivoted in the transmission housing.

5 Unique Integrated Drive Train The rotor shaft is integrated into the gear and is connected directly to the rotor. The rotor shaft is pivoted in the transmission housing. The gear is an enclosed three-step gear comprising two planetary steps and a succeeding spur wheel step. The gearbox bell housing is connected to the machine frame with elastomeric bearings which reduces noise and absorbs vibrations. State-of-the-art Assembly Plant Garuda has a modern nacelle and hub assembly plant at Kiliyanur Village, near Tindivanam, Villupuram district which is at 160 km south of Chennai and on the National Highway NH-66 towards Pondicherry. Garuda has chosen this location after a thorough study of available resources and considering its proximity to Chennai and easy availability of skilled manpower. The plant span is around 60,000 sq.ft. and is built on 5 acres of land. A part of the built up plant area is used for storage whereas the remaining is used as assembly shop floor. The plant is equipped to produce 30 nacelles and hubs per month. Blade Garuda WEG uses three bladed rotor which comes with specialized aero foils for exclusive use on pitch-turbines, ensures high performance and moderate loads. The Blade is made of Glass fibre reinforced Epoxy resin matrix using Vacuum Assisted Resin Infusion Molding (VARIM) process. The blade is painted with a special poly urethane 3 coat painting system with intermittent ambient temperature curing between each coat. The leading edge (LE) is protected by an erosion protection film. The paint though hand-rolled has a surface finish quiet close to a spray finish and matte (no gloss). The Blade is also fitted with Lightning Protection System. Aluminium receptors on either side of the shell from the tip side connects the root end aluminium ring on the blade through an Aluminium cable which runs across the surface of the Shear web from the tip to the root. The resistance of the cable is close to about 30 to 50 milli ohms. There's also a lightning registration card to measure the intensity of lightning in the event of lightning strikes on the blade. Variable Active Pitch System The variable active pitch system is controlled by individual high performance AC servo drives and cycloidal gearboxes. The AC servo motor with cycloidal gear and redundant power supply system designed & built for the maximum reliability results in lesser mechanical wear which maximises life and minimises maintenance costs. The AC servo motor is compact and offers high power density to reach required torque and speed needed for safe feathering of blades, high accuracy and error free blade angle measurement. 8 9

registered with the Department of Scientific and Industrial Research (DSIR), Ministry of Science & Technology, Govt. of India as recognition for its design capabilities.

5 m/s 1000 m IEC III A -10⁰C to +45⁰C -10⁰C to +50⁰C No. of Blades 3 Diameter 54 m Swept Area 2290 sq. m Rated Rotor Speed 26.

5⁰ Blade High Speed - Permanent Magnet Synchronous Generator Rated Power 770 kw Voltage 690 VAC Frequency 75 Hz Power Factor 0.

Power Converter With LC Filter Converter Rating 770 kw Voltage 690 VAC Frequency 50 Hz Power Factor Lead / Lag 0.

of Stage Three stage Rated Power 770 kw Ratio 1:56.

6 Technical Description of Garuda Wind Electric Generator Operational Data Rotor Certifications Garuda is an ISO 9001:2008 certified company and it has an in-house Research & Development (R&D) Department, registered with the Department of Scientific and Industrial Research (DSIR), Ministry of Science & Technology, Govt. of India as recognition for its design capabilities. Rated Power Cut In Wind Speed Cut Out Wind Speed Rated Wind Speed Highest Altitude Wind Class Operating Temperature Survival Op. Temp. Generator 700 kw 3.0 m/s 24 m/s 12.5 m/s 1000 m IEC III A -10⁰C to +45⁰C -10⁰C to +50⁰C No. of Blades 3 Diameter 54 m Swept Area 2290 sq. m Rated Rotor Speed RPM Orientation Horizontal Axis, Upwind Power Regulation Active Pitch Nominal Tip Speed 75 m/s Rotor Cone Angle 2.5⁰ Blade High Speed - Permanent Magnet Synchronous Generator Rated Power 770 kw Voltage 690 VAC Frequency 75 Hz Power Factor 0.98 Rated Speed 1495 RPM Degree of Protection IP 54 Thermal Class B Insulation Class H Cooling System Forced Air Cooling Full Power Converter IGBT Based Modular Designed Full Power Converter With LC Filter Converter Rating 770 kw Voltage 690 VAC Frequency 50 Hz Power Factor Lead / Lag 0.9 Cooling System Liquid Cooling System Main features LVRT & HVRT as per various grid code requirement Braking System Aerodynamic Brake 3 independent electrically driven pitch for full feathering of blades Mechanical Brake Hydraulic Active Brake System No. of callipers 1 Blade length Aerodynamic profile Maximum chord Material Gearbox m NACA m Glass Fibre Reinforced Epoxy (GFRP) Two stage Planetary and one stage spur gear with Integrated Rotor Shaft No. of Stage Three stage Rated Power 770 kw Ratio 1: General Cooling System Forced Air Cooling Yaw System Yaw speed Method Bearing Tower converter-fed electrical motors with cycloidal gearbox 24⁰ /min. Active Yaw Maintenance free, selflubricated sliding bearing Conical Tubular Steel Tower with internal access ladder Hub Height 73.0 m Sections 3 Elevator (Service Lift) Optional Corrosion Protection Multilayer Protective Paint ISO 9001:2008 Certificate Power Curve of Garuda Design Evaluation Conformity Statement Generated Power, (kw) Wind Speed, (m/s) Factors considered: Air density = 1,225 kg/m³ Turbulence intensity as per IEC with I ref =10% Wind shear exponent = 0.2 Certificate 11

GARUDA's Impeccable Service Offers 24X7 (Round the clock)

trained Engineers & Technicians Preventive and Scheduled

site Spare provision plan for critical parts and

Vehicle at site 24*7 for service team transportation.

Garuda's Capabilities Garuda considers service to be a key

Garuda adopts transparent and collaborative business

7 GARUDA's Impeccable Service Offers 24X7 (Round the clock) dedicated service team compressed of highly educated and trained Engineers & Technicians Preventive and Scheduled Maintenance Remote monitoring and Technical support to site Spare provision plan for critical parts and consumables at site. Vehicle at site 24*7 for service team transportation. SCADA system for turbine monitoring. Garuda's Capabilities Garuda considers service to be a key differentiator in the wind turbine industry. Garuda adopts transparent and collaborative business relationship with all its stake holders. Garuda offers complete turnkey solution i.e. from concept to commissioning and supports its customers with: Wind Resources Analysis (WRA) Project Development & Project Execution Long Term Comprehensive Operation & Maintenance (COM)

Reliability Driven By Technology. M a k e t h e r i g h t m o v e...

Reliability Driven By Technology M a k e t h e r i g h t m o v e... Make the right move... Business is akin to a master game of chess. The right strategy and the ability to anticipate the opponent's future