4 - V112-3.0MW_Vestas

Harnessing low and medium onshore winds for you.

V112-3.0 MW

Gianfranco Leoni - Vestas Italia

Agenda

1 The V112-3.0 MW – harnessing low and medium onshore winds for you

2The V112-3.0 MW is designed to optimize your energy production and reduce

energy costs

3 The V112-3.0 MW delivers business case certainty

2

4 Vestas wind turbines also benefit from advanced monitoring solutions

Vestas’ new wind turbine: The V112-3.0 MW

DESIGNED FOR IECIIA and IECIIIA ...

IEC IIEC IIIEC III

V80-2.0 MW

V90-1.8 MW

V100-1.8 MW

IEC IIIEC III IEC IIEC IIIEC III

Existing WTGs

3

6 6.5 7 7.5 8 8.5 9 9.5 10

Wind Speed [m/s]

�112 m rotor

�3.0 MW rated power

V90-3.0 MW

V112-3.0 MWNew WTG

The V112-3.0 MW covers almost three wind classes

500

1000

1500

2000

2500

3000

3500

Pow

er [k

w]

2

4

6

8

10

12

Fre

quency [%

]

V112-3.0 MW Power Curve Probability @7.5 m/s

AEP [MWh]V112-3.0 MW

V112-3.0 MW AEP Benchmarking

Optimized for onshore locations with low and medium wind speed

12.000

15.000

4

00 1 2 3 4 5 6 7 8 9 10111213141516171819202122232425

Wind Speed [m/s]

0

Annual Average Wind Speed [m/s]

�Approved for IECIIa and IECIIIa

�Optimized for wind speed 8,5 m/s

�Nominal rating 3.0 MW

Standard Air Density 1.225 kg/m3

High productivity

0

3.000

6.000

9.000

5,0 5,5 6,0 6,5 7,0 7,5 8,0 8,5

Industry Range

Agenda



energy costs


5


Pitch System�Double feeding pump system ensuring

redundancy and reliability�Solutions for safe work in hub integrated in

design

Blade55% larger swept area over V90-

Vestas CoolerTopTM

�Operation up to 2,000 m

altitude without derating

Permanent magnet generator & Full scale converter �Excellent grid support capability

�Reduced maintenance cost�Highly adaptable for future requirements

�HCCBA bearings (High Capacity Bearing)

Unprecedented energy production and reliable performance

6

Drive train� Integrated rotor lock system to improve

maintenance ability

• Best performing gear solutions (proven from VPDC data) implemented.

�55% larger swept area over V90-3.0 MW

�Large root diameter (Φ2.6 m) ensures blade bearing longevity

�Lightning receptors and internal grounding cable integrated

�Robust performing profiles less sensitive to dirt

�Reduced noise level

altitude without derating�No power consumption for

fans�No noise emission from

cooling system

Yaw System:�8 yaw gears�Robust plain bearing with build

in frictions

Robust DesignHigh Reliability

Lower energy costs

Reducing noise impacts power production minimally

90

95

100

105

110

3 4 5 6 7 8 9 10 11 12 13 14

Mode 2

Mode 1

Mode 0

Power reduction of various noise modes

�Site specific operation modes possible

�High production during low noise operation due to

� Low noise blade profiles

�The full-scale converter

�Permanent magnet generator

Sound power


Power (KW)

7

4.3%MODE 2: MAXIMUM SOUND EMISSION 104.5 DB(A)

0.3%MODE 1: REDUCED SOUND EMISSION AT LOW WIND SPEED

AEP REDUCTION @ 8 M/S

STANDARD MODES 105.0 DB(A)*

Power Reduction of Various Noise Modes

Higher yield

0

1.000

2.000

3.000

3 4 5 6 7 8 9 10 11 12 13

Mode 2

Mode 1

Mode 0


Power (KW)

V112-3.0 MW platform – the new power system

� Permanent magnet generator

�Synchronous

�No slip rings/brushes needed for operation

�Internal ventilation and water jacket cooled

�Compact design

�Low weight

�Hybrid bearings (ceramic)

8

�Hybrid bearings (ceramic)

�Full scale converter

�Water cooled

�Modular layout

�Transformer

� 650 V – 10-35 kV, air cooled

� High voltage cable

�Switchgear

Simple and effective power system with high efficiency and excellent fault ride

through capabilities

The new power system

FeaturesFull grid compliance

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Features� Designed for superior grid support� Power factor range: ± 0.9� Zero Voltage Ride Through: 0.5 s� Fast run back to 20%, spinning reserve 20% to 100%

Full grid compliance� Voltage range 0,8 – 1,2� Frequency 45-65 Hz � FRT Yes� Reactive current injection Yes

� Power Recovery Yes� Short-circuit contribution 1.5 pu� Max short-circuit level 23 kA� Fast ramp up Yes

Excellent grid support capabilityReduced Maintenance Cost

Highly adaptable for future requirements

Reactive power capability

P (pu)

0.5

0.3

0.4

Q (pu)

0.2

0.1

0.0

Power Factor = +/- 0.90

10

P (pu)

0.90.80.70.60.50.40.30.2 1.00.0-0.1

-0.2

-0.3

-0.4

-0.5

0.0

0.1

Under-excited Lagging Inductive

Over-excited Leading Capacitive Improved Grid CapabilityHigher Power Efficiency

Low voltage ride through

Voltage FRT-profile (WTG)

0,00; 1,10

0,00; 0,90

10,00; 0,80

10,00; 0,90

2,60; 0,80

0,45; 0,00

0,00; 0,00

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1,0

1,1

1,2

-0,5 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 6,0 6,5 7,0 7,5 8,0 8,5 9,0 9,5 10,0 10,5 11,0

Time (s)

U (

pu

)

� Designed for FERC 661A regulations

11

� Tested for FERC 661A regulations

Designed AND tested

Reduced BOP cost

Lower foundation costs� Advanced control algorithms (Load Management System)

reduce the loads� Low top head mass reduce the dynamic loads

Reduced substation cost� Full converter reduces the substation size and cost by

eliminating need for StatComs and switched capacitors

12

Reduced BOP cost

eliminating need for StatComs and switched capacitors

Reduced road and crane pad stand cost� No components weigh more than 70 tones'� Replacement of components can be done by tower crane

Designed for uncomplicated transport

Turbine split in modules

�“Easy” transport: In terms of weight, height and width, all of its components comply with local and international limits for standard transportation

�Standard trailers useable for main components

�Easy to use jacking system

13

Easy to transport

Designed for easy service

�Work area in nacelle increased by 60% over previous Vestas turbines

�Nacelle designed with technicians in the Virtual Reality Centre to ensure good working environment (easy access to tools, enough space to do service, etc)

�Service conditions improved by direct crane access to converter modules for quick and safe maintenance.

�Switch gear is controlled via internet connection

14

Designed for serviceability

�Switch gear is controlled via internet connection

�Serviceability build into design. Easy-to-understand storyboards describe exchange of all critical components

�Modular design allows easy access and fast component replacement

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First of its kind – Vestas’ virtual technology improves the arrangement in the hub

� Virtual Reality helps you make sure that service technicians can perform their jobs safely

� Visualisation and simulation technique allows Vestas to communicate and move knowledge much faster to you

15

Easy training of staff

Agenda



energy costs


16


Pitch System�Design based on V90-3.0 MW�Double feeding pump system ensuring

reliability

Blade

Permanent magnet generator & Full scale converter �PM generator: Designed by key employees Vestas acquired

from ePower LLC, which has 3 decades of experience in motor and generator technology

�VND The full-scale converter in the V112 is based on 10(+) years experience from design, operation and manufacture of converters for DFIG system

V112-3.0 MW design based on proven technology

Control system�Design based on V90-3.0

17

Drive train�Based on V90-2.0 MW gear technology�Best performing gear solutions (proven from

VPDC data) implemented

Blade�Design based on V90-3.0 MW�Red

Yaw System:�Design based on V90-3.0 MW

and V90-2.0 MW�Robust plain bearing with build

in frictions

Robust DesignHigh Reliability

Towers:�Designed based on V90-3.0

MW technology

�Design based on V90-3.0 MW

For the new gearbox MONITORING OF 20+ FAILURE MODES IN 12 SEVERE USER SEQUENCE TESTS has been conducted to identify known and unknown potential failure modes

RIGOROUS TESTING OF NEW COMPONENTS

GENERATOR

GEARBOX

GeneratorR = 90.0%

L10 @ 20 years

Vestas Test Center ensures V112-3.0 MW platform reliability

18

Comprehensive testing has been applied to ALL CRITICAL COMPONENTS

Stressors causing failure modes have been identified and TESTED IN SPECIALIZED RIGS to ensure reliability of each component

ENCODER

L10 @ 20 years

CI = 50%

Encoder, ground brushes

and lubrication systemR = 99.0%

L1 @ 5/20 yearsMTBR = 5 years

CI = 50%

HousingR = 99.8%

L0.1 @ 20 years CI = 50%

StatorR = 94.0%

L6 @ 20 years CI = 50%

BearingsR = 99.1%

L0.9 @ 20 yearsL10mh @ 400 khMTBR = 10.7 y

CI = 50%

Bearing

hardwareR = 99.9%

L0.1 @ 20 years

CI = 50%

RotorR = 99.0%

L10 @ 20 years CI = 50%

Stator coreR = 99.9%

L0.1 @ 20 years CI = 50%

WindingsR = 99.8%

L0.2 @ 20 years CI = 50%

Insulation

systemR = 99.0%

L1 @ 20 years CI = 50%

Electrical

connectionsR = 98.5%

L1.5 @ 20 years CI = 50%

Temperature

sensorsR = 96.7%

L3.3 @ 20 years CI = 50%

Rotor coreR = 99.9%

L0.1 @ 20 years CI = 50%

MagnetsR = 99.4%

L0.6 @ 20 years CI = 50%

Magnet

retention systemR = 99.9%

L0.1 @ 20 years CI = 50%

Fan and hubR = 99.8%

L0.2 @ 20 years CI = 50%

ShaftR = 99.99%

L0.01 @ 20 years CI = 50%

IDENTIFY FAILURE MODES & MECHANISMS DESIGN THE TEST

Specific procedures are in place for severe testing of new design elements

19

M10 Bolt

SCHOCK TEST

Y

M10 Bolt

Encoder

Vertical Table

Z

X

Slip Table

Encoder

Direction of vibration

Direction of vibration

CONDUCT THE TEST & EXTRAPOLATE SETUP THE TEST

Vestas has identified all critical processes for both in-house and sub-supplier production and is systematically installing and monitoring quality controls

QUALITY CONTROLS ACROSS PRODUCTION

Span of Control

Nacelles46%

5 SIGMA PRODUCTION PERFORMANCE

DESIGN

SPECIFICATIONS

• …………

•………….

•………….

•………….

5 sigma performance target to ensure EACH COMPONENT IS IDENTICAL to the validated design specifications

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VESTAS HAS A CLEAR OVERVIEWof span of control and sigma performance levels at component, platform, factory and process level

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Span of Control 50% 55% % 55% 45% 45% 0% 0% 35% 41% 35% 56% 56% 77%

Main Processes w ith Control 10 11 0 11 5 5 0 0 6 7 6 5 5 10

Count of Main Processes 20 20 0 20 11 11 11 11 17 17 17 9 9 13

Low est Sigma Level 4,01 2,04 1,51 4,06 3,67 4,5 3,94 4,5

Span of Control

Main Processes w ith Control

Count of Main Processes

3MW Hub

Span of Control 35%

Main Processes w ith Control 6

Count of Main Processes 17

Low est Sigma Level 3,944,06

77%

20

26

4,041,51 3,67 0

13

34

10

1860

10

44

2MW Nacelle 3MW V52

46%

99

2MW Hub 1.65MW

53%

32

38%

213

56%23%

Quality Assurance

Agenda



energy costs


21


Global 24/7/365 COVERAGE OF 16,227 TURBINES with more than 50,000 high speed data tracks per month

Identify performance deviation and issues in the fleet based on predictive models and INITIATE PREVENTIVE MAINTENANCE though conditioning monitoring system & Vestas Turbine monitor

MONITORIDENTIFY

& INITIATE

Vestas performance & diagnostic center offers prevention through prediction

22

Planning of maintenance based on weather forecast & making repairs to MINIMIZE LOST PRODUCTION FACTOR

Findings are used to improve predictive models to provide RELIABLE PERFORMANCE AND YIELD MANAGEMENT

INITIATE

PLAN & REPAIR

LEARN & IMPROVE

Vestas condition monitoring (CMS) - predicting costly mechanical failures

Vibration level

Functional loss

Inspect damage Order spare parts Repair work

Production loss

Corrective service

Predictive service

Using condition monitoring

Damage detected

WITHOUT condition monitoring

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Time

Inspect component Order spare parts Repair work

monitoring

Cost reductionOptimization of maintenance efficiencyMaximized availability and production

�Assessment of the "health" of a machine by analysis of measured signals

�Estimation of time of failure�optimised planning of maintenance activities

VestasOnline® – Vestas’ SCADA solutions

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This SCADA system turns a group of wind turbines into a

wind power plant

Grid meter

Standard features � Plant Layout view� Event notification� Basic Statistics� Online Production View� Event View� 24/7 surveillance� Standard Production Reports

VestasOnline® is the most advanced system on the market today

25

Add-on features� Production Control� Grid Control� 3rd Party grid integration� Plant Customization� Maximized production at PCC� Customized Reports

Allows monitoring of complete park including

substation

THANK YOU FOR YOUR ATTENTION

26

Copyright Notice

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notice from the documents. The documents are provided “as is” and Vestas Wind Systems A/S shall not have any responsibility or liability whatsoever for the results of use of the documents by you.

Vestas wishes to acknowledge and respect all copyrights in connection with the illustrations used in this presentation. In case we have unintentionally violated copyrighted material, we want to be informed

immediately in order to straighten things out and thus to honour any obligatory fees.

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4 - V112-3.0MW_Vestas