Introducing UK Wind Turbine Market Opportunities For UK Companies
Who is going to make them? Who is going to make them? Who is going to make them?
Developing the opportunities for UK companies in the wind energy market Funded by Advantage West Midlands East Midlands Development Agency Yorkshire Forward
Project Objectives To identify, contact, evaluate, encourage, support and promote UK companies to enable them to enter the wind turbine To identify opportunities for product development and innovation and encourage supplier groupings to bring these to market
The Wind Energy Market 40,000MW installed world-wide Europe has 67% of the world capacity Average annual growth rate for the industry over the last 5 years is 26% p.a. Offshore development expected to take off from 2007 European OEMs dominate the market
Wind Energy in the UK UK targets 10% of electricity produced from renewables by 2010 New Target of 15% by 2015 Aspiration of 20% by 2020 Over 90% of renewable energy expected to come from wind power
Wind Energy in the UK In 2003 = ~0.5% from wind power 1030 turbines operating - all but 2 onshore Autumn 2003 First large offshore wind farm (North Hoyle) on stream
UK inland grid
Round One Sites 7 now have planning consent Construction Round 2004-2007 One sites Limited to 30 turbines
Round Two Sites No restrictions on number of turbines
Typical offshore installation
Typical onshore installation
First major UK offshore installation North Hoyle - 7.5km of North Wales coast 30 turbines of 2MW - Vestas
Wind Turbines in the UK 7 projects constructed in 2003 Over 100MW came online - 20% increase - best year yet 22 new projects planned for 2004 - a total of 474MW (314 turbines) 2nd large scale offshore farm (Scroby Sands) turbines now being installed, online by Autumn Planning regime creating a backlog
UK Market Potential Germany has ~15,000 wind turbines producing 14,600MW of electricity Up to 25,000 wind turbines will be required to meet UK targets A 50 billion investment
World shares of OEMs Others 2,8% Desarrollos (E) 0,1% Ecotécnia (E) DeWind (D/UK) Suzlon (India) Repower (D) Mitsubishi (J) 0,8% 1,1% 1,8% 1,9% 2,6% Spain 13% Others 7% Denmark 44% Made (E) Nordex (D) 2,8% 6,7% Germany 36% Bonus (DK) 8,7% Gamesa (E) 9,5% GE (D/USA) 12,7% NEG Micon DK) 12,8% Enercon (D) 15,2% Vestas (DK) 24,1% 0% 5% 10% 15% 20% 25%
WindSupply Wind Turbine Component Supply Opportunities
What products are required? What can UK companies supply? Who is going to make them?
Wind Turbine - Major Components
A REpower 2MW wind turbine
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Peripheral components Meteorological sensors Obstruction lights Protective coatings Fastening systems Towers & foundations Electrical components Grid connections Generators Lightning protection Control systems Composite components Rotor blades Canopies Spinners Standard components - Access towers - Cooling equipment - Hydraulic equipment - Lubricating systems - Pumps - Scaffolding/ Ladders
Wind Turbines - Major Components Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Bedplates Secures the position of the drive train Provides a stable platform for all other components Iron castings are preferred, but fabricated construction also used High demands on stiffness Minimise weight
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Machine bedplate - typical example Material - S235JR/S355J2G3 Weight - 7,000kg Length - 3,900mm Width - 2,300mm Height - 1,360mm Certification - DIN 18800
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Hubs Rotor hub connects the rotor blades to the main shaft (low speed) Contains the equipment to alter pitch of blades Subject to high and variable stress levels from the blades
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Hubs - typical example Material - EN-GJS-400-18 - LT/DIN, EN 1563 Weight 6,000kgs Length 2,160mm Width 2,680mm Height 2,320mm
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Bearings Bearings are usually designed specifically for wind turbines Self-aligning bearings e.g. spherical roller bearings for main shaft Single and double row tapered roller bearings in combination with cylindrical roller bearings are suitable for hubs Need to withstand high loads during gusts and braking Scheduled replacement and condition monitoring required
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Examples of bearings (FAG) 3.0MW - single, 2 row tapered roller bearing (1900x2350x290mm) 3.6MW - 3 point support spherical roller bearing (1120x1600x460mm) 4.5MW - hub bearing, 2 row tapered roller bearing (950x1300x350mm) 4.5MW - hub bearing, cylindrical roller bearing (1700x2100x290mm)
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Shafts Low speed main shaft between hub and gearbox High speed shaft between gearbox and generator Typically forged alloy steel (30 CrNiMo 8)
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Example of shaft specification Length - 2,950mm Shaft diameter - 600mm Flange diameter - 1,470mm Weight - 7,200kg Steel - 30 CrNiMo 8 (1.6580) Yield stress - >600N/mm² UTS - >800N/mm² Impact - >35J (Charpy ISO-V)
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Gearboxes Step up low rotor shaft speed to the high speed needed to drive the generator Bearings require high quality lubricants to prevent damage Oil filtering and cooling systems are important Regular monitoring and maintenance required Many gearboxes replaced due to bearing failure
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Typical gearbox 3 stage planetary/spur Nominal power 1,615MW Nominal torque 916kNm Ratio 1 : 104.2
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Couplings Link and transmit torque from gearbox to generator Compensates for misalignment Electrically isolates the generator Torque levels from up to 22,000Nm
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Coupling - typical parameters Typical rotation speed -1,500rpm Max rotation speed - 9,000rpm Max nominal torque - 22,000Nm Temperature - -57 to +121ºC Axial misalignment - 0.8-6.4mm Parallel misalignment - 0.1/0.9mm Angular misalignment - 3º Torsional stiffness - 0º Outside diameter - 47-850 mm
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Yaw systems Yaw system aligns rotor axis with wind direction to extract maximum energy Exact alignment avoids stresses on the turbine caused by oblique wind flow Yawing achieved by four geared motors operating on external gear teeth of bearing Hydraulically or electrically actuated Anchored by 10 yaw brake callipers Need to be checked and lubricated regularly
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Pitch systems Enables the rotor blades to turn on longitudinal axis Blade bearings need to withstand variable and heavy loads as well as vibration Individual regulation of the pitch of each blade is microprocessor controlled Hydraulic or electrically operated systems
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Brake systems Required on both drive train and yaw systems Certification regulations demand two independent brake systems on main shaft to prevent overspeed First is pitching of blades out of the wind Second braking system is usually disc brakes on the high speed shaft Important safety devices - must be failsafe
Mechanical components Bedplates & hubs Bearings & shafts Gearboxes & couplings Yaw & pitch systems Brake systems Hydraulic units Hydraulic systems Applied to brake systems, pitch & yaw controls Also on-board cranes and locking systems for canopies Main components: pumps, drives, oil tanks, filters, pressure valves and control systems
Grid connection Internal cabling usually 690 V Standard electrical equipment used for connection to grid Substations, transformers, switchgear, capacitors, protection and control equipment Parameters defined by grid operator for quality of electricity produced: voltage frequency reactive power Electrical components Grid connections Generators Lightning protection Control systems
Generators Synchronous or asynchronous generators Synchronous use electromagnets in the rotor fed by DC from electrical grid Most wind turbines now use three phase asynchronous (induction) generators Speed variation with torque level important Ring generators (e.g.enercon) do not require a gearbox Electrical components Grid connections Generators Lightning protection Control systems
Example of asynchronous generator Poles - 4 Power - 350kw Voltage - 690 V Configuration - Delta Speed - 1524 rpm Rated slip - 1.6% Rated current - 315 A Rated torque - 2310Nm Power factor - 0.93 Efficiency - 95.6 Weight - 2,450kg Electrical components Grid connections Generators Lightning protection Control systems
Generator performance Main failures are bearings and electrical insulation Bearings damaged by high and alternating loads and insufficient lubrication Bearings replaced several times during life of wind turbine Closed ventilation circuits for offshore to minimise corrosion Electrical components Grid connections Generators Lightning protection Control systems
Lightning protection Protection class IEC-10274-1/2 690 V network in main switchboard protected by spark gap (coarse protection) 690 V network in nacelle switchboard and 400 V network in main switchboard protected by varistors (medium protection) All components in controller and telecom modules protected by special varistors (fine protection) Blades frequently have lightning receptors at tip Lightning receptor mounted on nacelle top Electrical components Grid connections Generators Lightning protection Control systems
Control systems Sophisticated control systems becoming increasingly important SCADA necessary for implementation of long term forecast systems required by grid operators Condition monitoring of critical components required by operators and insurers Remote control and full monitoring especially for offshore applications Electrical components Grid connections Generators Lightning protection Control systems Scope for innovation
Rotor blades Usually made from either GRP or wood laminate Manufactured in one piece Up to 60 metres long Longer blades may require 2/3 part construction Regular inspection and repair of tears and small cracks in blades required Need to be cleaned Lifespan? (Reblading) Composite components Rotor blades Canopies Spinners
Canopies and spinners Usually GRP Weight and rigidity important Nacelle canopy typically 22m long 12m wide,weighing 9 tonnes Spinner covers the hub and pitch assemblies Composite components Rotor blades Canopies Spinners
Peripheral components Meteorological sensors Lighting Protective coatings Fastening systems Towers & Foundations Meteorological sensors Nacelle mounted anemometer for wind speed De-icing equipment important Potentiometer wind vanes allow control system to point turbine into the wind Sensors for air temperature, humidity and atmospheric pressure also required
RECENT INNOVATION LED lights built into rotor blade tips Peripheral components Meteorological sensors Obstruction lights Protective coatings Fastening systems Towers & Foundations Obstruction lights Wind turbines with an overall height exceeding 100m require obstruction lights 250W, 24V halogen lamp Focal depth 380mm Protective system - IP 44 Acrylic lens, stainless steel cap 463mm diameter, 430mm height
Peripheral components Meteorological sensors Lighting Protective coatings Fastening systems Towers & Foundations Protective coatings Harsh atmospheric and corrosive conditions Lifespan 20-30 years Maintenance not practical after installation, protective coatings required Abrasion and corrosion protection Offshore installations present a market opportunity
Peripheral components Meteorological sensors Lighting Protective coatings Fastening systems Towers & Foundations Fastenings Major components joined by bolts Foundations, tower and main frame generally require pre-tensioned bolting with well defined mechanical properties Wide range of fasteners required for ancillaries 4 tonnes of fasteners per turbine
Peripheral components Meteorological sensors Lighting Protective coatings Fastening systems Towers & Foundations Towers & Foundations Towers mainly of tubular steel construction and conical typical height 80-100m 100m tower weighs 250 tonnes manufactured in 5/6 sections 10-25m in length Lattice towers require less steel but appearance disliked Foundations of reinforced concrete (onshore) and fabricated monopiles (offshore)
Towers & Foundations Sections for 100m tower for MD77/S77 Section length Flange base Flange top 6 23,300mm 3,544mm 2,955mm 5 22,000mm 4,100mm 3,544mm 4 14,000mm 4,100mm 4,100mm 3 12,800mm 4,100mm 4,100mm 2 12,800mm 4,100mm 4,100mm 1 11,250mm 4,100mm 4,100mm Peripheral components Meteorological sensors Lighting Protective coatings Fastening systems Towers & Foundations
Turbine Cost Breakdown Main components in nacelle, % cost Nacelle Cover 4% Converter 17% Hub Casting Machined 5% Hydraulic Cylinder 1% Blade Bearing 5% Rotor Shaft 4% Control Cabinet 4% AC Generator 13% Gearbox 31% Hydraulic System 6% Yaw Drives 4% Front Bedplate 4% Yaw Bearing
Typical Project Cost Breakdown Turbine 45% Foundations 25% Installation 7% Connection 13% Transmission 8% Management 2% Approx. cost = 1million per MW
Failure Analysis Reasons for failure of wind turbine electrical control systems...13% gearbox..12% yaw system.8% generator.5% hydraulics 5% grid connections.5%
Component Outsourcing Gearbox 100% Generators 90% Blades 50% Towers 40% Electrical controls 30% Other components 100%
UK Wind Turbine Market Vestas Celtic Wind Technology World leading Danish company Factory at Campbeltown, Scotland Manufactures towers from steel plate Assembly of nacelles from kits imported fully complete from Denmark UK component supply being progressed
UK Wind Turbine Market NEG Micon Danish manufacturer Manufacturing blades in IOW Hub design and prototyping in Surrey Merger with Vestas announced in December 2003
UK Wind Turbine Market FKI DeWind German wind turbine manufacturer acquired by FKI group in 2002 Assembly relocated to Loughborough Initially using German supply chain Actively seeking UK suppliers www.dewind.de/en/zulieferer/index.htm
UK Wind Turbine Market REpower Systems AG German manufacturer of wind turbines Joint venture with Peter Brotherhood, Peterborough announced in Sept 2003 Initially sales & service for REpower wts Manufacturing in UK by end 2004
UK Wind Turbine Market Gamesa Eolica Leading Spanish manufacturer Acquired other Spanish OEMs Actively seeking a UK operation
UK Wind Turbine Market GE Wind Energy Leading German/US manufacturer Evaluating a UK facility
Planned Project Actions
Project Actions Extend involvement to a wider range of companies and product sectors Visits to wind turbine manufacturers in UK and overseas Visits to major component suppliers in the current supply chain Liaison with testing bodies & approval organisations
Project Actions Central point for wind turbine market supplier information Creation of database of UK manufacturers capable of supplying the market Establish the WindSupply website as the portal for UK manufacturers Continue a programme of Wind Turbine Workshops during 2004
WindEnergy Exhibition 15 companies exhibited 30 companies on missions
Project Actions Conferences & Exhibitions WindEnergy Conference and Exhibition, Hamburg, 11-14 May 2004-15 companies exhibited on the WindSupply stand, 30 companies joined market appraisal missions Power Expo Exhibition, Zaragoza, Spain, 22-24 September 2004 - Mission being planned European Wind Energy Conference & Exhibition Wembley 22-25 November 2004 - Stand booked approach being planned
Project Actions Encourage supplier partnerships & groupings to produce sub-assemblies Involvement of the UK s innovation and R&D resources at Universities and Research Organisations
WindSupply Product Focus Groups
Entering the Wind Turbine Market Existing supply chain operating Experienced suppliers Established relationships UK companies have no track record in the sector Standards and specifications are mainly German & Danish How can UK companies win business?
Entering the Wind Turbine Market INNOVATION & PRODUCT DEVELOPMENT
Opportunities for Innovation Forecast growth may outstrip supply capabilities New market requirements - offshore Larger wind turbines being developed Increased reliability required Speed of installation increased Ease of maintenance demanded Pressure to reduce cost in all areas UK content gives a market advantage
The Route to Innovation Understand the current products and how they operate Review the specific components and manufacturing/assembly processes involved Identify the drivers behind development - what will the item look like in 5 years? How? PRODUCT FOCUS GROUPS
Product Focus Group Structure OEMs WINDSUPPLY PRODUCT FOCUS GROUP MANUFACTURERS UNIVERSITIES
Product Focus Groups OEMs: To outline the existing function of the sub assembly and the potential areas for new developments, designs and innovations Manufacturers: To review capabilities and partnerships required to produce the new design and realise the innovation Universities: To analyse the potential innovation areas, link in with any existing work and identify a route to develop each innovation
Rotor Hub Product Focus Group First meeting held in April 2004 Hosted by Vestas (NEG-Micon Rotors) 11 manufacturers attended + University Innovation opportunities identified: blade bearings hub casting control systems hydraulics Follow on meetings will concentrate on each of these specific areas
Product Focus Groups Groups are being established for all major elements of a wind turbine Rotor Hub (castings, bearings, hydraulics) Composites (blades, nacelles, spinners) Drive Train (shafts, gears, gearboxes, couplings) Electrical (generators, transformers, converters) Control Systems (operational, protective & CM) Structural/Access (Towers, ladders, moorings) Connections (substation, cables, grid connections) Standards/Certification (DIN v EN v ISO etc.)
Product Focus Groups OBJECTIVE To make UK companies an innovative and intrinsic part of the supply chain for wind turbine components initially in the UK then to use this as a basis to build business in export markets
Project Contacts WindSupply MEBC Projects The Arch, 48-52 Floodgate Street Birmingham B5 5SL Tel: 0121 693 8330 Fax: 0121 693 8448 E-mail: info.ebc@btconnect.com Website: www.windsupply.co.uk