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WTG Testing Labs
Gurutz Urzelai
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CENER in numbers
Annual 2008 budget: 23 MM 60% self-financing
200 employees Researchers, technicians and support staff
Total investments (2001-2008): > 90 MM
More than 200 customers in all five continents
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LEA WTG Test Laboratory
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Focused to full-scale WTG components/systems testing
inaccordance with international standards
Activities
Blade testing
Power Train/Generator/Converters/Nacelle testing
Aerodynamic/aeroacustic Wind tunnel Composite materials and
process laboratory
Wind turbine field testing
Experimental wind farm
LEA in numbers
35 engineers and technicians
Invested > 50 M
LEA WTG Testing
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WTG Systems & Components
Rotor
Drive Train
FrameConverters
Control systems
Electric systemYaw system
Tower
Foundation
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WTG design & validation workflow
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WTG costs
WTG costs
main components & systems
Cost % Cost % Cost %
Rotor 27.7 27.7
blades 16.5
hub 7.2
pitch system 4.0
Nacelle & Drive Train
drive train 17.4 46.4
gearbox 13.4
main shaft 2.3
main rolling bearings & rotor lock 1.3
vibration isolation 0.3
generador isolation 0.1
frame 3.8 29.0
generador cooling system 0.3
brakes & hidraulics 0.6couplings 0.3
nacelle cover 1.9
generator 6.7
converters 6.9
trasformer 2.5
cables 2.0
switchgear 1.4
yaw system 1.8control systems & safety 0.8
Tower 20.5 20.5 20.5Foundation 5.4 5.4 5.4
100.0 100.0 100.0
0 5 10 15 20 25
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LEA Blade Testing Laboratory
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LEA Blade Testing Laboratory
Performs structural tests on WTG blades IEC TS-61400-23
standard
Static/Fatigue
Up to 75 m blade lengths Sections of 100m blades length
Static Tests Mass, COG, moments of inertia
Stiffness bending/torsion
Ultimate strength
Max. deflection
Fatigue Tests Modal analysis
Endurance/fatigue
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LEA Power Train Test Laboratory
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LEA Power Train Testing
Power Train testing WTG power train up to 5MW
Functional tests on mechanical parts
Endurance test till 8MW
Generator/converters testing Functional/accelerated lifespan
test of WTG generator/power
electronics
Electrical transient testing (voltage dips)
Functional testing, vibration, acoustic noise, heating, etc.
Over speed testing and transients surges
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LEA Power Train Test Laboratory
Nacelle testing tests on complete nacelle
electrical transient simulation Voltage dips
Nacelle assembly site test of nacelle assembly
WTG erecting and nacelle setup procedures
Use of auxiliary assembly cranes
Maintenance procedures tuning, including major corrections
Staff training in the assembly and maintenance
Training in evacuation and security operations
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LEA Wind Tunnel
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LEA Wind Tunnel
Designed as a tool for aerodynamic andaeroacustic R&D of WTG
blades
Optimised to perform 2D test on blade profiles Outstanding
quality very low turbulence/noise levels
Test can be developed to 3D blade elements andblade tip
Can to be updated for trial needs in subsonicaerodynamic
tunnels
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LEA Wind Tunnel
Technical characteristics Reynolds Num. > 6 million
Acoustically conditioned closed circuit tunnel Test section 2.8
x 1.4 x 8 meters (H/W/L)
Maximum test speed 90 m/s
Turbulence level better than 0.1%
System of dynamic support for 2D profile models
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LEA Wind Tunnel
Equipment 150 channels static pressure
100 channels non-stationary pressure (>50 Hz) 3 channels hot
wire anemometer probes
DAS for charging cells
Phased microphone array for acoustics
Stereoscopic PIV system (Particle Image Velocimetry)
High speed CCD cameras
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LEA Composites/Process Lab
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LEA Composites/Process Lab
used to Evaluate feasibility of new designs
Optimize the manufacturing process for composites
Characterize process control variables
Determine the physical, chemical and mechanical properties
ofmaterials
equipment CSC
SMTA
Viscosimeter, gel meter, etc.
Optical microscope with image treatment Machine for static
tensile/compression tests up to 600kN
Machine for fatigue tests of 250kN
Hot plate press polisher, mixer, scales, oven, etc.
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LEA Wind Turbine Field Testing
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LEA Wind Turbine Field Testing
in order to carry out WTG certification tests
field tests accredited by ENAC
under MEASNET seal and recommendations
in accordance with IEC international standards Power Curve IEC
61400-12-1
Acoustic Noise IEC 61400-11
Energy Quality IEC 61400-13
Mechanical Loads IEC 61400-21
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Experimental Wind Farm
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Experimental Wind Farm
6 calibrated positions used to install WTF prototypes of
machines up to 5 MW
perform complex field text on prototypes
certify wind turbines
equipment 6 meteorological towers 120 m high
6 sites up to 5 MW electrical network connection 20KV/66KV
technological services
Certification IEC tests (Power Curve/Noise/PQ/Mech. Loads)
Verification of response to voltage dips
Others (design, optimization, validation, etc.)
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C/ Ciudad de la Innovacin, 731621 Sarriguren Navarra
(Spain)
Tel.: +34 948 25 28 00Fax: +34 948 27 07 74Email:
[email protected]
www.cener.com
mailto:[email protected]:[email protected]
