our customers permanent performance during the entire operational lifetime of twenty years or more. The heavy-duty, lowmaintenance character of the Z72-design makes our product your best choice for coastal, near-shore or offshore locations with a demanding high-speed wind regime. Operational philosophy The company Zephyros is a Dutch developer and manufacturer of multi-megawatt gearless wind turbines for electric power generation. Our company was founded in 2000 and is a cooperation between some of the most experienced Dutch For the most innovative key components of the turbine, Zephyros collaborates with a limited number of dedicated partners. ABB is our most important partner and is responsible for the generator and the power conversion system. Other components of the turbine, such as the tower, the nacelle and the rotor, are procured from local partners according to Zephyros design specifications and quality standards. wind engineers, electrical engineering giant ABB, and transport and heavy-lift specialist Mammoet. Triodos Ventures, a Dutch green fund, and BVT Energie- und Umwelttechnik of Germany are the majority shareholders in Zephyros. Worldwide presence Zephyros considers the Benelux, France and the UK as its home market. Besides this home market, Zephyros aims at establishing a worldwide presence by setting up a network of franchise partners in a number of key geographical regions. Product and design philosophy Zephyros has developed a gearless 2.0 MW class wind turbine, the Z72, with as few (moving) parts as possible. The second part of our quality strategy is to use only highly proven commercially available components from A-brand subcontractors. Our franchise partners will be responsible for local sales, installation and maintenance of Zephyros turbines in their respective regions. Zephyros remains responsible for product development, training & support of franchisee staff, the procurement of key components from partners and quality assurance. The result is a robust and reliable wind turbine with a novel 4,000-Volt permanent magnet direct drive generator, which guarantees
ZEPHYROS PARTNERS & SUPPLIERS ABB Generator, Control system, AC-DC-AC Converter Electrical engineering giant ABB operates in some 100 countries and employs around 135,000 people worldwide. The generator for the Zephyros turbine was developed in partnership with ABB and is produced in its Helsinki factory. The converter is a standard ABB piece of equipment, in use for example in trains of the German Railways, and is produced in Switzerland. Mammoet Erection & Transport Mammoet is specialised in solving heavy-lift and transport challenges at any onshore or offshore location in the world. For example, Mammoet was responsible for raising the Kursk from the bottom of the Barentz Sea. In partnership with Mammoet, Zephyros has developed special equipment for easy installation and transport of the Z72 turbine. LM Blades LM is one of the world s leading independent blade manufacturers. Our first series of turbines are equipped with standard blades from LM. Depending on the region, other A-class blade manufacturers may be used as well. Zephyros or franchise partners Assembly & Commissioning The assembly of the building blocks on site and subsequent commissioning is done by Zephyros or its local franchise partners. Zephyros Quality Assurance / Product Guarantees Zephyros remains responsible for the quality of all Z72s built, independent whether they are built in our home market or delivered by one of our franchise partners. Local suppliers Tower, Nacelle & Rotor Hub The tower, nacelle and rotor are large, welded or cast iron components, which can best be manufactured close to the installation site. Zephyros cooperates with local partners to have these pieces manufactured on demand.
The product Design considerations The Zephyros Z72 turbine was designed with demanding offshore and remote applications in mind. Key design considerations were: easy access to the hub internals where the blade pitch mechanism is housed. The nacelle itself is virtually airtight, and in addition put under permanent overpressure with filtered air. This measure prevents High wind loads (IEC Wind Class I) Low-maintenance requirements Easy access to key components, also in extreme weather conditions Excellent power quality characteristics Erection with a relatively light, inexpensive crane saline air particles from entering the generator internals and pitch blade system. The converter is placed at the bottom of the tower. Alternatively, due to the 4,000-Volt generator concept, converters of multiple turbines can be grouped in a central conditioned building. The latter solution enables Concept The result is the Z72; a 2 MW, permanent magnet easier maintenance, and for offshore conditions easier all-weather access. direct drive wind turbine with only a few moving parts, designed for a maintenance interval of only one year. This pitch-regulated three-bladed up-wind turbine operates at variable speed. Major advantages of the permanent magnet design are the lower generator losses and the superior partial load efficiency. Elimination of the gearbox in the drive train takes away Another Zephyros innovation is the special hoisting device which can be placed on top of the nacelle. This system facilitates easy installation of the generator, the rotor and the blades, especially in remote areas and/or complex terrain. The novel installation technique also results in a substantial crane costs reduction. an important potential source of system failure. Summarised The generated power with variable frequency is fed into the grid via an advanced AC-DC-AC converter system that meets the latest power quality standards. The power factor of the inverter is fully adjustable for active grid support. The system is also resistant to brief grid power dips (<200ms). This allows utilities to optimise and sometimes even expand wind power generation capacity when utilising Z72 wind turbines in existing grids. The generator is fully integrated into the structural design of the turbine. This has resulted in a very compact nacelle layout. The drive train comprises only one automatically lubricated single main bearing. The hollow bearing and generator support structure, together with the absence of a main shaft facilitates One year maintenance interval and high reliability due to a minimum number of moving parts. Easy access to key components (generator, single main bearing, inverter, pitch control mechanism), also in heavy weather. Reduced generator losses, superior partial load efficiency and less chance of failure by permanent magnet generator design. Airtight nacelle with overpressure, which prevents saline air from entering the generator and pitch system. Excellent power quality, and built-in capabilities for active grid support. Special hoisting device allows installation of the 2MW Z72 turbine on locations where competitors are limited to a maximum capacity of about 600 kw.
Product details THE BLADES The turbine consists of various large components or building blocks assembled on site into a complete wind turbine system. THE Z72 TURBINE THE GENERATOR Generator Nacelle Hub Rotor blades Tower The generator and bearing assembly is directly bolted onto the nacelle. The generator mass is 49,000 kg, diameter and length are 3.8 m 2.2 m. Responsible for the manufacture is ABB Finland. Generator In partnership with ABB, Zephyros developed a 4,000-Volt permanent magnet synchronous direct drive generator. The latter design is based on the latest developments in generator- and drive systems technology. The stator is located on the outside, and directly cooled by passing outside air. The stator windings are vacuum impregnated, with a 7,000-Volt insulation value commonly used in medium voltage generators. Circulation of dried Nacelle The nacelle is a compact structure composed of nodular cast iron. It accommodates the yaw mechanism, service hoist and switchboard. The geometry of the casting assures an almost ideal transfer of loads to the tower. The mass of the nacelle assembly is 12,000 kg, and it measures 3.5 m 2.8 m 2.8 m (length width height). THE NACELLE and filtered air assures an equal temperature distribution inside the generator. The huge generator bearing is a three-row cylindrical roller type unit. The inner stationary ring is fitted to the generator stator. The outer rotating ring fits between the hub and generator rotor. The bearing takes axial and radial loads as well as bending moments, and is equipped with an automatic lubrication system, continuously monitored THE HUB by the turbine controller. THE HOISTING DEVICE
Tower The nacelle is put on a fully corrosion protected tubular steel tower. The complete tower consists of multiple sections, bolted together on site. The total tower mass is 100,000 kg for the 65 m tower version, against 150,000 kg for the 80 m version. Converter The converter is a standard ABB ACS 1000 type mediumvoltage AC-DC-AC unit, slightly adapted for use in the Zephyros turbine. The entire power output is fed through the converter, which is a standard feature of synchronous type generators. Generator output is a function of rotational speed, which is managed by the pitch-control system. Converter and pitch control act as a master-slave system. The reactive power is fully controllable but set to zero (cosϕ=1) by default. A UPS-system gives the Z72 wind turbine a unique capability to remain in operation in case of a grid voltage dip of up to 200 milliseconds. The converter is produced by ABB Switzwerland. Hub The rigid rotor hub is composed of nodular cast iron and fitted directly to the single main bearing. The blades are connected to the hub using a so-called four point prestressed ball bearing. The hub houses the blade pitch control system and a slip-ring unit for the power supply. The hub is sufficiently large to provide a working environment for two service technicians. The mass of the fully assembled hub measures 19,000 kg. Its dimensions are 2.5 m 2.2 m 2.2 m (length width height). Control and safety system Zephyros and ABB were jointly responsible for the functional integration of generator controls and the turbine control system (blade pitch, power output and rotor speed). The control PLCs are connected by means of an optical glass fibre communication line. Communication is performed by a standard Ethernet network protocol. Rotor blades The three rotor blades are constructed from glass fibre reinforced polyester composite (GFRP). The mass of each The rotor blades are each controlled by a synchronised frequency converter driving a DC motor. Each blade has an emergency battery pack for fail-safe operation. blade is 5,500 kg. The length of the blades is 34.0 metres, with an outer blade root diameter of 1.9 metres and a maximum cord of 3.1 metres. All blades are equipped with a lightning protection system. The Zephyros Z72 turbine can be fitted with blades of various suppliers. For the first turbine series a choice was made for standard type blades produced by the Danish manufacturer LM Glasfiber. Hoisting device In co-operation with Zephyros partner Mammoet, a special hoisting device was designed which can be placed on top of the nacelle. The hoist facilitates the installation of the generator, the rotor and the blades in remote areas and/or complex terrain and reduces crane costs.
Specifications Z72 SPECIFICATIONS Z72 Rotor diameter 70.65 m Power conversion system Z72 Rotor speed Variable, nominal 23.5 rpm Generator ABB multiple-pole, 4,000-Volt permanent magnet, synchonous machine Nominal power 2.0 MW* Protection IP54 Transmission Direct drive generator, single main bearing Insulation class F Rated wind speed 13 m/s Converter ABB AC-DC-AC full-size conversion Cut in / cut out wind speed 3-25 m/s Power factor control Fully adjustable, with active grid support (capacitive and inductive, upon request) Survival wind speed 70 m/s Grid connection rules Remains grid-connected during voltage dips of up to 200 msec Rotor speed control Blade pitch Tower Wind class I and S, according to IEC 61400-1 Type Tubular steel or lattice tower Generator mass 49 tons Hub heights 65 m (100 tons) and 80 m (150 tons) Rotor mass 36 tons Safety Nacelle mass 12 tons * For noise critical sites nominal power can be reduced to an output level of 1.5 MW. This corresponds to a nominal rotational speed of 18 rpm. Type Activation Independent blade pitch (3 safety systems) Redundant electrical-mechanical drive units POWERCURVE Z72 Corrected for turbulence intensity of 10% according to IEC 61400-I V (m/s) P (kw) 2000 3 4 4 32 5 103 1500 6 219 7 373 Output (kw) 1000 8 570 9 816 10 1,110 11 1,430 12 1,770 500 13 1,882 14 1,962 15 1,990 0 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Wind Speed (m/s) 16 2,000
SITE ASSEMBLY Zephyros bv www.zephyros.com Olympia 1a-b 1213 NS Hilversum The Netherlands T +31 (0)35 646 26 05 F +31 (0)35 646 27 10 E info@zephyros.com Zephyros (Ζεφυρς) is the ancient Greek god of the West Wind. Any soft and gentle breeze nowadays is referred to as a zephyr. Theophrastus, a 4th century BC scholar who left us with a complete account of mythical Greek winds, wrote: Zephyros, the west wind, is the most gentle of all the winds and it blows in the afternoon and towards the land, and is cold.