10-09-2009di.dk/SiteCollectionDocuments/Do-Gyoon Kim.pdf · Doosan 3MW Offshore ... •HANVICO(Vietnam) :Power & Industrial Plant •HPL ... Innovative Gear Box Design for Light Weight

10-09-2009

1

© Copyright by DOOSAN Heavy Industries & Construction Co. 2009

All Rights Reserved.

Development of

Doosan 3MW Offshore

Wind Turbine System

Korea-Denmark Energy

Conference

September 7, 2009

Do-Gyoon Kim, Staff R&PD Engineer

Wind Power Engineering Team

Power Plant

Doosan Heavy Industries & Construction Co.

Ltd.

2

Company Introduction

Status of Korean Wind Energy Market & Policy

Development of 3MW Class Offshore Wind Turbine(WinDS3000TM

)

Blueprint of Korea-Denmark Wind Energy Cooperation

Contents

2

10-09-2009

2

3

Location

3

⊙ Seoul

◎

Changwon

Head Quarter : Changwon, Korea

Foundation year : 1962

No. of Employee : 5,000

Sales : 3,200 mil. EUR in 2008

Organization : 5 Business groups and 5 Departments

I. Company Introduction

Global Leader in Power and Water

4

• Beijing

• Taipei

• Kuala Lumpur

• Tokyo

• CHICO(Sri Lanka )

• HANVICO(Vietnam) :Power & Industrial Plant

• HPL(Papua New Guinea)

• Doosan E&S(India)

• Frankfurt

• DOOSAN IMGB(Rumania) : Steel Manu./

Casting&Forging

• Doosan Bobcock Energy

• Dubai, Abu Dhabi (UAE)

• Kuwait

• New Jersey (US)

• Schenectady (US)

• Pittsburgh (US)

Asia

• Shanghai

• New Delhi

• Hanoi

• Bangkok

• Mumbai

• Riyadh (Saudi Arabia)

• Tripoli

• Windsor (US)

• Pittsburgh

Europe

Middle East

North America

Branch (19)

Corporation (4)

Subsidiary (9)


Global Networks

10-09-2009

3

5

Korean Wind Resource

5

Korean Wind Resource

Source : KIER (Korea Institute

of Energy Research)

Theoretical Available

• Onshore: 186.5 18.6 TWh/yr

• Offshore: 460.5 46.1 TWh/yr

Source : A Renewable Energy Whiter Paper 2005,

Ministry of Knowledge Economy, Korea

Year 2008 2009 2010 2011 2012 2013

Cumulative Capacity

Installed (MW)311 461 711 1011 1411 1911

Growth rate (%) 63 % 48 % 54 % 42 % 40 % 35 %

Korean Wind Capacity Forecast

Source : BTM Consult ApS – March 2009

II. Status of Korean Wind Energy Market & Policy

6

Class

DOOSAN

HYOSUNG

Rated

Power

3,000 kW

750 kW

2,000 kW

750 kW

2,000 kW

1,500 kW

2,500 kW

1650 kW

2000 kW

2,000 kW

IEC IA

IEC IA

IEC IIA

IEC I/II/IIIA

IEC II/IIIA

IEC IIA

IEC IIA

IEC IA

IEC I/II/IIIA

IEC IIA

Rotor Dia.

91.6 m

48 m

90.6 m

50/54/57 m

88/93 m

70 m

90 m

77 m

76/86/93 m

86 m

• WinDS3000

• HS-48

• HS-90

• U-50/54/57

• U-88/93

• HJWT1500

• SAMSUNG

• HQ1650/200

0

• HR-D86

Model Description

• ’06.09~’09.08 (Oct, ’09, prototype test

scheduled)

• ’01.12 ~’04.12 (DEWI-OCC type cert.)



• ’04.09 ~’07.08 (Prototype testing)


• Developing

• Developing

• Developing

• ’08.10 ~ ’11.07 (Developing)

UNISON

HANJIN

Korean Local Manufacturer

SAMSUNG

HYUNDAE

HYUNDAE

ROTEM


6

10-09-2009

4

7

2030 Vision & Target of Korea Wind Industry


Korea Wind Industry Support Policy

2011

Global

market 33

GW

Target 2%

(660 MW)

2020

Global

market 75

GW

Target 10%

(7.5 GW)

2030

Global

market 158

GW

Target 20%

(31.6 GW)

2011

Top 20

2020

Top 5

2030

Top 1

2030

Global

wind

market

leader

Source : Ministry of Knowledge Economy,

Renewable Energy RD&D Strategy 2030

PTC (Product Tax Credit)

RPS

(Renewabl

e Portfolio

Standard)

Green

Certificate

FIT (Feed In Tariff)

USA

USA*

Italy England

Australia Belgium

Norway Japan

New Zealand

Ireland

Finland

Austria

New

Germany Spain

Korea Denmark

Czech Rep.

France Portugal Greece Swiss

Canada Holland Hungary

Korea Wind Energy Supply Trend

Source : 2008. Korea Power Exchange

(www.kpx.or.kr)

Cumulative

New Cumulative

8

III. Development of 3MW Class Offshore Wind Turbine (WinDS3000TM)

Design Requirements of WinDS3000TM

8

Enhanced Blade Design

Integrated Drive Train

Innovative

Gearbox Design

Multi-Body Dynamics Analysis

PMG + Full Power Converter

Advanced Control System

Component & System Design Concepts: High RAMS + Low COE

SCADA & CMS

High RAMS & Low COE

Simulation-Driven

Hub & Mainframe Design

High Reliability

Maximized

Availability

Reduced O&M Cost

10-09-2009

5

9

Specifications of WinDS3000TM

Power regulation Pitch regulated Electrical

with variable speed Grid frequency 50/60 Hz

Operating data Converter type Full power converter

Rated power 3,000 kW Generator type Synchronous PM

Wind class - IEC Ia Voltage 690 V

Cut-in wind speed 4 m/s

Rated wind speed 13 m/s Main dimension

Cut-out wind speed 25 m/s Blade length 44 m

Operational temperature range -20/50 oC Max. chord 4.15 m

Sound power level at 11.5 m/s 105.6 dB Nacelle dimension

(height x width x length) 5.5 x 4.5 x 12.6 m

Rotor

Number of blade 3

Rotor diameter 91.3 m

Swept area 6,539 m2

Rotor speed (rated) 8 ~ 20.4 (15.71) rpm

Gearbox

Type 2 planetary + 1 parallel

Gear ratio 92.92

Tower

Type Tubular steel tower

Height 77.78 m

9


10

10


Blade Design & Manufacturing

Length : 44 m

Weight : 10.3 tons (incl. T-Bolt & Nut & Platform)

Aerodynamic load reduction

- Slim blade has been applied for load

reduction

EU-90-2300 (basic

model)

Enhanced Blade

Material & manufacturing process changes

- OCF111A(GFRP) SE1500 (GFRP)

- Hand lay-up Vacuum infusion

Structural design and analysis

- Optimized internal structure for weight

reduction

- 11.2 ton (basic model) 9.9 ton (design

model)

Design Improvement

Specifications

10-09-2009

6

11

Flexible pin

2 Planetary / 1 Parallel

Transmission ratio: 92.92

Compact Size

Light Weight

High Reliability

Differential gear

11

Rotating housing

Multi-planet

Innovative Gear Box Design for Light Weight and High Reliability


12

System Efficiency - Windpower 2007, GE

0

50

100

0 5 10 15 20Wind Speed

Eff

icie

ncy,

%

PMG

DFIG

No direct connection

between grid & generator

Easy 50/60Hz grid frequency

conversion

Excellent efficiency

in partial load

Full Power Converter

PMG

Full

Power

Converter

System protection from grid impact

Grid-friendly system

PMG AC/DC DC/AC

Increased annual energy production

- General : 2% more AEP

- Superior AEP in low speed region

12

Permanent Magnet Generator with Full Power Converter

G/B


10-09-2009

7

13

13

Torque

Control

Drive Train

Damper

Power

Control

Tower

Control

Individual

Pitch Control

Maximizing power production

below rated wind speed

Reducing gearbox torque vibration

- by active control of generator torque

Limiting power production

above rated wind speed

Reducing tower vibration and load

Reducing load fluctuation due to wind shear

- increase fatigue life of blade & drive train

Control System


14

14

Sensors• Key phaser

• Accelerometer

• Pressure

• Temperature

• Fiber strain

TCS

(Turbine Control System) SCADA

Client PC• Configuration S/W

• Display S/W

Field Access

CMS Server

•Configuration S/W

•Direct data access & analysis

MASTER

CMS

Wind Turbine

Condition Monitoring System (CMS) & SCADA


10-09-2009

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15

Gearbox cooling system

- Air to oil cooler

- Pump number : 2 EA

Generator cooling system

- Water to air cooler with shaft integrated fan


Inverter cooling system

- Air to water cooler


: 1 EA for each inverter (master/slave)

Nacelle cooling system

-Air to air heat exchanger

Heating Air Inlet

Cooled Air VentThermal Exchange

Aspirator/Ventilation Duct

15

Cooling System


16

Small Jack-up

Barge +

Winch Pulley

System

Doosan WayConventional O&M System

Large Jack-up

Barge +

Crawl Crane

16

Internal Maintenance Crane : Concept

III. Development of 3MW Class Offshore Win Turbine (WinDS3000TM)

10-09-2009

9

17

Enhanced blade design & manufacturing

Weight reduction due to Integrated drive train

Innovative gearbox concept

(rotating housing, differential gear, flexible pin)

Permanent magnet generator with full power converter system

Advanced control system

Condition monitoring system

Isolated nacelle system

Easy maintenance crane concept

Anti-corrosion surface coating against salinity and humidity

Advanced Design

Feature

Offshore Application

WinDS3000 high RAMS and low COE requirements

17


18

Test

Setup

2009. 02

Test with

witness

• No Load (step 1) Full Load (step 10)

Load Test

• Inspection Completed

Certification

Back to Back Test

• Simulated condition at -15℃

• VG1000 instead of VG320

• 5℃ Operating Temp.

Low Temp. Test

18

Back to Back Test for Gearbox


10-09-2009

10

19

• According to GL Guideline

• Load distribution by 2 whiffle tree sets

Test Loads

• Flapwise & Edgewise direction

• 1st & 2nd Natural Frequencies with Accelerometer

Procedure

Static

Test

• Flapwise max & min (2 Steps)

• Edgewise max & min (2 Steps)

Procedure

Modal

Test

2009. 03

19

Full-Scale Blade Static Test


20

• IEC 61400-1

Guideline

Back to Back Test

• Visual Inspection

• Dielectric Test & No Load Test

• Phase Rotation Test

• Over Speed Test

• Demagnetization Test

• Load & Efficiency Test

• Temperature Rising Test

Test

• Winding & Insulation Resistance

• Vibration, Sound Level, THD*

Measure

*THD: Total harmonic distortion

Rotor AssemblyRotor Balancing test Stator Wiring

20

Back to Back Test for Generator


2009. 05

Test

Setup

10-09-2009

11

21

Acquisition of

C-Design Assessment

21


2009. 02. 25

22

Foundation

ConstructionErection

Blade Transportation

(’09. 06)

(’09. 08)

Prototype Test

Tower Transportation

(’09. 08)

(’09. 09)

(’09. 10~)

Nacelle Transportation

(’09. 08)

22


Installation Procedure – Finished & Scheduled

10-09-2009

12

23

1/4

’09 ’10

2/4 3/4 4/4 1/4 2/4 3/4 4/4

• Foundation

• Erection & Test Operation

• Power Curve Assessment

• Load Assessment

• Noise Assessment

• Type Certification

1/4 2/4

’11

Schedul

e• PJT Term : ’09. 05 ~’11.04 (24 months)

• Site : Kimnyeong, Jeju

Project

Scope

• Prototype WinDS3000 Installation

• Operating tests and Measurements

• Type Certification

23


3MW Onshore Prototype Test

24

’09 ’11

• WinDS3000 Manufacture

• Foundation Design

• Foundation Manufacture

• Erection

• O&M

Schedul

e

2/4

’12

Project

Scope

• WinDS3000 1 Unit manufacture

• Offshore foundation manufacture and installation

• Offshore windfarm operation and maintenance

1/4 2/4 3/4 4/4 1/4 2/4 3/4 4/4 1/4 2/4 3/4 4/4 1/4 2/4 3/4 4/4

’10

• PJT Term : ’09. 05 ~’12.04 (36 months)

• Site : Offshore near Woljeong, Jeju

24


3MW Offshore Prototype Test

10-09-2009

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25

Doosan Vision for Wind Energy Business

World Best

Products

Desalination Plant

HRSG

Crank Shaft

Work Roll

Mould Steel

8th World Best Product

Offshore Wind Turbine

Cast Steel

26

IV. Blueprint of Korea-Denmark Wind Energy Cooperation

Reliable market approach and extension

by licensing contract

Employing Vestas’s retired and senior

technical engineers as managers and

consultants of Korean wind power man-

ufacturers and related agencies

Utilizing Korea as new Asian service hub

to consider technology and quality

Including prominent Korean component

makers as Vestas’s major supply chain

Mutual patent cross-licensing

Foundation of collaborative research center

Mutual investment, etc

Including leading Danish component

makers as Korean major supply chain

http://www.google.com/imgres?imgurl=http://corearo.com/img/F003.jpg&imgrefurl=http://corearo.com/about2.html&h=432&w=630&sz=25&tbnid=yAgu8XuTxHtYEM:&tbnh=94&tbnw=137&prev=/images?q=%EA%B5%AD%EA%B8%B0&usg=__NCV8X4zZwxTTCIT1qOyG2TI7_G8=&ei=yo6KSuCtFpDasQOHtNTCDQ&sa=X&oi=image_result&resnum=3&ct=image

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Thanks for Your Attention !!

[email protected]

28


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History

10-09-2009

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29

II. Status of Korean Wind Energy Market & Technologies

What is Wind Energy?

29

Energy converting system from wind to electrical power

Theoretical maximum energy efficiency can be reached up to 59.3%

The efficiency limited to 20~50 % due to aerodynamic, mechanical, electrical losses

Gear Box Generator Electronics GridRotor

Rotation

Energy

Increase

Speed

Electric

EnergyAD to DC or

DC to AC

Electric

Energy

6

30

Global Wind Energy Market Forecast

30

Global Market Growth Rate 29%: 121GW in 2008 to

190GW in 2010

USA and Asia catch up Europe: New installations

Source: World Wind Energy Report 2008, WWEA

II. Status of Korean Wind Energy Market & Technologies

http://blog.naver.com/rnrnrn707.do?Redirect=Log&logNo=140007120939

10-09-2009

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31

High RAMS

Ocean Wind

Easy Approach

Onshore

Offshore

Salinity & Humidity

- Isolation design

- Anti-corrosion coating

Offshore Condition

Load Condition by Offshore Wind


Design Issues for Offshore

31

32

0

20

40

60

80

100

120

0 10 20

Wind vel. (m/s)

He

igh

t (m

)

Onshore

Offshore

Wind

Velocity Onshore Offshore

Wind

Profile

Wind turbine

classI II III

Vref 50 42.5 37.5

Vave 10 8.5 7.5

Vgust50* 70 59.5 52.5

Vgust1** 56 47.6 42

Power factor 0.2

Wind turbine

classI II III

Vref 50 42.5 37.5

Vave 10 8.5 7.5

Vgust50* 62.5 53.125 46.875

Vgust1** 50 42.5 37.5

Power factor 0.14

Wind

Wind speed 10m/s at Hub height 80m

Unit: m/s

*Average max. wind speed during 3sec. with recurrence period of 50 years

** Average max. wind speed during 3sec. with recurrence period of 1 year


Difference of Design Load Between Onshore & Offshore

32

10-09-2009

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33

Conventional Doosan

Way

- Annual failure ratio : 10%

- Average required maintenance cost

during 20 years of design lifetime (unit :

mil. $)

Innovative Customer Value

Creation for maintenance

0.92 G/B

0.92 GEN

1.84

0.52

0.23 GEN

0.23 G/B

0.06 Initial Cost

Immediate ActionSaving Cost (per 1 Unit)

• Small Jack-up Barge Lent

dramatic maintenance time

60 days

Doosan

Way

12 days

Conventional

33

Internal Maintenance Crane : Innovation for Maintenance


* 1 $ = 1275 Won

Cost Save : 1.3 mil. $

Cost Reduction Ratio : 72 %

34


(May ~ August, 2009)

Nacelle Assembly & Nacelle Functional Test

34

http://images.google.co.kr/imgres?imgurl=http://www.bonfiglioli.com/photo_gallery/700t_2.jpg&imgrefurl=http://www.bonfiglioli.com/gallery_prodotti_uk.html&usg=__s1_-aSX8dBY_2kdqnj7O0U2P_0Y=&h=397&w=567&sz=18&hl=ko&start=1&um=1&tbnid=7AURyEcQIU-akM:&tbnh=94&tbnw=134&prev=/images?q=bonfiglioli+wind+yaw+drive&complete=1&hl=ko&lr=&sa=N&um=1&newwindow=1

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Site location Youngdeok, Gyeongbuk

Wind park capacity 39.6 MW

Estimated AEP 96,680 MWh/year

WTG model NM82 (V82)

WTG type class IEC IIB

Number of WTG units 24 x 1.65 MW

Weibull parameter Shape factor (A) : 7.8

Scale factor (k) : 1.98

Project status ’05.3 : start operation

Site location Daegwanryung, Gangwon

Wind park capacity 98 MW

Estimated AEP 244,400 MWh/year

WTG model V80

WTG type class IEC IA & IIA

Number of WTG units 49 x 2.0 MW

Weibull parameter Shape factor (A) : 7.95

Scale factor (k) : 1.61

Project status ’06.10 : start operation


Large Wind Farms in Korea

35

36

Korean Wind Farm Status (2008.09)

36

Already installed To be installed


10-09-2009

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37

Global Wind Energy Forecast

37

2008 2008 2009 2010 2011 2012 2013 Sum Accu.

Total Americas 28,918 9,527 7,650 10,450 12,450 16,200 18,300 65,050 93,968

Total Europe 65,971 9,179 11,580 13,505 15,900 18,080 20,150 79,215 145,186

Total South & East Asia 22,174 8,201 9,650 10,300 12,400 13,400 15,300 61,050 83,224

Total OECD-Pacific 4,256 1,051 1,100 1,350 1,600 1,900 2,250 8,200 12,456

Total other areas 840 232 645 1,035 1,470 1,810 2,520 7,480 8,320

Total MW new capacity every

year:28,190 30,625 36,640 43,820 51,390 58,520 220,995 343,153

Accu. capacity (MW) 122,158 152,783 189,423 233,243 284,633 343,153

Source: BTM Consult ApS - March 2009

Cum

ula

tive

insta

lled

capacity

(MW

)by

end

of

2013

Forecast 2009-2013

Cum

ula

tive

insta

lled

capacity

(MW

)by

end

of

in

2008

Insta

lled

capacity

(MW

) in

2008

Insta

lled

capacity

betw

een

2009-

2013

(incl. Offshore)


© Copyright by DOOSAN Heavy Industries & Construction Co. 2009

All Rights Reserved.

Development of

Doosan 3MW Offshore

Wind Turbine System

Korea-Denmark Energy

Conference

September 7, 2009

Do-Gyoon Kim, Staff R&PD Engineer

Wind Power Engineering Team

Power Plant

Doosan Heavy Industries & Construction Co.

Ltd.