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October 30, 2007 © SKF Group Slide 0
Wind power from a component industry perspective
Presented at Chalmers Energy Conference
Presented by Olle Bankeström Programme Manager, Application Development
Gothenburg 2012-03-28
October 30, 2007 © SKF Group Slide 2
1 SKF in wind energy
October 30, 2007 © SKF Group Slide 3
Snapshot of wind energy in 2005
Annual Wind Power DevelopmentActual 1990-2005 & Forecast 2006-2010
0
5,000
10,000
15,000
20,000
25,000
30,000
1990 1995 2000 2005 2010
MW
Europe USA Asia Rest of World ExistingSource: BTM Consult ApS - March 2006
The wind energy market 2005 • Mainly a European centered industry • Wind turbine manufacturing mainly in Germany, Denmark & Spain. • Installation of 11 542 MW (2005) • Totally installed 59 399 MW • Average turbine size installed; 700 kW
SKF position in wind energy 2005 • Well connected with several leading wind turbine & gearbox manufacturers • Offering range of standard bearings. • Manufacturing of LSB-Wind range in Germany and Sweden • Wind energy business represented around 1% of SKF Group global sales
October 30, 2007 © SKF Group Slide 4
Snapshot of wind energy in 2010
The wind energy market 2010 • Industry quickly becoming global with China developed to largest market. • Wind turbine manufacturing well distributed to China, Germany, Denmark, India, Spain. USA, S. Korea and other emerging markets • Installation of 39 404 MW (2010) • Totally installed 199 520 MW • Aftermarket business potential gradually becoming significant • Average turbine size 2010; >1600 kW
SKF position in wind energy 2010 • Established key-supplier and development partner with most leading wind turbine & gearbox manufacturers. • Close interaction with leading design consultants established • Industry customized offering range from several platforms. • Manuf. of LSB-Wind range in Germany, Sweden, France, USA, China and India • Wind energy business represented 4-5 % of SKF Group global sales
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
1990 1995 2000 2010 2015
MW
Annual Wind Power Development
Europe USA Asia Rest of World ExistingSource: BTM Consult - A Part of Navigant Consulting -March 2011
Actual 1990-2010 & Forecast 2011-2015
October 30, 2007 © SKF Group Slide 5
Global wind manufacturing structure & SKF large size bearing-wind mfg footprint
Major turbine & gearbox OEM market
Major turbine OEM market Major gearbox OEM market
Smaller/emerging turbine OEM market
Emerging/potential turbine OEM market
Source: SKF
October 30, 2007 © SKF Group Slide 6
Major growth area: China, India, South Korea,
Expected business growth area 2012-2015; USA and Canada.
Next emerging manufacturing region: Latin America, mainly Brazil & Argentina
Core of Wind-Offshore development and installations.
Global wind manufacturing structure & SKF large size bearing-wind mfg footprint
Source: SKF
Major turbine & gearbox OEM market
Major turbine OEM market Major gearbox OEM market
Smaller/emerging turbine OEM market
Emerging/potential turbine OEM market
October 30, 2007 © SKF Group Slide 7
VESTAS (DK) 14.8%
SINOVEL (PRC) 11.1%
GE WIND (US) 9.6%GOLDWIND (PRC)
9.5%ENERCON (GE)
7.2%
SUZLON GROUP (IND) 6.9%
DONGFANG (PRC) 6.7%
GAMESA (ES) 6.6%
SIEMENS (DK) 5.9%
UNITED POWER (PRC) 4.2%Others 20.9%
Top-10 Suppliers (Global) in 2010
Source: BTM Consult - A Part of Navigant Consulting - March 2011
% of the total market 39,404MW
Globally leading suppliers of wind turbines
October 30, 2007 © SKF Group Slide 8
Pitch bearings
Yaw bearing
Mainshaft housings and locknuts
Condition Monitoring WindCon/WebCon
Couplings
Automatic distributed lubrication system
Monitoring and diagnostics services
Mechanical repairs & refurbishment
Sealing solutions
Bolt tensioning tools Tower alignment services
Engineering Consultancy Services
Plain bearings
Maintenance tools and grease
SKF contribution to wind turbine technology
Gearbox bearings TRB/CRB/SRB/CARB/DRTRB
Generator bearings DGBB/InsoCoated/Hybrid
Mainshaft bearing(s) NautilusTM, , SRB/CARB, TRB, DRTRB/CRB
October 30, 2007 © SKF Group Slide 9
2 Market challenges and technology development
October 30, 2007 © SKF Group Slide 10
Major trends in Wind Energy
• Quick globalization of an emerging industry • Massive growth by leading Asian turbine manufacturers • Going into extreme climates; Deserts, Arctic areas • Industry going Offshore -> new requirements on turbines and O&M. • Expanding turbine sizes, MMW-class gaining importance • Direct drive turbines expansion versus gearbox-equipped • Major expansion and maturing of windfarm service business • An industry driven (and limited) by political decisions.
October 30, 2007 © SKF Group Slide 11
Recent SKF market launches towards wind energy
New CRB-design with extra-high carrying capacity + new (2010) separable version
WindCon 3.0/WebCon for early detection of mechanical failures
New pitch bearing design with improved corrosion protection
Nautilus™ -unit with segmented cage for minimized friction
XL Hybrid bearings with ceramic balls for superior insulation of wind-generators
Automatic centralized lubrication kits for reduced maintenance costs.
Remote analysis & monitoring services of wind farms
October 30, 2007 © SKF Group Slide 12
Early warning of turbine problems; SKF WindCon
time
Wear/ damage
initial damage
breakdown
measureable damage
prewarning time (analysing, documentation, planning)
velocity / endoscopy/ gearbox oil debris
human sense
enveloping of vibration signal
x
x
x exchange parts
October 30, 2007 © SKF Group Slide 13
SKF WindCon for improved windfarm efficiency
Benefits & Values: • Vibration measurement to detect initiating failures before they lead to major breakdowns • Monitor all mechanical components and sub-systems • With predictive maintenance, better utilisation of service teams on shorter planned stops • Reduce overall costs for maintenance, repair and sparepart in the windfarm • Improve overall uptime of the windturbine • Increase overall returns on windfarm investments
SKF Service: Installation - Monitoring – Analyzing – Predictive maintenance – “top-of-turbine” repairs, spare part management SKF Wind Industry Service Centers all ove the world are monitoring around 1000 turbines
October 30, 2007 © SKF Group Slide 14
3 Knowledge engineering with SKF
October 30, 2007 © SKF Group Slide 15
From an SKF perspective we can: Take a system approach and integrate knowledge
CASE: The gearbox and the generator that were related BENEFIT: Finding the root cause
Bridge between involved parties e.g. OEM and end user CASE: The generator that kept failing BENEFIT: Increased service life
Benchmark with other industries CASE: Very reliable gearboxes in railway, trucks and automotive BENEFIT: Sharing experience
October 30, 2007 © SKF Group Slide 16
The gearbox and the generator that were related...
Gearbox, split torque flow
Input Output
Locating Bearing
Floating Bearing
Benefit: Finding the root cause
October 30, 2007 © SKF Group Slide 17
From an SKF perspective we can: Take a system approach and integrate knowledge
CASE: The gearbox and the generator that were related BENEFIT: Finding the root cause
Bridge between involved parties e.g. OEM and end user CASE: The generator that kept failing BENEFIT: Increased service life
Benchmark with other industries CASE: Very reliable gearboxes in railway, trucks and automotive BENEFIT: Sharing experience
October 30, 2007 © SKF Group Slide 18
The generator that kept failing…..
From SKF Brochure 6160 Electrically insulated bearings
Benefit: Increased service life
October 30, 2007 © SKF Group Slide 19
Product development based on market needs
Information Analysis Insights SKF
Engineered Solution
Providing customer value through new developments ”Outside -> In !!”
Integrate knowledge based on full asset life cycle from different functions and platforms
Convert market challenges into new developments
October 30, 2007 © SKF Group Slide 20
From an SKF perspective we can: Take a system approach and integrate knowledge
CASE: The gearbox and the generator that were related BENEFIT: Finding the root cause
Bridge between involved parties e.g. OEM and end user CASE: The generator that kept failing BENEFIT: Increased service life
Benchmark with other industries CASE: Very reliable gearboxes in railway, trucks and automotive BENEFIT: Sharing experience
October 30, 2007 © SKF Group Slide 21
Thirty years of development in other transmissions
Locomotives Trucks Cars
Power per kilo
Bearing or other similar problems
Development priorities
Almost doubled Doubled More than doubled
Cleanliness
Expected service life
25 yrs / 100000 h 15 yrs / 50000 h 15 yrs / 5000 h
Power then / now 500 kW / 1 MW 200 / 400 kW 50 / 100 kW
(to ~ 0) (to ~ 0) (promille)
”Active bearing” 2,5 kg 2 kg 0,5 kg
Mounting Dynamics Noise Lubrication
Cleanliness Mounting Stiffness Lubrication
Stiffness Sealed bearings
”SKF talk about their gearbox experiences”
October 30, 2007 © SKF Group Slide 22
SKF
The Knowledge Engineering Company
Thank you for your attention !
