(Presentation) Shankir - Review of Wind Turbines' Drive Systems and Why Gearless Direct Drive

RCREEEWindEnergyBuildingCapacityProgram Stage2Rabat,Tangier29 March 2nd April2010 p
ReviewofWindTurbinesDriveSystemsandwhy GearlessDirectDrive Gearless Direct Drive

DRYehiaShankir
www.elsewedyelectric.com
Contents
1. ELSewedyElectric&SWEG 1 EL Sewedy Electric & SWEG 2. WindTurbinescomponentsandgeneratortypes 3. WindTurbinesdrivesystemsadvantagesand 3 Wi d T bi d i d d disadvantages 4. ComparisonsofWindTurbinesdrivesystems 5. Conclusions 6. Appendix 7. References
2
ElsewedyElectric
ELSewedyElectricWind EL Sewedy Electric Wind Sector
I TOWERS
SIAGCompanyOverview

Theleadingtubularsteeltowersupplierin GermanyandEurope Marketsharemorethan30% Leadingtechnologyinsteelindustry Nearly1000employees Proventrackrecord ofgrowthinEurope f th i E
II TURBINES
MTorresCompanyOverview
OneofthemostInnovative EngineeringcompaniesinSpain Startedinthepaperindustries& nowoneoftheleadersin supplyingmachinesforthe aerospaceindustry Atotalof500highskilled employees
MTorresWindDivision MT Wi d Di i i
2001thefirstinnovative 1.5MWprototype MTOIengineering, MTOI engineering manufacturing, development,O&M
IIIBLADES
WindRotorBladesFactoryinEgypt Stateoftheartproduction State of the art production technologytransferfroma leadingGermanmanufacturer. StateoftheartBladesDesign licensedbyleadingDutchand licensed by leading Dutch and GermanDesigners Thefactorywillbeequipped withthemostadvanced Fiberglassmouldsand Fib l ld d equipmenttoproduce200sets ofbladesinstage1expandable to500sets Nearly500employeesand technicianswillbeemployedin thefirststage
SWEG ELSewedyforWindEnergyGeneration EL S d f Wi d E G ti theWindSectorArm
10
Wind Turbines components and g generator types yp
11
WindTurbineSystemMain Wind Turbine System Main Components

Mechanical P M h i l Power
WindPower Rotor Gearbox (Optional)
Electrical P El t i l Power
PowerConverter Transformer Generator (Optional) Grid
GearlessSystems Gearless Systems

ElectricalExcited Synchronous Generator(EESG) Generator (EESG) PermanentMagnet Synchronous Generator(PMSG) Generator (PMSG)
GearedSystems Geared Systems
Types of Generators
(AC Machines)
SquirrelCage InductionGenerator ( (SCIG) ) DoubleFeed InductionGenerator (DFIG)

12
WoundRotorIM SquirrelCageIM InductionMachine

+ve T
Grid
Motor SubSynch(+veslip) veT ve T Generator Supersynch(veslip)
Generator
Motor
OperatingTorque T
Synch Speed= 120f/p /p www.elsewedyelectric.com

13
SynchronousGenerator Synchronous Generator
WoundRotor
PermanentMagnet Generator
Freq=Pxn / /120 Vdc www.elsewedyelectric.com

14
Wind Turbines Drive Systems, g g advantages and disadvantages
15
TheTypicalTypesofDriveSystemsforLarge The Typical Types of Drive Systems for Large WindTurbines

Fixed Speed Squirrel C S i l Cage Induction Generator (SCIG) Variable Speed Double Feed Induction Generator (DFIG) Variable Speed Electrical Excited Synch Generator (EESG) Variable Speed Permanent Magnet Synch Generator (PMSG) www.elsewedyelectric.com
16
Squirrel C S i l Cage Induction G I d ti Generator t Geared, (SCIG)
Directlyconnectedtogrid ve Agearboxisrequiredinthedrivetrain Torque AlmostaFixedspeed.Operatesinnarrow Al Fi d d O i rangeofspeed Theonlyspeedcontrolisthrough pole changingwhichleadstworotationspeeds.
P=4
P=2
%ofSynchSpeed
17
AdvantagesofGearedSCIG
Cost (SCIG)isaverypopularmachine,ithasLow specificmass(kg/kW)andsmallerouter diameter(lownumberofpoles)hencelower di t (l b f l )h l cost. Mechanical,Maintenance&Reliability h i l i & li bili Mechanicalsimplicity,robuststructure
18
DisadvantagesofGearedSCIG
Mechanical,Reliability&Maintenance Agearbox inthedrivetrainisrequired: Electrical&PowerQuality Directlyconnectedtothegrid Directly connected to the grid SCIGwoulddisconnectfromthegrid evenduringquitesmalldisturbances. Theydidnothaveanyfaultride Th did t h f lt id throughcapability, Themachinealwaysrequiresreactive power,anditsvaluecannotbe controlled.Thismakesitimpossibleto supportgridvoltagecontroltherefore nogridsupport, Needdifferentgearboxesfordifferent gridfrequencies50Hz/60Hz Control Nopossibilityofspeedcontrol,onlyapole changeablecanbeused,whichleadstwo rotationspeeds. p Theturbinespeedcannotbeadjustedtothe windspeedtooptimizetheaerodynamic efficiency. efficiency.` Windspeedfluctuationsaredirectly translatedintoelectromechanicaltorque variations(nodampingcontrol),Thiscauses variations (no damping control) This causes highmechanicalandfatiguestressesonthe system(P=T.W)
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Double Fed Induction Generator, Geared, (DFIG)
Power flow in Powerflowin +ve T
O Operating i Speed Powerflowout N3 N1 N2 Generator
Directlyconnectedtogrid RotorConnectedtogridviapower converter Agearboxisrequiredinthedrivetrain Variablespeed,Speedcanbecontrolled Variable speed, Speed can be controlled withina+/ 30%aroundsynchronous speed(TheconverterisFeedingor Absorbingpowerfrom/tothegrid) Absorbing power from/to the grid)
ve T Operating Torque T
Motor
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Cost Lowspecificmass(kg/kW)andsmallerouterdiameter(lownumberof Low specific mass (kg/kW) and smaller outer diameter (low number of poles)hencelowercost. TheconverterforaDFIGissmall(30%ofratedpower).Thereforeitis cheaperthanforadirectdrivegenerator. h th f di t d i t MorecomplexstructurethanSCIG Electrical&PowerQuality Thereactivepower canbecontrolledbycontrollingtherotorcurrentswith theconverter,thisallowsthesupplyofvoltagesupporttowardsthegrid. Howeverreactivepowerislimitedbytheconverter30%rating. However reactive power is limited by the converter 30% rating. Control DFIGsupportsawidespeedrangeoperation,dependingonthesizeofthe frequencyconverter.TypicallyVariablespeedrangeis+30%aroundthe f t T i ll V i bl d i +30% d th synchronousspeed InDFIG,windgustsleadtovariationsinthespeedwithoutlargetorque variations.
AdvantagesofGearedDFIG
21
DisadvantagesofGearedDFIG
Mechanical,Reliability&Maintenance Agearboxinthedrivetrainisrequiredwhichshowareliability negativerecord. DFIGhavebrushes,whichneedregularinspectionandreplacement. DFIG have brushes which need regular inspection and replacement Theyareapotentialcauseofmachinefailureandlosses. Electrical&PowerQuality Statordirectlyconnectedtogrid d l d d Accordingtogridconnectionrequirementsforwindturbines,incase ofgriddisturbances,aridethroughcapabilityofDFIGisrequired,so thatthecorrespondingcontrolstrategiesmaybecomplicated. Undergridfaultconditions,ontheonehand,largestatorcurrents resultinlargerotorcurrents,sothatthepowerelectronicconverter g , p needstobeprotected Needdifferentgearboxesfordifferentgridfrequencies50Hz/60Hz
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Electrical Excited Synchronous Generator, Gearless (EESG)
NoGearboxisrequired No Gearbox is required Nodirectconnectiontothegrid, Connectedthroughapowerconverter Theamplitudeandfrequencyofthe suppliedvoltagecanbefullycontrolled Thefluxisfullycontrolledtominimize lossesindifferentoperatingranges Operateinawiderangeofspeedeven toaverylowspeed to a very low speed
23
AdvantagesofGearlessEESG
Mechanical,Maintenance&Reliability NoGearboxsohighreliability,lessnoise, lesscost, DFIGhavebrushes,whichneedregular DFIG have brushes which need regular inspectionandreplacement.Theyarea potentialcauseofmachinefailureand losses. losses Electrical&PowerQuality Theconverterpermitsflexiblefull control ofactiveandreactivepowerincaseof normalanddisturbedgridconditions.this allowsthesupplyofvoltagesupport towardsthegrid. Thesamegeneratorsuitablefordifferent gridfrequencies50Hz/60Hz Thefullpowerconvertertotally The full power converter totally decouplesthegeneratorfromthe grid.Hence,griddisturbanceshave nodirecteffectonthegenerator no direct effect on the generator Control Theconverteroffersawiderangeof d l l d speedcontrolevenatverylowspeed thereforeahigherenergyyield Theamplitudeandfrequencyofthe voltagecanbefullycontrolledbythe converter EESGhastheopportunitiesof pp controllingthefluxforaminimized lossindifferentpowerranges
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DisadvantagesofGearlessEESG
Cost Highspecificmass(kg/kW)andLargeouterdiameter(highnumber ofpoles) henceHighercostandmoreweight.Thisweightis partiallybalancedbytheeliminationofthegearbox. partially balanced by the elimination of the gearbox Theconverteris100%ofratedpower.itismoreexpensivethanfor aDFIG.Thisextracostisbalancedbytheeliminationofthegearbox MorecomplexstructurethanSCIG Mechanical,Reliability&Maintenance Mechanical, Reliability & Maintenance EESGhavebrushes,whichneedregularinspectionand replacement.Theyareacauseofmachinefailureandlosses.
25
Permanent Magnet Synchronous Generator, Gearless (PMSG)
NoGearboxisrequired No Gearbox is required Nodirectconnectiontothegrid, Connectedthroughapowerconverter Theamplitudeandfrequencyofthe suppliedvoltagecanbefullycontrolled Nofluxcontrolandnosliprings becauseofpermanentmagnets Operateinawiderangeofspeedeven toaverylowspeed to a very low speed
26
AdvantagesofGearlessPMSG
Mechanical,Maintenance&Reliability Theconverterpermitsveryflexiblefull NoGearboxandbrushessohigher controloftheactiveandreactivepowerin reliability,lessnoise,lesscost, caseofnormalanddisturbedgrid improvementinthethermal p conditions.thisallowsthesupplyofvoltage characteristicsofthePMmachinedue supporttowardsthegrid. totheabsenceofthefieldlosses, Control Electrical&PowerQuality Electrical & Power Quality Theconverteroffersawiderangeofspeed Thefullpowerconvertertotally controlevenatverylowspeedthereforea decouplesthegeneratorfromthegrid. higherenergyyield higher energy yield Hence,griddisturbanceshavenodirect Hence grid disturbances have no direct Theamplitudeandfrequencyofthevoltage effectonthegenerator canbefullycontrolledbytheconverter Thesamegeneratorsuitablefor PMSGhastheopportunitiesofcontrolling PMSG h th t iti f t lli differentgridfrequencies50Hz/60Hz / thefluxforaminimizedlossindifferent Noadditionalpowersupplyforthe powerranges magnetfieldexcitation,
27
DisadvantagesofGearlessPMSG
Cost HighcostofPMmaterialandLargeouterdiameter(highnumberof poles),howeverthisisbalancedthroughalowerspecificmass (kg/kW)andtheeliminationofthegearbox. (kg/kW) and the elimination of the gearbox Theconverteris100%ofratedpower.itismoreexpensivethanfor aDFIG.Thisextracostisbalancedbytheeliminationofthegearbox Mechanical,Reliability&Maintenance DemagnetizationofPMathightempduetoseverloadingorshort circuit. Difficultiestohandleinmanufactureandintransportation,
28
ComparisonsofWind TurbinesDriveSystems Turbines Drive Systems
29
SummaryComparison Summary Comparison

Comparison base Investment Cost, size and weight Mechanical and structure Simplicity Reliability d R li bilit and maintenance t l i t to lower maintenance cost and increase availability(Gearbox and brushes) Grid support and LVRT Suitability for 50HZ & 60 HZ Speed control to damp mechanical stresses Speed control to optimize p p aerodynamic efficiency to maximize energy yield Sourcing of material and handling in manufacturing and transportation SCIG (++) (++) (-) (-) (-) (-) (-) (+) DFIG (+) (+) (--) (+) (-) (+) (+) (+) EESG (-) (-) (+) (++) (+) (++) (++) (-) PMSG (-) (-) (++) (++) (+) (++) (++) (--)
If in the middle of a desert with hot sandy, and dusty weather or if offshore If the point of common connection in the middle of a complex grid
Annual Energy Yield due to control , reliability and less down time Cost of Kwh (Levelized Energy Cost)
(-) (-)
(+) (+)
(++) (++)
(++) (++)
30
WindturbineTopTenmanufacturersandtheir Wind turbine Top Ten manufacturers and their generatortypes

Current manufacturers of Direct Drives Turbines 3.6 MW 3.5 3 5 MW Companies who p recognized the DD concept and now Joining g
31
Conclusions
Themultiple stagegeareddriveDFIGsystemsisstill The multiplestage geared drive DFIG systems is still dominatingthecurrentmarket, Themarketshowsinterestinthedirectdrivesystemswitha fullscalepowerconverter.Newcompaniesrecognizedtheir advantagesandalreadystarted, Weight,sizeandinitialcostarehigherindirectdrivesystems. Weight size and initial cost are higher in direct drive systems Overallefficiency,reliabilityandavailabilityarehigherin directdrivesystemsbecauseofomittingthegearbox, Maintenancecostishigheringeareddrivesystemsspeciallyin rulerarea,desert,andoffshorealsoinhotanddustyweather, ThecostofKWhislessindirectdrivesystems, The cost of KWh is less in direct drive systems Intermsofgridsupportdirectdrivewindturbineswithafull scalepowerconvertermaybemoreeffectiveandless complicatedtodealwithgridrelatedproblems,
32
Nacelle Front
33
Nacelle Rear
34
Thank Th k you for your attention f tt ti
35
Appendix
36
Gearboxes and Reliability

Gearboxesareoneofthemostexpensivecomponentsofthewindturbinesystem, Thehigherthanexpectedfailureratesareaddingtothecostofwindenergy. Thefutureuncertaintyofgearboxlifeexpectancyiscontributingtowindturbine priceescalation. Turbinemanufacturersaddlargecontingenciestothesalespricetocoverthe warrantyriskduetothepossibilityofprematuregearboxfailures. Ownersandoperatorsbuildcontingencyfundsintotheprojectfinancingand incomeexpectationsforproblemsthatmayshowupafterthewarrantyexpires.
ImprovingWindTurbineGearboxReliability,ConferencePaperNREL/CP50041548,May2007
Forexample,replacingagearboxina1.5MWturbinecancostacompanymore than$500,000whenyouaddinthepriceofanewgearbox,labor,cranerental,and lostrevenuefromturbinedowntime. lost revenue from turbine downtime.

http://www.windpowerengineering.com/maintenance/how-to-keep-them-worki... 3/17/2010
37
Electrical & Power Quality

Theidealvoltagesourceprovidesa g p perfectlybalancedvoltageinthethree phases,apuresinewavewithaconstant frequencyandmagnitude. q y g Whentheseconditionsarenotmet,itis saidthatthepowerqualityofthegridis deteriorated. deteriorated TherequirementssetbytheTransmission SystemOperators(TSOs),arebeing constantlyreviewedandexpanded: constantly reviewed and expanded: Powerquality(Constantvoltage, harmonics,flickers) reactivepowercontrol(powerfactor) faultridethrough(voltagedipsand voltageswells) g )
38
DFIG Control System y
39
EESG & PMSG Control System y
40
TWT 1.65 Poles
41
References
H.Polinder,,Sjoerd W.H.deHaan,M.R.Dubois,JohannesG.Slootweg,BasicOperationPrinciplesand ElectricalConversionSystemsofWindTurbines, J.Soens,J.Driesen,R.Belmans,InteractionbetweenElectricalGridPhenomenaandtheWindTurbine's Behaviour,PROCEEDINGSOFISMA2004, H.Li*Z.Chen,OverviewofdifferentwindgeneratorsystemsandtheircomparisonsPublishedinIET RenewablePowerGenerationReceivedon24 January2007Revisedon Renewable Power Generation Received on 24th January 2007 Revisedon 23rd August 2007 doi:10 1049/iet August2007doi:10.1049/iet rpg:20070044, GNewman,SPerera,VGosbell andVSmith,VOLTAGESAGRIDETHROUGHIMPROVEMENT,OFMODERN ACDRIVES:REVIEWOFMETHODSANDACASESTUDY,IntegralEnergyPowerQualityCentre, C.Rahmann,H. J.Haubrich,L.VargasandM.B.C.Salles, InvestigationofDFIGwithFaultRide Through C. Rahmann, H.J. Haubrich, L. Vargas and M. B. C. Salles, Investigation of DFIG with Fault RideThrough CapabilityinWeakPowerSystems,InternationalConferenceonPowerSystemsTransients(IPST2009)in Kyoto,JapanJune36,2009, ,K.S.Sandhu,D.K.Jain ,LVRTofGridInterfacedVariableSpeedDrivenPMSGforWECSduringFault Rajveer Mittal,InternationalJournalofComputerandElectricalEngineering,Vol.1,No.4,October,2009 17938163, Anca D.Hansen*,Nicolaos A.Cutululis*,Poul Srensen*,FlorinIov+,Torben J.Larsen,*Simulationofa flexiblewindturbineresponsetoagridfault,Ris NationalLaboratoryincooperationwithAalborg University, MartaMolinas,Bjarne N M t M li Bj Naess,WilliamGullvik,ToreCageInductionGeneratorsforWindTurbineswith Willi G ll ik T C I d ti G t f Wi d T bi ith PowerElectronicsConvertersintheLightoftheNewGridCodes,Undeland NORWEGIANUNIVERSITYOF SCIENCEANDTECHNOLOGY,
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RCREEEWindEnergyBuildingCapacityProgram Stage2Rabat,Tangier29 March 2nd April2010 p

ReviewofWindTurbinesDriveSystemsandwhy GearlessDirectDrive Gearless Direct Drive

ELSewedyElectricWind EL Sewedy Electric Wind Sector

Theleadingtubularsteeltowersupplierin GermanyandEurope Marketsharemorethan30% Leadingtechnologyinsteelindustry Nearly1000employees Proventrackrecord ofgrowthinEurope f th i E

SWEG ELSewedyforWindEnergyGeneration EL S d f Wi d E G ti theWindSectorArm

Wind Turbines components and g generator types yp

WindTurbineSystemMain Wind Turbine System Main Components

GearlessSystems Gearless Systems

GearedSystems Geared Systems

SquirrelCage InductionGenerator ( (SCIG) ) DoubleFeed InductionGenerator (DFIG)

WoundRotorIM SquirrelCageIM InductionMachine

Synch Speed= 120f/p /p www.elsewedyelectric.com

SynchronousGenerator Synchronous Generator

Freq=Pxn / /120 Vdc www.elsewedyelectric.com

Wind Turbines Drive Systems, g g advantages and disadvantages

TheTypicalTypesofDriveSystemsforLarge The Typical Types of Drive Systems for Large WindTurbines

Squirrel C S i l Cage Induction G I d ti Generator t Geared, (SCIG)

Directlyconnectedtogrid ve Agearboxisrequiredinthedrivetrain Torque AlmostaFixedspeed.Operatesinnarrow Al Fi d d O i rangeofspeed Theonlyspeedcontrolisthrough pole changingwhichleadstworotationspeeds.

Double Fed Induction Generator, Geared, (DFIG)

Power flow in Powerflowin +ve T

O Operating i Speed Powerflowout N3 N1 N2 Generator

Electrical Excited Synchronous Generator, Gearless (EESG)

Permanent Magnet Synchronous Generator, Gearless (PMSG)

ComparisonsofWind TurbinesDriveSystems Turbines Drive Systems

SummaryComparison Summary Comparison

WindturbineTopTenmanufacturersandtheir Wind turbine Top Ten manufacturers and their generatortypes

Thank Th k you for your attention f tt ti

Gearboxes and Reliability

Forexample,replacingagearboxina1.5MWturbinecancostacompanymore than$500,000whenyouaddinthepriceofanewgearbox,labor,cranerental,and lostrevenuefromturbinedowntime. lost revenue from turbine downtime.

Electrical & Power Quality

DFIG Control System y

EESG & PMSG Control System y

TWT 1.65 Poles

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