核研所中小型風機的設計驗證

The Design Certification for INER Small/Medium Size Wind Turbine

張 欽 然 Chin-Jen Chang核能研究所 Institute of Nuclear Energy Research (INER)

2008.07.31 C.J. Chang (INER)-1

2008.07.31 C.J. Chang (INER)-2

Contents1. The Notion of Developing

Small/Medium WT at INER

2. Current Status of INERWT Program

3. The Practice of Small/MediumWT Certification

4. The Design Certification of INER-25CA WT

5. Conclusion

演講內容

1. 核研所發展中小型風機的理念

2. 核研所發展中小型風機的現況

3. 中小型風機驗證實務之推動

4. 25kW風機設計驗證之內涵

5. 結論

2008.07.31

1. 核研所發展中小型風機的理念(The Notion of Developing Small/Medium WT at INER)

市場在哪裡 ( Where is the market ?)

產業在哪裡 ( Where is the technology ?)

技術在哪裡 ( Where is the industry ?)

產品特色在哪裡 ( What are distinguishing features of the product ?)

2008.07.31 C.J. Chang (INER)-3

市場在哪裡 ( Where is the market ? ) – Global(1)2008.07.31 C.J. Chang (INER)-4

$12,910,920 3,354 5,372 $27,936,140 7,100 8,159 Total $10,593,840 2,888 5,303 $13,581,920 3,981 7,743 Off-Grid $ 2,317,080 466 69 $14,354,220 3,119 416 On-Grid

Sales ($USD

abroad)

kW (sold

abroad)

Units (sold

abroad)

Sales ($USDin U.S.)

kW (in U.S. )

Units(in U.S.)

U.S. MFRS.(美國廠家)

$13,179,800 2,904 711 $ 5,268,500 1,465 170 Total$ 1,263,000 156 359 $ 406,500 62 133 Off-Grid $11,916,800 2,784 352 $ 4,862,000 1,403 37 On-Grid

Sales($USD

abroad)

kW (sold

abroad )

Units (sold

abroad.)

Sales ($USDin U.S.)

kW (in U.S..)

Units(in U.S.

Non-U.S. MFRS.

(非美國廠家)

59,295,36014,82326,090,72033,204,6406,2588,5656,0838,329

14,412

Sales inNon-U.S.

Sales inU.S.

kW inNon-U.S.

kW inU.S.

Units in Non-U.S.

Units in U.S.

GloballyTOTAL

Ref: 2007 AWEA Small Wind Global Market Study (Data Revision)

A market survey for 2006 global small wind turbine market

市場在哪裡 ( Where is the market ?) – Global(2)2008.07.31 C.J. Chang (INER)-5

6,258 kW

~10,800 kW

compared with PV system

Ref: 2008 AWEA Small Wind Global Market Study (Data Revision)

Cumulative Installed in 2007 : 50~60 MW

29%/yExpected Cumulative Installed in 2015 ~ 288 MW

市場在哪裡 ( Where is the market ?) – Global(3)2008.07.31 C.J. Chang (INER)-6

An outlook of potential for small/medium size wind turbine market

Ref：(1)AWEA 2002-The US Small Wind Turbine Industry(2) US DOE, 2004 - Low Wind Speed Technologies Program Subcontract Overview

Note: An EWEA Target for WT Installation in 2020 Is 1,200,000 MW Globally.

211,800 130,950 Totals1.5~2.0 kW17,400 9,800 Miscellaneous1.5~2.0 kW24,400 13,650 Facilities

10 kW66,000 49,000 Village System0.3~0.4kW104,000 58,500 Single Home System

Countries Outside U.S.138,725 合 計

1.0 kW350 –Water Pumping250 kW50 –Off-grid Communities3.0 kW450 –Off-grid Homes50 kW8,000 –Public Facilities25 kW16,875 –Commercial Buildings7.5kW113,00097,500Rural Single Home

U.S.Average Size (kW)2020 (MW)2010 (MW)

Far Beyond Reachable

市場在哪裡 ( Where is the market ?) – Taiwan(1)2008.07.31 C.J. Chang (INER)-7

5.04.06.52.54.06.56.513.0Peak Load ExpectedIn 2015(MW)

5.64.913.03.04.0Grid-tied to Taiwan

(2MW Emg.)

4.07.5InstalledDiesel (MW)@2006

200,00014,000100,00052,000110,000167,00047,000400,000Tourist

A total of 20~30MW renewable energy is expected for 121 remote islands of Taiwan.

3.02.54.01.52.54.02.53.6Peak Load (MW)@ 2006

5,6001,8005,2003,1001,50013,0003,0003,200Population

LeihyuIsland(烈嶼)

BeiganIsland(北竿)

NanganIsland(南竿)

CimeiIsland(七美)

WanganIsland(望安)

LiuchiuIsland

(小琉球)

OrchidIsland(蘭嶼)

Green Island(綠島)

The electricity demand at several outThe electricity demand at several out--lying islands of Taiwan*lying islands of Taiwan*

•Ref: Taiwan Institute of Economic Research &. Institute of Nuclear Energy Research “A strategic planning evaluation for deploying an integrated renewable energy system among remote islands of Taiwan ,“ 2006

An early market for deploying homemade small/medium WT

市場在哪裡 ( Where is the market ?) – Taiwan(2)2008.07.31 C.J. Chang (INER)-8

Comparisons of the electricity capital costs at out-lying islands of Taiwan with respect to costs of various energy types

NTD/kWh

4

8

12

16

20

2005 TaiwanElectricityPrice

Peak Average 3.0Average 2.05Off-Peak Average 0.8

Magong Wangan Cimei(Penghu Archipelago)

OrchidIsland

GreenIsland Wind

SolarElectricity

Biomass

1st Gen.PV

Estimated 3rd Gen. PV

6.56

11.00

9.20

11.00

2010

2015

SolarThermal

2010

Geothermal

2010

11.00

2010

LargeWindTurbine

SmallWindTurbine

OTEC

2010

Including Deep Sea Marine Products

USD:NTD= 1:32.5 during Oct. 2007

市場在哪裡 ( Where is the market ?) – Taiwan(3)2008.07.31 C.J. Chang (INER)-9

14814

10

114 6

25

5

17

213

104

4

Ref: Taiwan Leisure Farming Developing Association (台灣休閒農業發展協會)

The Distribution of Leisure Farms in Taiwan

Total : 147

(1)Actual Leisure Farms are far more than 147 ( > 500 ). 休閒農莊

(2)There are about 40 Leisure Fishing Areas (Seashore &. Ponds). 休閒魚場

(3) There are about 60 Recreation Garden. 遊樂園區

For those spots mentioned above, half of it have the WT installation potential and the installed capacity is 25~200kW each.

A total of 40 MW small/medium WTearly market is expected.

產業在哪裡 ( Where is the industry ?) - Domestically2008.07.31 C.J. Chang (INER)-10

————Hydraulic or Elec. Motors

————————Bearing/Slip Ring (軸承/滑環)

——————————Certification (設計與實體驗證)

————System Integration (系統整合)

————Inverter (併網電力轉換器)——Tower/Foundation(塔架/基礎)

——Control/Monitoring (監控)

————PM (永磁)

Induction (感應)

Offshore> 3MW

Large> 200kW

Medium

技術在哪裡 ( Where is the technology ?)

2008.07.31 C.J. Chang (INER)-11

空氣動力設計Aerodynamic Design

葉片結構設計與分析Blade Design

整機組件與結構設計與分析Integrated Mechanic Design

運轉邏輯設計Operation Logic

液壓或電動馬達控制Hydraulic or Elec.Motor Control on

傾角馬達 Pitch motor轉向馬達 Yaw motor煞車馬達 Break motor

發電機 Generator滑環 Slip Ring

閃電條 Lightening Strip感測器 Sensors

併網電力轉換器 Inverter儲能系統 Power Storage

運轉與控制人機介面Operation &. Control

Man-machine Interface

輪轂/主軸 Hub/Shaft軸承 Bearing

齒輪箱 Gear Box機身 Nacelle轉向機構 Yaw煞車機構 Break

塔架 Tower

設計負載計算與分析 Design Load Case Load Envelop Analyses

葉片 Rotor Blades傾角機構 Pitch

產品特色在哪裡(What are distinguishing features of the product ?)

2008.07.31 C.J. Chang (INER)-12

便宜(Low capitalized cost)?

整機高效率(High integrated efficiency)?

抗颱/防震(Anti-typhoon, Anti-earthquake)?

美觀/低噪音(Artistic outlook, low decibel)?

操作容易/低維修(Easy operation &. maintenance)?

前瞻型的風機形式(Advanced WT model )?

2008.07.31 C.J. Chang (INER)-13

2. 核研所發展中小型風機的現況(Current Status of INER WT Program)

Technical Cooperation with Domestic Industry – (1) 6m &.13m WT Blade Fabrication, (2) 36kW PM Generator, (3) 180kW PM Generator, (4)36kW Grid-Tie Inverter (with MPPT), (5)180kW Grid-Tie Inverter (with MPPT), (6) 50m Truss Tower Technical Transfer to Domestic Industry – (1)TI F2812Chip DSP Control Technology： 1 contract signature on processing (2) WT Blade

Design and Fabrication Process：1 contract signature on processing；(3) 1kW Vertical WT System Integration ：1 case under negotiation

(1)Small/Medium Size WT System Integration

(2) IEC61400-1&.2 Compliance(3)Mechanical Structure Design

and Safety Assessment (Static /Dynamic Rotation Analysis )

ANSYS-WorkBench/ YAWDYN(4)High Level CAD/CAM

SolidWork/Pro-E/NX…..

System Integration Design &. Analysis

System Integration150kW WT – Under Design. Figure shows the fabrication of its 13m long WT blade. Rated at 11~12 m/s， Pitch/Yaw/Break Active Control, Grid-Tie with MPPT.

25kW Commercial Type WT – Both Passive and Active Type are Developing. Figure show the test of a passive type Class-IA WT, rated at 9~10 m/s, Grid-tie with MPPT.

25kW Pilot WT – Pitch/Yaw/Break Active Control. Under Operation. Figure shows the operation at INER WT test site and the maintenance at machine shop。

Core TechnologiesCore Technologies

200kW Dynamo and Torque Meter Test Station

(1) 2D&.3D Aerodynamic and Loading Assessment -BEM/FLUENT/AERODYN/FAST

(2)WT FRP Blade Structure Design and the Development of Fabrication Process

(3)DSP Control/Sensors/Motor Monitoring and Control &. Man-machine Interface

(4) AC/DC Power Conversion and Grid-tie Technology

(5) Generator Driver Design and Electromagnetism Theory – Maxwell

(1)WT Siting and Wind Potential Assessment – Wasp 9.0

(2)Wind Farm Siting and Assessment - WindFarm

(3)High Performance Cluster Computing Environment for Wind Field Forecasting (i) MM5+Wasp 9.0 (ii)WRF+Wasp 9.0

Ground Dynamo Test Station

Key Components Design and Analysis

Wind Field Assessment &. Forecasting

2008.07.31 C.J. Chang (INER)-14

2008.07.31 C.J. Chang (INER)-15

3. 中小型風機驗證實務之推動(The Practice of Small/Medium WT Certification)

Q4Q4Q3Q3Q2Q2Q1Q1Q4Q4Q3Q3Q2Q2Q1Q1Q4Q4Q3Q3201020102009200920082008

預期進展 (Proposed action plan)

(1) INER-C25A design evaluation conformity IEC-61400-2 (TUV-Nord)

(2)INER-C25A power measurement IEC-61400-12 (and accredited for site testing )duration test (load measurement IEC-61400-13 and Blade tests IEC-61400-23)

(3) INER-C25A manufacturing evaluation (if there is a whole system technical transfer)

technical transfer

(4) INER-P150A design evaluation conformity

(5) INER-P150A power measurement and duration test

(6) INER-P150A manufacturingevaluation

technical transfer

(7) dynamo station laboratory accreditation

2008.07.31 C.J. Chang (INER)-16

IEC WT-01 Type Certificate Schemes

相關驗證技術之建立 - 核研所所區實地風場測試(Past practice – power measurement of INER-P25 at INER)

-21.2 ~ 21.2

-163 ~ 102.4

2.3 ~ 73.7

-22.0 ~ 47.6-132.3 ~ -15.3

21.3 ~ 101.5

-161.5 ~ 143.5

-179.2 ~ -84.8受影響之風向 d

0

149.7

38

12.8-73.8

61.4

171

-132方位角θ

41.414.10.960.5A Vertical WT

94.6187.5515Tree 4

71.425.25.9411.4Tree 3

69.546.410.3636Tree 211717.612.2748Tree 1

80.246.613.8929.4Building 039

55.1395.3322.8Building 072

94.4135.4327.3Building 049αLe (m)De (m)Ih (m)Iw (m)障礙物

測試場址必須依照 IEC-61400-12 Annex B進行校正 (Practice on IEC-61400-12 Annex B)

2 4 6 8 10 12 140

2

4

6

8

10

12

Wind Speed (m/s)

Gen

erat

or O

utpu

t Pow

er (k

W)

DataCFX Prediction

Pitch 75

2 4 6 8 10 12 140

5

10

15

20

25

Wind Speed (m/s)

Gen

erat

or O

utpu

t Pow

er (k

W)

DataCFX Prediction

Pitch 85

2008.07.31 C.J. Chang (INER)-17

PC

NI

Wind Field Simulation and WT Model Regulating Software System 風速 Wind Speed風向 Wind DirectionWind power modelBlade/Turbine model

待測物平台Test Devices :

Gear Box,Generator,

WT without Blade….

RegulatingGear

Control Area

180kWLoad Bank

Electricity Distributor

200kWDynamo

Driver

LoadController

Testing Area

TorqueMeter

Couplings

控制器設計Controller Design

MPPTMatlab/Simulink

ω

τ

200kW風機地面動力測試平台—2007年 8月建置完成

相關驗證技術之建立 - 200kW 地面動力測試平台(Past practice – 200kW dynamo test station )

2008.07.31 C.J. Chang (INER)-18

卡板測量及檢查翼面的尺寸於中科院航研所進行極限風速拉力測試

真空注膠過程

葉片發泡模具成形

拉力測試圖

相關驗證技術之建立 -葉片製程與拉力測試(Past practice – blade fabrication examination and static test )

2008.07.31 C.J. Chang (INER)-19

2008.07.31 C.J. Chang (INER)-20

4. 25kW風機設計驗證之內涵(The Design Certification of INER-25CA WT)

INER-C25A IEC-61400-2(Ver. 2006)design conformity evaluation (TUV-Nord)

設計驗證項目 (Items submitted for review)(1)Load Envelop(2)Safety System and Manuals(3)Rotor Blade(4)Machinery Components (5)Electrical Equipment(6)Towers

2008.07.31 C.J. Chang (INER)-21

IEC-61400-2 氣動力程式計算需考慮的負載案例(IEC-61400-2 Design load cases – aerodynamic modeling )

2008.07.31 C.J. Chang (INER)-22

IEC-61400-2 的簡化估算或經由氣動力程式計算負載(IEC-61400-2 simplified model or aerodynamic model assessment ?)

簡化估算模式(IEC-61400-2 7.4)通常過於保守The simplified model (IEC-61400-2 7.4) is usually too conservative.

氣動力程式計算負載(Load assessment by aerodynamic model)

BEM-INER

ANSYS-CFX

FLUENT

YawDynAeroDyn

FASTFLUENT

XFoilCL、 CD、CM…

SolidWork

UG

2D Aerodynamic Analyses二維葉型氣動力分析

3D Aerodynamic Analyses &. WT Model三維葉型氣動力分析及風機/塔架模型

Design Load CasesScreening設計負載案例之篩檢

Max. Extreme &.Fatigue Loads設計負載案例之最大極限與疲勞負載

Bmodes(Blade/Tower Freq.)

IEC-Wind

2008.07.31 C.J. Chang (INER)-23

設計負載範圍分析 – 運轉邏輯建立The load envelop assessment – the operation logic

Special Operation

Emg.Shutdown

NormalPark

TyphoonMode

ForcedIdling

Normal Operation

Initiation

Startup

Normal Op.

Rated Op.

Stall Idling

Idling

Fault RecoverSafety System Operation Logic

2008.07.31 C.J. Chang (INER)-24

設計負載範圍分析 – 軟硬體安全控制機制The load envelop assessment – monitoring &. control scheme

風機控制策略 風機監控系統

系統初始化

正常運轉

滿載運轉

惰速待機

惰速

緊急停機

颱風模式

手動惰速

正常停機

控制器 (RT+FPGA)

温度感測器

編碼器

限制開關

風速計

風向計

Pitch系統

主軸煞車液壓系統

Yaw系統

Yaw煞車液壓系統

監控電腦

人機介面 (UI)

Auto/Mannual Mode

傾角控制

煞車控制

調向系統

歷史資料查詢

即時資料查詢

遠端監控

温度感測程式

風速計感測程式

風向計感測程式

Pitch轉速感測程式

Yaw轉速感測程式

Yaw煞車控制程式

主軸煞車控制程式

Pitch液壓幫浦驅動程式

Yaw液壓幫浦驅動程式

壓力感測程式

濾網感測程式

控制系統硬體

系統初始化控制程式

惰速待機控制程式

正常運轉控制程式

滿載運轉控制程式

惰速待機控制程式

惰速控制程式

緊急停機控制程式

颱風模式控制程式

手動惰速控制程式

正常停機控制程式

異常處理控制程式

FPGA 風機控制系統

Labview 程式

RT- NI/cRio9004 FPGA- NI/cRio9102

FPGA: Field Programmable Gate Array RT: Real Time

2008.07.31 C.J. Chang (INER)-25

設計負載範圍分析 – 設計負載案例之篩檢(一)The load envelop assessment – design load cases screening (I)

Example : DLC 2.2 – at least 28 analyses

0 2 4 6 8 10 12 14 16 18 20 22 24 26 280

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2x 10

4

DLC 2.2-xx

Bla

de In

-pla

ne M

omen

t, M B

x (N

-m)

Blade In-Plane Moment

0 2 4 6 8 10 12 14 16 18 20 22 24 26 280

2000

4000

6000

8000

10000

12000

14000

DLC 2.2-xx

Bla

de O

ut-o

f-pla

ne M

omen

t, M B

y (N

-m)

Blade Out-Plane Moment

0 2 4 6 8 10 12 14 16 18 20 22 24 26 280

50

100

150

200

250

300

350

400

450

500

DLC 2.2-xx

Bla

de P

itchi

ng M

omen

t, M B

z (N

-m)

Blade Pitching Moment

0 2 4 6 8 10 12 14 16 18 20 22 24 26 280

0.5

1

1.5

2

2.5

3

3.5

4x 10

4

DLC 2.2-xx

Sha

ft To

rque

, MSx (

N-m

)Shaft Torque

0 2 4 6 8 10 12 14 16 18 20 22 24 26 280

2000

4000

6000

8000

10000

12000

DLC 2.2-xx

Sha

ft Th

rust

For

ce, F

Sx (

N)

Shaft Thrust Force

0 2 4 6 8 10 12 14 16 18 20 22 24 26 280

500

1000

1500

2000

2500

3000

3500

4000

4500

DLC 2.2-xx

Sha

ft La

tera

l For

ce, F

Sy (N

)

Shaft Lateral Force

0 2 4 6 8 10 12 14 16 18 20 22 24 26 280

500

1000

1500

2000

2500

DLC 2.2-xx

Sha

ft V

ertic

al F

orce

, FSz

(N)

Shaft Vertical Force

0 2 4 6 8 10 12 14 16 18 20 22 24 26 280

1000

2000

3000

4000

5000

6000

7000

8000

DLC22 xx

Turb

ine

Yaw

Mom

ent,

M z (N

-m)

Turbine Yaw Moment

2008.07.31 C.J. Chang (INER)-26

設計負載範圍分析 – 設計負載案例之篩檢(二)The load envelop assessment – design load cases screening (II)

There are total of 183 DLC simulation cases for INER-C25A

For Blade, Shaft, and Yaw, maximum ultimate loading and fatigue loading cases and values are identified.

For cases mentioned above, FLUENT calculations are performed for further verifications.

Example Example

2008.07.31 C.J. Chang (INER)-27

設計負載範圍分析 – 最大極限與疲勞設計負載之決定The load envelop assessment – extreme &. fatigue Loads

1.2-3 1.2-6a 1.2-6b 1.3-16 1.3-19 1.3-22 2.2-4 2.2-23 2.2-27a 5.1-5 5.1-15 6.1-39 6.1-37 6.1-500

0.5

1

1.5

2

2.5

3x 10

4

Design Load Case

Bla

de In

-pla

ne M

omen

t, M B

x (N

-m)

Example:FLUENT calculated blade In-Plane Moment (Ultimate))

1.2-3 1.2-6a 1.2-6b 1.3-16 1.3-19 1.3-22 2.2-4 2.2-23 2.2-27a 5.1-5 5.1-15 6.1-39 6.1-37 6.1-500

0.5

1

1.5

2

2.5

3x 10

4

Design Load Case

Sha

ft Th

rust

For

ce, F

Sx (

N)

Example: FLUENT calculated shaft thrust force (ultimate)

0 2000 4000 6000 8000 10000 12000

2.2-42.2-10a2.2-10b2.2-132.2-232.2-25

2.2-27a2.2-27b5.2-5a5.2-5b5.2-5c5.2-65.2-9

5.2-10a5.2-10b5.2-10c

Des

ign

Load

Cas

e

Blade In-plane Moment, MBx (N-m)

Example: FLUENT calculatedshaft thrust force (Fatigue)

Example: FLUENT calculated blade In-Plane Moment (Fatigue)

0 0.5 1 1.5 2 2.5 3

x 104

2.2-42.2-10a2.2-10b2.2-132.2-232.2-25

2.2-27a2.2-27b5.2-5a5.2-5b5.2-5c5.2-65.2-9

5.2-10a5.2-10b5.2-10c

Des

ign

Load

Cas

e

Shaft Torque, MSx (N-m)

2008.07.31 C.J. Chang (INER)-28

重要組件應力與疲勞分析Key components stress and fatigue analyses

INER-C25A

2008.07.31 C.J. Chang (INER)-29

5. 結論 (Conclusions) – Learning to grow

核研所致力於由小而大建力風機整體系統設計與整合技術。希望與各界進行合作或技轉。INER has endeavored to establish WT system design and

integration technologies, rooting from small/medium size WT.

驗證是系統整合的重要內涵與技術重點，提供對風機特性的完全掌握，對中大型風機尤其重要。

The certification is an essential for WT system integration,providing to know well the characteristics of your WT design. It is especially important for medium/large size WT.

2008.07.31 C.J. Chang (INER)-30

中小型風機比起大型風機，有因地制宜、分散式電力供給、小容量供電區易於調節的發展特色，同時在全機系統組件國內自給供應鏈上幾乎立即可成，而且小而美及成本降低能力一向就是國內產業的競爭優勢。There are chances for small/medium size WT industry: (1) Easily tailored for local condition (2) Distributed generation for remote area(3) When centrally connected at low capacity area,

the electricity dispatch is more facile.(4) Sufficient domestic supplied chain

謝謝聆聽 Thank you !