Wind Energy: A new energy with new challenges Edward Ross Engineering and Technology Engineering and Technology 9/14/2011 PAGE 1
Introduction to Edward Ross Edward.Ross@rwe.com Introduction > Graduate from Edinburgh University with a degree in Mechanical Engineering > Joined RWE npower in February 2007 RWE Innogy Role > Mechanical Engineer within the Engineering & Technology department based in Swindon > Main responsibilities are: Performing WTG Inspections Preparing asset integrity reports Identifying and resolving technical issues on wind turbines Engineering and Technology 9/14/2011 PAGE 2
Introduction to RWE Innogy > RWE Innogy is a Renewable Energy utility company that was launched in February 2008. > Is a subsidiary of the German utility company RWE (Rheinisch- Westfälisches Elektrizitätswerk). One of the worlds largest power generation companies. >RWE Innogy combines the various renewables technologies owned by RWE throughout Europe into a dedicated organisation. Country Install Capacity Wind Install Capacity Hydro Germany 447MW 376MW UK 466MW 69MW Spain 401MW 12MW Netherlands 201MW - Engineering and Technology 9/14/2011 PAGE 3
The Modern Wind Turbine > The Standard Modern Wind Turbine is a Upwind Horizontal Axis Wind Turbine. > The design features a main bearing, low speed shaft, 3 stage gearbox, high speed shaft and a generator. A series of yaw motors turn the turbine > RWE Innogy owns turbines with capacity ranging from 450kW to 3.6MW. > Newer turbine designs have 5 to 7MW capacities. The drawing board has 10MW designs > Typical dimensions for a 2MW wind turbine are: Blade Diameter 70-80m, Hub Height 60-70M Engineering and Technology 9/14/2011 PAGE 4
UK Downtime WTG 2006-2008 > Possible to conclude from this that the 3 main areas of concern should be Gearboxes, Generators and Blades > However, does this apply to every turbine? Engineering and Technology 9/14/2011 PAGE 5
RWE Innogy Downtime by Turbine Capacity > Are these differences due the size of turbine? > Are they due to differences between manufacturers? > Have we forgotten how to make a decent gearbox? Engineering and Technology 9/14/2011 PAGE 6
Downtime Conclusions > Are these differences due to the size of turbine? In general smaller capacity turbines are older Smaller capacity have less access to replacement parts increasing downtime Components should be approaching end of design life (circa 20 years) > Are they due to differences between the manufacturers? Data used is for 3 different manufacturers and is reasonably consistent for them all. > Have we forgotten how to make a decent gearbox? Gearbox design has in fact got Smarter Engineering and Technology 9/14/2011 PAGE 7
Speed kills Engineering and Technology 9/14/2011 PAGE 8
Challenging Gearboxes Pt 1 - Design Pout > Early wind turbine gearboxes were initially adapted from other industries. Pin > Design calculations tended to be rough & ready encouraging the use of larger margins of safety > Newer gearboxes are designed with more advanced tools, such as FEA/FEM, rotor dynamics software > More advanced tools however require more advanced information. Pinion Gear Wheel Shaft Planet Ring Gear Pout Pin Engineering and Technology 9/14/2011 PAGE 9
Challenging Gearboxes Pt 2 Technical Issues > Wind Turbine gearboxes show a variety of failure modes but the majority are related to bearings and tooth failures > If in doubt, blame Zeus! Engineering and Technology 9/14/2011 PAGE 10
The solution to Gearboxes? > Scrap it! Enercon turbines are all direct drive using large generators with Permanent Magnets Other companies have started to follow this design as well Engineering and Technology 9/14/2011 PAGE 11
Challenging Blades pt 1 > Wind Turbine blades are made from a number of different materials with older blades favoring Wood/Foam and newer blades made from Glass/Carbon Fibre > Blades should be monitored. A number of techniques are used, Knocking, Ultra Sound and Themography > However, given their location Visual Inspection is often the only practical option! Engineering and Technology 9/14/2011 PAGE 12
Challenging Blades pt 2 > Few companies outside WTG OEMs and blade manufacturers have the ability to repair and inspect blades in situ. Resulting in: High costs for their services Long lead times in maintenance activities Reports may not be balanced > It is desirable to perform blade repairs in situ. However: More challenging to perform a good repair The risk for the employees increase significantly > The Midge Ridge Performance of blade decreases with dirt Engineering and Technology 9/14/2011 PAGE 13
Number of Employees The Biggest Challenge of them all: Siemens Wind Power Employees 6000 5289 5500 5000 4000 3294 3000 2000 1000 801 1208 2176 0 2004 2005 2006 2007 2008 2009 Year > The Renewables Sector has seen fantastic growth in previous years This has resulted in many staff with little experience in wind turbines and in some cases of even working in a professional industry Many causes of downtime can be traced to individuals and simple mistakes Engineering and Technology 9/14/2011 PAGE 14
THANK YOU VERY MUCH FOR YOUR ATTENTION Engineering and Technology Engineering and Technology 9/14/2011 PAGE 15