MODERN WIND GENERATORS

© M. Ragheb
2/28/2010

INTRODUCTION
An exposition of the characteristics of modern wind generators designs from the
leading manufacturers is advanced to show their components and their respective design
characteristics.
Modern wind turbines design and production is a modern high-tech technology at
the same level of airplane manufacture. Consider that the rotor blade span diameter of a
2.3 MW wind turbine is 93 meters; this is larger than the wingspan of a Boeing 747-400
Jumbo Jet, which measures only 70 meters.
We consider modern wind turbine designs from different manufacturers and
discuss their prominent features and differences.

MAIN CHARACTERISTICS
Four major developments characterize modern wind machines. The first
development was considered for a while as a trade secret and involves the almost
universal adoption of flexible or teetering rather than rigid hub structures, preventing
catastrophic failure under gust wind conditions.
The second development involves the use of the economy of scale with larger
capacity turbines reaching the 5-7 MW level, particularly for offshore siting.
The third development is the use of variable speed turbines. Variable speed
operation is a design feature that ensures that the turbines work at high efficiency,
compared with fixed speed wind turbines which only reach peak efficiency at a particular
wind speed. While constant speed rotors must deflect high wind gust loads, the variable
speed operation absorbs the loads from the wind gusts and converts them into electric
power.
The fourth development is the adoption of gearless wind turbines eliminating the
gearbox as the weakest link in the chain in the design of modern wind turbines:
gearboxes last for an average of 5 years failing probably due to misalignment during
operation over the 20 years design lifetime or to severe strain and shape changes under
sudden wind gusts. In addition, it eliminates the need for oil cooling avoiding one cause
of fires and environmental pollution in the case of the lubricating oil spillage. Like small
wind turbines, these have inverters instead of synchronous generators, that is to say, a
separate controller that converts the AC electrical power generated into a form that the
grid can be fed with. This last gearless feature has not yet been universally adopted like
the flexible hub concept.

MAIN MANUFACTURERS
The main wind manufacturer percentage of the electrical installed capacity
worldwide is shown in Table 1. There are 10-12 manufacturers of large utility scale
systems; marketing 200 kW to 7 MW rated capacity systems of different configurations.
These include three-bladed turbines with full span pitch control and two-bladed stall
control machines with teetering hubs.

Table 1: Wind turbines manufacturers share of installed capacity as of 2005.

Manufacturer Installed Installed Share

Capacity Capacity 2005
2004 2005 [percent]
[MW] [MW]
Vestas, Denmark 17,580 3,186 27.9
General Electric (GE), 5,346 2,025 17.7
USA
Enercon, Germany 7,045 1,505 13.2
Gamesa, Spain 6,438 1,474 12.9
Suzlon, India 785 700 6.1
Siemens, Germany 3,874 629 5.5
Repower, Germany 1,169 353 3.1
Nordex, Germany 2,406 298 2.6
Ecotècnia, Spain 744 239 2.1
Mitsubishi, Japan 1,019 233 2.0
Japan Steel Works, JSW, 4,359 557 5.0
Japan, and others
Total 100.0

In late 1996, the now defunct Enron Company in the USA purchased Zond
Systems based in California, which used designs based on the Vestas Danish company.
Enron was a mediocre steward of the Zond technology, which was apparently its only
economically viable division. The General Electric (GE) company in the USA purchased
it in 2003, in addition to the German manufacturer Tacke, consequently maintaining the
USA’s position visibility in the global wind turbine market.

VESTAS WIND GENERATORS

The Vestas V90 3.0 MW three blades wind generator uses carbon fibers as a
structural material for the load bearing spars. Carbon fiber is intrinsically lighter than
fiberglass used in other designs and its strength and rigidity also reduce the quantity of
material needed, thus cutting overall weight.
The V90 has a swept area of 6,362 m2 with blades with a diameter of 90 m. Their
nominal revolution speed is 16.1 rpm with an operational interval of 9-19 rpm. Power
regulation is through pitch/variable speed control. Its air brake is by full blade pitch by
three separate pitch cylinders. The hub can be built on top of towers that are 65, 80, 90 or
105 m in height.
The cut-in wind speed is 4 m/s, with a nominal wind speed of 15 m/s. The cut-out
wind speed is 25 m/s.
The generator is asynchronous with a converter rated at a nominal 3.0 MW at 60
Hz and 1 kV.
The gearbox consists of two planetary stages and one helical stage.
Control is achieved with microprocessor based control of all the turbine functions
with the option of remote monitoring. Output regulation and optimization are via
variable speed control and pitch regulation.
For a tower height of 105 m, the tower weights 275 metric tonnes (mt), the
nacelle 68 mt, the rotor 40 mt, for a total of 383 mt.
The profile of the V90 blades optimizes the relationship between the overall load
impact on the turbine and the volume of energy generated annually. The airfoil improves
energy production, while making the blade profile less sensitive to dirt on the leading
edge and maintains a favorable geometrical relationship between successive airfoil
thicknesses. This translates into an increase in output combined with a decrease in load
transfers.
To increase fatigue strength magnets are used to fasten the internal components to
the tower walls.

Fig. 1: Vestas V90 3.0 MW wind generator. Source: Vestas.

Fig. 2: Power curve of the V90 3.0 MW Vestas wind generator. Source: Vestas.
 Fig. 3: The Vestas V90 3.0 MW wind generator nacelle components. Source:
Vestas.

The nacelle integrates the hub bed plate directly into the gearbox, eliminating the
main shaft and thus shortening nacelle length. The result is a nacelle that can generate
much more power without any appreciable increase in size, weight or tower load.

Fig. 4: Wind speed, pitch angle, generator speed and power output of V90 3.0 MW
wind generator. As the wind speed varies, the variation in the pitch angle and the
speed of the rotor and generator maintain a constant power output. Source: Vestas.

The V90 3.0 MW allows the rotor speed to vary within a range of approximately
60 percent in relation to nominal rpm. Thus the rotor speed can vary by as much as 30
percent above and below synchronous speed. This minimizes both unwanted fluctuations
in the output to the grid supply and the loads on the vital parts of the construction.

GENERAL ELECTRIC, GE WIND TURBINES

Nacelle (1), Heat Exchanger (2), Generator (3), Control Panel (4), Main Frame (5),
Impact Noise Reduction (6), Hydraulic Parking Brake (7), Gearbox (8), Impact
Noise Reduction (9), Yaw Drive (10 and 11), Main Shaft (12), Oil Cooler (13), Pitch
Drive (14), Rotor Hub (15) and Nose Cone (16).

Fig. 5: The General Electric GE 1.5 MW Wind turbine Nacelle. Source: GE.

The GE Company had a $4 billion wind energy revenue in 2007, increasing to $6

in 2008. In 2008 it had a $1 billion contract with Invenergy Wind LLC from Chicago,
Illinois for 750 MW of wind power to be installed by 2010. This followed another $1
billion contract for European wind farms to be built by 2009. At 3.75 kW electrical
usage per household, this would provide electricity to 750,000 /3.75 = 200,000 homes.
The capital cost amounts to 109 / 750,000 = 1,333.3 $/kW of installed capacity.
The GE 1.5 MW wind turbines are active yaw and pitch regulated with
power/torque control capability and an asynchronous generator. The yaw system is
electro-mechanically driven with a wind direction sensor and automatic cable unwinding
that could cause shorts and fires. Power is varied using active blade pitch control. The
blade pitch angle is continually adjusted for optimum rotational speed and maximum lift-
to-drag at each wind speed.
Variable speed operation as a design feature ensures the turbines work at high
efficiency, compared with fixed speed wind turbines which only reach peak efficiency at
a particular wind speed. While constant speed rotors must deflect high wind gust loads,
the variable speed operation absorbs the loads from the wind gusts and converts them to
electric power. Cut-in and cut-out wind speeds are 3 m/s and 25 m/s respectively. The
three blades give a rotor diameter of 77 m with a swept area of 4,657 m². Rotor speed is
variable between 10.1 rpm and 20.4 rpm.

OVERSPEED IN STRONG GUSTY WINDS

The generator torque in the turbines is controlled by the frequency converter. The
turbine rotor can overspeed in strong, gusty winds to reduce the torque loads in the drive
train. The GE's turbines store the energy in gusts by accelerating the rotor. The
operating speed range is notably wider than the slip range used by other wind generators
manufacturers, which produce heat rather than electric power when regulating power in
strong, gusty winds.
The conversion system generates reactive power or current leading voltage to
improve transmission efficiencies and voltage stability, particularly useful in weak grid
applications. It automatically maintains defined grid voltage levels and power quality in
fractions of a second.

FAIL-SAFE BRAKING AND LIGHTNING PROTECTION

The wind generator's fail-safe braking system has electromechanical pitch control
for each blade with three self-contained systems and a hydraulic parking brake.
Lightning receptors are installed on the blade tips, with surge protection for the electrical
components.
The turbines can remain on-line and feed reactive power to the electric grid right
through major system disturbances. A Low Voltage Ride Thru (LVRT) feature enables
wind turbines to meet transmission reliability standards similar to those demanded of
conventional power plants thermal generators.
Active damping of the entire wind turbine system gives less tower oscillation than
constant speed wind turbines. Active damping also limits peak torque, providing greater
drive train reliability, reduced maintenance cost and longer turbine life. The bedplate
drive train design provides that all nacelle components are joined on a common structure
for durability. A three-step planetary spur gear system is used, with both the generator
and the gearbox supported by elastomeric elements to minimize noise emissions.

SUZLON WIND GENERATORS

A design feature in the Suzlon 1.25 MW wind turbine generator is the
minimization of energy losses. A direct grid connected high speed generator, in
combination with a multiple stage combined spur/planetary gearbox, offers greater
robustness and reliability than a low-speed generator connected to the electrical grid via
AC-DC-AC inverter systems. It delivers harmonics free and grid friendly power.
The salient features of such a design are:
1. Optimized efficiency and wind rotor power coefficient (Cp).
2. Well balanced weight distribution ensures minimum static stress and dynamic loads.
3. An advanced hydrodynamic fluid coupling system absorbs peak loads and vibrations
assuring shock load free operation.
4. Intelligent control technologies inspired by operational experience maximizes the
yield.
5. High speed asynchronous generator with a multi-stage intelligent switching
compensation system delivers power factor up to 0.99 assuring a maximum power factor
operation.
6. Hermetically sheltered, advanced over voltage and lightning climatic shield protection
system.
7. Micro fine rotor pitch control with a 0.1 degree of rotation resolution to extract
maximum power from the wind stream.
8. Grid friendly design generates harmonics-free pure sinusoidal power

Fig. 6: The Suzlon 1.25 MW wind turbine generator yaw mechanism. Source:
Suzlon.

Fig.7: The Suzlon 1.25 MW electrical generator. Source: Suzlon.

STRESS AND LOAD REDUCTION

The wind turbine is subjected to combination of static, dynamic and peak load
induced stresses. The static stresses are taken care of by a well-balanced weight
distribution design. Wind induced dynamic radial loads are picked up by the separate
main shaft bearing, which is integrated into the gearbox housing.
Peak loads are compensated by a torque adjustable fluid coupling which also acts
as an excellent vibration separation and shock-dampening device.

AMBIENT CONDITIONS PROTECTION

In addition to mechanical stresses, a wind turbine is also subjected to thermal

stresses, moisture, salinity, dust, snow, lightning strikes and extreme wind conditions.
The components are hermetically sheltered. An over-voltage and lightning protection
system is in compliance with international standards.

Fig. 8: The Suzlon 1.25 MW wind generator. Source: Suzlon.

Fig. 9: The Suzlon 1.25 MW wind turbine power curve. Source: Suzlon.

TECHNICAL SPECIFICATIONS

Operating S.64/1250 S.64/1250 S.66/1250 S.66/1250

Data (50 Hz) (60 Hz) (50 Hz) (60 Hz)
Rotor 64 m 64 m 66 m 66 m
diameter
Hub height 65 m (variable as per requirement)
Installed 1,250 kW
electrical
output
Cut-in wind 3 m/s
speed
Rated wind 12 m/s 12 m/s 12 m/s 12 m/s
speed
Cut-out 25 m/s
wind speed
Survival 67 m/s
wind speed

Rotor S.64/1250 S.64/1250 S.66/1250 S.66/1250

(50 Hz) (60 Hz) (50 Hz) (60 Hz)
Blade 3 bladed horizontal axis
Swept area 3217 m² 3217 m² 3421 m² 3421 m²
Rotational 13.9 / 20.8 rpm
speed
Regulation Pitch regulation

Generator S.64/1250 S.64/1250 S.66/1250 S.66/1250

(50 Hz) (60 Hz) (50 Hz) (60 Hz)
Type Asynchronous 4/6 poles
Rated 250 / 1250 kW
output
Rotational 1006/1506 1208/1807 1006/1506 1208/1807
speed rpm rpm rpm rpm
Frequency 50 Hz 60 Hz 50 Hz 60 Hz

Gearbox S.64/1250 S.64/1250 S.66/1250 S.66/1250

(50 Hz) (60 Hz) (50 Hz) (60 Hz)
Type Integrated (1 planetary and 2 helical)
Ratio 74.917 : 1 89.229 : 1 74.917 : 1 89.229 : 1
 Yaw S.64/1250 S.64/1250 S.66/1250 S.66/1250
System (50 Hz) (60 Hz) (50 Hz) (60 Hz)
Drive 4 electrically driven planetary gearbox
Bearings Polyamide slide bearings

Braking S.64/1250 S.64/1250 S.66/1250 S.66/1250

System (50 Hz) (60 Hz) (50 Hz) (60 Hz)
Aerodynamic 3 independent systems with blade pitching
brake
Mechanical Hydraulic fail-safe disc brake system
brake

Control S.64/1250 S.64/1250 S.66/1250 S.66/1250

Unit (50 Hz) (60 Hz) (50 Hz) (60 Hz)
Type Programmable microprocessor-based; high speed
data communication, active multilevel security,
sophisticated operating software, advance data
collection remote monitoring and control option,
UPS back up, real time operation indication

ROTOR BLADES

The rotor blades are aerodynamically optimized to provide high lifting forces and
low air resistance values. They are manufactured using Resin Infusion Molding (RIM)
technology, which makes them lightweight, and at the same time possess high stiffness
and mechanical strength. Their low weight to diameter ratio results in lower stresses
enhancing the life and efficiency of the turbine.
The rotor blades are the starting point of the train for power transmission. Even a
small increase in blade efficiency is magnified across the power train to give higher
efficiencies for the entire machine.

MICRO PITCH SYSTEM

The rotor blades are connected to the hub via pitch ball bearings and can swivel
fully perpendicular to the direction of rotation. The motors of the pitching system have
an in-built intelligent system, with frequency control drives controlled by their own
microprocessor. These intelligent frequency drives communicate with the control system
in real time, with a response time of 30 ms. The control system updates the motors after
gauging the available wind regime, and the motors constantly update the control system
on the instant blade angle.
A precision electromechanical micro pitch mechanism achieves 0.1 degree
pitching resolution, resulting in extreme fine tuning of the aerodynamic profile.

ELECTRICAL GENERATOR MACRO SLIP MECHANISM

 The flexible, adjustable slip system in the electrical generator offers a maximum
slip of as high as 16 percent, thereby increasing the efficiency of energy conversion by
ensuring extremely low loss of power from wind due to gusts and frequent changes in
wind speeds.
The robust and compact mechanism ensures that the overall machine reliability is
maximized. The system is simple, easy to use and cost effective to service. The main
advantage of the system is that it allows the use of standard, conventional generators with
proven reliability. The macro slip mechanism is finely synchronized with the micro
pitching mechanism to give optimum performance. The entire related power electronics
is static and does not rotate at high speeds, increasing their reliability and overall life.

GEARBOX

A multi stage planetary and spur wheel gearbox ensures the highest possible
mechanical efficiency and power. The first planetary gear stage takes up the slow rotor
movement and distributes the high torque input to the subsequent planetary gears.
Reduced torque values and increased rotational speeds are optimally converted to
the high-speed operation of the generator.
A permanent, mechanically driven oil-pump supplies the gearbox and main shaft
bearings with pressure lubrication, in addition to the splash lubrication.
A micro filtering system retains the quality of the oil and assures an extended
service interval. An oil cooling device provides temperature optimization under full load
operation.

ASYNCHRONOUS GENERATOR

A 4 pole, single winding, asynchronous slip ring type generator with a highly
adaptable and flexible macro slip mechanism leads to high efficiency values.
The high slippage is achieved by varying the resistance on the rotor windings
dynamically. The resistors are connected to the rotor windings via a slip ring mechanism
making them static and mountable outside the generator cage. Externally mounted
resistors provide excellent heat dissipation and the resistors do not rotate at the high
speed of the rotor, which results in a longer service life.
These generators are robust and have a proven track record of decades in
operation. The moisture repellant insulation in a high class F configuration combined
with a forced surface air cooling system provides total protection from moisture and dust.
A welded squirrel cage, vibration resistant windings and a regreasing device with
a grease collection chamber result in increased service life and longer maintenance
intervals.

DIGITAL CONTROL SYSTEM

The control system is scalable in nature with standard interface options including
RS232/422/485, Ethernet, Fiber optic link, CAN Bus, and networking. An option for
web-enabled communication is also available. The entire control system is modular and
offers a high degree of customization.
 The grid connection module is designed for soft connection to the grid. With
COS PHI circuitry, it ensures effective current control at all times, before, during and
after the synchronous point. The pitch module has its own microprocessor to perform the
pitch calculations. Various safety modules for rotor revolution and vibration ensure safe
and reliable running of the turbines. The control systems have a condition monitoring
feature to help monitor the health of the turbine for any predictive and preventive
maintenance.
A graphical display unit shows information about the performance and the state of
various parameters. The remote monitoring and control options have various
combinations which can be customized.
The system is designed to perform in tough environmental conditions, and can
withstand shock, vibration and temperatures ranging from arctic cold to hot and humid
tropical.

YAW SYSTEM

A braking torque adjustable polyamide slide bearing transmits the loads from the
nacelle to the tower through an expansive surface.
The yawing movement is activated and controlled by 3 electrically braked gear
motors. Precise wind direction measurement and an advanced statistics software ensure
an exact alignment of the rotor to the wind, thereby reducing energy losses and additional
loads caused by oblique incident flows.
A cable twist sensor in the yaw system monitors over twisting of cables due to
constant wind direction changes and alerts the controller to untwist the cables.

MECHANICAL BRAKING SYSTEM

In addition to the aerodynamic braking system, the turbines are equipped with
mechanical braking to stop the wind turbine in case of an emergency.
The disc brake is configured to be fail-safe. It is activated by spring forces and
released hydraulically.
This combination of aerodynamic and mechanical systems, allows for complete
load control during braking processes and maximum load reduction in any operational
case, ensuring safety to the wind turbine even in case of an emergency.

HYDRAULIC SYSTEM

A hydraulic system, similar to the one found in jet planes, supports the
mechanical braking devices. A motor and pump assembly draws oil from a reservoir and
pushes it via high efficiency filters through the system to ensure that the hydraulic oil
remains clean during an extended service interval.

STRUCTURAL TOWER

An option of tubular or lattice tower can be chosen. Stiffness of both these

designs eliminates the critical natural frequencies of the tower. This reduces the dynamic
stressing of the tower and the entire wind turbine to a minimum.
A high corrosion protection system comprising several layers of either epoxy
coat, in case of tubular towers, or hot dip galvanization, in case of lattice towers, protects
the structure and increases its service life.
Nondestructive testing, including ultrasonic and x-ray tests are part of the quality
management system. The climbing guard system meets the requirements of international
safety supervisory authorities.

NACELLE COVER

The nacelle cover is made of fiber reinforced plastic and designed in such away
that the internal components are fully protected against various ambient conditions. It
also ensures adequate noise dampening.

SIEMENS WIND TURBINES

DESIGN CHARACTERISTICS

The salient characteristics of the Siemens wind turbines designs are:

1. Simple generator systems without slip rings.
2. A fail-safe double safety systems approach.
3. A rugged, conservative structural design.
4. Use of well proven lightning protection methods of the rotor blades, the nacelle and the
controller.
5. Automatic lubrication systems with ample suppliers.
6. Climate control of the internal environment for turbines of 2.3 MW rated power and
higher.

TURBINE DESIGN VARIANTS

The SWT-2.3-93, 2.3 MW wind turbine is a large rotor variant of the SWT-2.3-82
VS. It provides optimum project economy for low and medium wind sites.
The SWT-2.3-82 VS, 2.3 MW turbine is a variable speed turbine with pitch power
control referred to as the proprietary CombiPitch variant of the 2.3 MW turbine. It fits a
noise restricted segment of the SWT-2.3 spectrum.
The SWT-1.3-62, 1.3 MW wind turbine is a widely-proven work horse for small
and moderate size projects and for projects with noise or structural tower height
restrictions.
The SWT-2.3-82, 2.3 MW wind turbine is a recommended option for utilities and
other large developers and is particularly suited for high wind sites.
1 Spinner 10 Brake disc
2 Spinner bracket 11 Coupling
3 Blade 12 Electrical generator
4 Pitch bearing 13 Yaw gear
5 Rotor hub 14 Tower
6 Main bearing 15 Yaw ring
7 Main shaft 16 Oil filter
8 Gearbox 17 Generator cooling fan
9 Service crane 18 Canopy

Fig. 10: Nacelle components of the SWT-2.3-93, 2.3 MW Siemens wind turbine.
Source: Siemens.
 Fig. 11: Interior view of a Siemens wind turbine nacelle. Source: Siemens.

CHARACTERICTICS OF THE SWT-3.6-107, 3.6 MW WIND TURBINE

The SWT-3.6-107 wind turbine is meant for both offshore and for onshore wind
farms.

Rotor

The rotor of the SWT-3.6-107 turbine is of a three blade cantilevered

configuration, mounted upwind of the tower. The power output is controlled by pitch
regulation. The rotor speed is variable in order to maximize the aerodynamic efficiency
and the speed compliance during power regulation. This also minimizes the dynamic
loads on the transmission system.

Rotor blades

The rotor blades are manufactured of Fiber Glass Reinforced Epoxy (GRE) and
are manufactured by Siemens in a single operation. No glue joints exist between the
spars and the shells, with no weak points and no easy access for water or lightning
strikes.
The aerodynamic design of the rotor blades has been tested at a test site under
both static and dynamic loadings. They are mounted on pitch bearings and can be
feathered 80 degrees for shutdown purposes. Each blade has its own independent fail
safe pitching mechanism capable of feathering the blade under any operating condition,
and allowing fine tuning to maximize the power output.
 Gearbox and brakes

The gearbox is a custom built 3 stage planetary helical design that is mounted on
the nacelle with flexible rubber bushings, thereby providing a compact high performance
construction and the lowest possible noise level. The gearbox is fitted with fail safe
mechanical brakes at the high speed electrical generator shaft.

Electrical generator

The electrical generator rotor construction and stator windings are designed for
high efficiency at partial loads. It is fitted with a separate thermostat controlled
ventilation system. With efficient cooling, the electrical generator can be operated at
temperatures well below the normal level of the standard insulation class, thereby
providing the best possible lifetime of the winding insulation.

Structural tower

The structural tower is of a tapered tubular steel configuration. The tower has
internal ascent and direct access to the yaw system and nacelle.

Turbine controller

The turbine controller is a microprocessor based industrial controller. It is self

contained with switch gear and protection devices. It is self diagnosing and has a
keyboard and display for easy readout of status and for adjustment of the settings.

Operation

The wind turbine operates automatically and is self starting when the wind
reaches an average speed of about 3–5 m/s. The output increases linearly with the wind
speed until the wind reaches 13–14 m/s. At that point the power is regulated at the
turbine’s rated power output. If the average wind speed exceeds the maximum
operational limit of 25 m/s, the turbine is shut down by feathering of the blades using the
pitch mechanism. When the wind drops back below the restart speed the safety systems
reset automatically.

Safety system

The turbine has several redundant levels in the safety system, including an
independent pitch system for each of the rotor blades, and as a result the turbine can shut
down safely from any operational condition.

Remote control

The turbine is equipped with the WebWPS Surveillance, Control and Data
Acquisition (SCADA) system. The system offers long distance control and a variety of
status views and useful reports from a standard internet web browser.

Grid compliance

The turbine is fitted with a NetConverter system that is compliant with demanding
grid codes. It has a ride through capability for all normal faults.

TECHNICAL SPECIFICATIONS, SWT-3.6-107

Rotor
Type 3- bladed, horizontal axis
Position Upwind
Diameter 107 m
Swept area 9,000 m²
Rotor speed 5-13 rpm
Power regulation Pitch regulation with variable speed
Rotor tilt 6 degrees
Blades
Type B52
Blade length 52 m
Tip chord 1.0 m
Root chord 4.20 m
Aerodynamic profile NACA 63.xxx, FFAxxx
Material Fiber Glass Reinforced Epoxy (GRE)
Surface gloss Semi-matt, <30 / ISO2813
Surface color Light gray, RAL 7035
Blade manufacturer Siemens Wind Power A/S
Aerodynamic brake
Type Full span pitching
Activation Activate, fail safe
Load supporting parts
Hub Nodular cast iron
Main bearings Spherical roller bearing
Transmission shaft Alloy steel
Nacelle bedplate Steel
Transmission system
Coupling hub - shaft Flange
Coupling shaft - gearbox Shrink disc
Gearbox type 3-stage planetary-helical
Gearbox ratio 1 : 119
Gearbox lubrication Forced lubrication
Oil volume About 750 liters
Gearbox cooling Separate oil cooler
Gearbox designation PZAB 3540
Gearbox manufacturer Winergy AG
Coupling gear - generator Double flexible coupling
Mechanical brake
Type Fail safe disc brake
Position High speed shaft
Number of calipers 2
Generator
Type Asynchronous
Nominal power 3,600 kWe
Synchronous speed 1,500 rpm
Voltage 690 V
Frequency Variable
Protection IP 54
Cooling Integrated heat exchanger
Insulation class F
Generator designation AMB 506L4A
Canopy
Type Totally enclosed
Material Steel / Aluminum
Yaw system
Type Active
Yaw bearing Internally geared slew ring
Yaw drive Six electric gear motors
Yaw brake Active friction brake and six brake motors
Controller
Type Microprocessor
SCADA system WebWPS
Controller designation KK WTC 3
Structural tower
Type Tapered tubular
Hub heights 80 m or site specific
Corrosion protection Painted
Surface gloss Semi-matt 30-40 ISO2813
Surface color Light gray, RAL 7035
Operational data
Cut-in wind speed 3-5 m/s
Nominal power speed 12-14 m/s
Cut-out wind speed 25 m/s
Maximum 2 s wind gust 55 m/s (standard version)
60-80 m/s (special version)
Weights
Rotor 95 t
Nacelle 125 t
Tower Site specific

OFFSHORE APPLICATIONS
Fig. 12: Installation of the rotor blades on an offshore wind turbine. Source:
Siemens.
 Fig. 13: Blades ready for offshore installation. Source: Siemens.

Fig. 14: Offshore 3.6 MW Siemens wind turbines at the Burbo offshore wind site
operated by Dong Energy. Source: Siemens.

Siemens pioneered the offshore installation of wind turbines with the world’s first
offshore wind farm at Vindeby, Denmark, installed in 1991.
Later notable projects include the Middelgrunden offshore wind farm outside
Copenhagen and the world’s largest offshore wind farm at Nysted in the Baltic Sea.
Siemens offshore turbines have the following features:
Corrosion protection: The external turbine components are painted with offshore-grade
painting systems that minimize any corrosion caused by salty air and water. The nacelle
and tower are fully enclosed with climate control including dehumidifiers constantly
maintaining the internal humidity below the 60 percent corrosion threshold.
Cooling systems: Cooling is carried out with air-to-air heat exchangers. Ambient air is
not circulated through the nacelle or tower but is limited to flow through the external side
of the heat exchangers. As a result, the internal nacelle climate can be controlled.
Engineered safety features: The lightning protection system minimizes the risk of
damage from lightning strikes that occur frequently in some locations offshore. The
turbines are normally fitted with navigational lights and aerial warning lights meeting the
relevant safety standards. Rescue equipment is provided at the foundation level.

ROTOR BLADES

The blades used for the SWT-1.3-62, SWT-2.3-82, SWT-2.3-82 VS, SWT-2.3-93
and SWT-3.6-107 turbines are fitted with Siemens blades manufactured with its
proprietary IntegralBlade technology. It manufactures the wind turbine blades in one
piece using a closed process. The glass fiber reinforcement is laid out to dry using a
special molding arrangement with a closed outer mold and an expanding inner mold.
After completion of the lamination of the fiber glass, the epoxy resin is injected under
vacuum. Following this injection, the blade is hardened at a high temperature while still
enclosed in the mold. Once the blade is hardened, it is removed from the outer mold, and
the inner mold is collapsed with a vacuum and pulled from the blade. The result is a
complete, seamless blade finished in one process.
The blades are made of fiber Glass Reinforced Epoxy (GRE) and their external
design represents state of the art wind turbine aerodynamics.
Compared with the traditional processes used by other blade manufacturers, the
process has several advantages. It is efficient in man power requirements and space,
requiring only one mold set for the manufacturing cycle. There are no issues relating to
tolerances between shells and spars. The resulting blade is an integral structure with no
glued joints that act as weak points potentially exposing the structure to cracking, water
ingress and lightning.
The blade factory offers a clean and attractive work environment. The resins
applied to the blade do not release Volatile Organic Compounds (VOCs) pollutants to the
atmosphere and the risk of exposure of the workers to allergenic compounds is minimal.

LIGHTNING PROTECTION

The lightning protection aims to protect from the effects of both direct and nearby
strikes. Even though protection from lightning cannot be wholly assured, the lightning
protection system has shown very good performance in wind turbine applications all over
the world.
The overall design basis adheres to the international standard IEC 1024-1 and the
Danish Standard DS 453.
The components of the wind turbines are protected in various ways:
Blades: The blades are protected with a dedicated protection system that has been
laboratory tested to currents of 200 kA without showing any signs of damage other than
superficial weld marks from the strike itself. Each blade has a lightning rod fitted close
to the tip. The rod projects slightly above the blade surface on both sides. A flexible
steel wire located inside the blade provides the conduction path from the rod to the rotor
hub which in turn is used as a conductor to the main shaft. The electrical and hydraulic
equipment located inside the hub is completely protected by the Faraday cage effect of
the hub itself.
Nacelle: The canopy is fabricated from a 5-mm steel plate, acting as a Faraday
cage for the nacelle. The meteorological instruments at the rear of the canopy are
protected by a separate lightning rod projecting well above the instruments. All main
components are efficiently grounded, and metal oxide arrestors in the controller provide
transient protection from the electromagnetic pulse effects of nearby strikes.
Turbine controller: Metal oxide lightning arrestors protect the turbine controller.
The arrestors are installed with mechanical overload protection to prevent explosion in
case of a direct lightning strike. The controller is fitted with three arrestors, one for each
phase, all connected to the local grounding system. All metal parts, such as DIN-rails,
cabinet doors, and components are efficiently grounded.
Structural tower: The steel tower acts as a conductor from the nacelle and
controller to the ground. The ground connection is provided through several copper
leads. Grounding is achieved to a resistance of less than 10 ohms, using two depth
electrodes and a grounding ring surrounding the foundation.

ELECTRICAL GRID CONVERTER

The NetConverter power conversion system allows generator operation at

variable speed, frequency and voltage while supplying power at constant frequency and
voltage to the MV transformer.
This system provides maximum flexibility in the turbine response to voltage and
frequency requirements and fault conditions and can be adapted to meet the requirements
of relevant grid codes.
The power conversion system uses a number of modular water cooled converter
units in parallel mounting for easy maintenance.

POWER REGULATION

Limitation of the power output in high winds is necessary on all wind turbines;
otherwise the turbine would become overloaded. A runaway turbine would be subjected
to such high forces that it would disintegrate.
Two types of power limitation are used: stall regulation and pitch regulation.
Both methods are based on the continuous adjustment of the pitch setting of the blades
relative to the hub. Each blade has its own hydraulic actuator unit with position
feedback, ensuring continuous stable operation.
CombiStall: Stall regulation is used on constant speed turbines such as the
SWT-1.3-62 and SWT-2.3-82. In low and medium wind speeds the blade pitch setting is
slowly adjusted to provide maximum power output at any given wind speed. When the
rated wind speed is reached, the blades are adjusted to a more negative pitch setting,
tripping aerodynamic stall and thereby spilling the excess power. At higher wind speeds,
the pitch angle is adjusted continuously to maintain the maximum power specified. The
advantage of stall regulation is that it is very simple and efficient, working well with
constant speed operation. The disadvantages are that the noise level and blade deflection
in high wind are somewhat higher than with pitch regulation. These disadvantages are of
little importance for smaller turbines, but for very large turbines they tend to outweigh
the benefits of the robust constant speed operation.
CombiPitch: Pitch regulation is used on variable speed turbines such as the
SWT-2.3-82 VS, SWT-2.3-93 and SWT-3.6-107 turbines. In low and medium wind
speeds the blade pitch setting is slowly adjusted to provide maximum power output at any
given wind speed. When the rated wind speed is reached, the blades are adjusted to a
more positive pitch setting, thereby reducing the aerodynamic forces and maintaining the
power level programmed into the turbine controller. At higher wind speeds, the pitch
angle is adjusted continuously to maintain the maximum power specified. The advantage
of pitch regulation is that it provides low aerodynamic noise and moderate blade
deflections. Furthermore, even lower noise can be obtained by special operation. The
disadvantage is that variable speed operation is required to provide the necessary
flexibility in regulation. However, this disadvantage is of little importance for large
turbines, where the benefits of pitch regulation clearly outweigh the added complexity of
variable speed operation.

MONITORING SYSTEM

The WebWPS SCADA system is based on standard World Wide Web (www)
technologies, including XML, XSL style sheets, Microsoft Internet Information Server
(IIS) and ASP. With its flexible architecture the system is fairly easy to adapt to project-
specific requirements, customized data and report formats. The web server on site
generates reports and stores historical data and remote terminals can be connected via
modem, routers or an ethernet network.
Communication network: On site, the SCADA and the wind turbines are linked
with an internal communication network using optical fiber cables preferably on a single-
mode basis. Depending on the site layout the network is split into loops each consisting
of 8 to 10 turbines.
WebWPS software: The main component of the WebWPS software is installed
on the site server. It has three distinct parts:
1. The communication driver controls the site network. It is fully configurable and can
be set up to handle any project-specific combination of turbines, net masts, and grid
monitoring stations.
2. The database management system that also generates the reports is based on Microsoft
ActiveX Data Objects (ADO). The report generation engine offers customized reports as
well as a number of predefined reports with setup based on typical wind farm operator
requirements.
3. The web server delivers information such as reports and real time data mostly based on
XML and XSL style sheets. It can be expanded easily to provide project-specific pages.
Status displays: A detailed view of a specific turbine will typically present the
following data:
1. Wind turbine data: Wind speed, active and reactive power, yaw angle, etc. and
command, operational and fault status.
2. Electrical and mechanical data: 3 phases and current voltage, power factor, frequency,
rotational speeds of generator and rotor, temperatures of gear oil, generator and nacelle.
3. Statistical data: Total and subtotal turbine statistics such as availability, external errors
hours, and calendar hours.
4. Meteorological data: Wind speed and direction, air pressure, temperature, mean wind
speed and any other project-specific data.
5. Grid data: Three phases and current voltage, active and reactive power and any
project-specific data.
Reports: The WebWPS SCADA system provides both standardized and
customized reports. All of them can be easily exported to an Excel work sheet allowing
quick analysis of these reports within customer organization. Some of the standards
include:
1. Browsing and filtering of date, station, alarm codes, and historical data.
2. Daily, weekly and monthly reports on turbine performance, meteorological and grid
data.
3. Project-specific reports.

SIEMENS SWT-2.3-82 VS VARIABLE SPEED TURBINE

The SWT-2.3-82 VS variable speed wind turbine with 2,3 MW of rated power
and 82 m diameter rotor, is a variable speed version of the standard SWT-2.3-82 turbine,
a preferred choice for utilities and other large developers. The VS version is suited for
locations with noise restrictions.

ROTOR

The rotor of the SWT-2.3-82 VS turbine is a three blade cantilevered

construction, mounted upwind of the tower. The power limitation is regulated by pitch
regulation.

ROTOR BLADES

The blades are made of fiber Glass Reinforced Epoxy (GRE) and are
manufactured using a single integral operation. No glued joints are generated between
the spars and shells avoiding weak points and eliminating water ingress as well as
discouraging lightning strikes paths.
The aerodynamic design of the blades has been tested under both static and
dynamic loadings. The blades are mounted on pitch bearings and can be feathered 90
degrees for shutdown purposes. Each blade has its own independent fail safe pitching
mechanism capable of feathering the blade under any operating condition, and allowing
fine-tuning to maximize power output.

GEARBOX AND BRAKE

The gearbox is a custom built 3 stage planetary helical design, mounted on the
nacelle with flexible rubber bushings, thereby providing a compact high performance
construction and the lowest possible noise level. The gearbox is fitted with a fail-safe
mechanical brake at the high speed shaft.

GENERATOR

The generator rotor construction and stator windings are specifically designed for
high efficiency at partial loads. The generator is fitted with a separate thermostat-
controlled ventilation arrangement, and by ensuring a very efficient cooling the generator
can be operated at temperatures well below the normal level of the standard insulation
class, thereby providing the best possible lifetime of the winding insulation.

TOWER

The SWT-2.3-82 VS turbine is mounted on a tapered tubular steel tower. The

tower has internal ascent and direct access to the yaw system and nacelle.

CONTROLLER

The turbine controller is a microprocessor based industrial controller. The

controller is complete with switch gear and protection devices. It is self diagnosing and
has a keyboard and display for an easy readout of status and for adjustment of settings.

OPERATION

The turbine operates automatically under all wind conditions. When the wind
speed increases from a calm condition, the turbine will self start at about 4 m/s average
wind speed. The small generator winding remains connected to the grid up to
approximately 7 m/s wind speed. At higher wind speeds, the generator switches to the
main winding. The wind turbine output increases roughly linearly with the wind speed
until the wind reaches 13-14 m/s. At that point the power is limited at the rated power.

SAFETY FEATURES

The turbine has several redundant levels in the safety system, including an
independent pitch system for each of the blades, and as a result the turbine can shut down
safely from any operational condition.

REMOTE CONTROL

The turbine is equipped with the WebWPS SCADA system. The system offers
long distance control and a variety of status views and useful reports from a standard
internet web browser.

GRID CONNECTIVITY

The SWT-2.3-82 VS turbine is fitted with the NetConverter system that is

compliant with demanding grid codes. It has a ride through capability for all normal
faults.

1: Spinner, 2: Spinner bracket, 3: Blade, 4: Pitch bearing, 5: Rotor hub, 6: Main

bearing, 7: Main shaft, 8: Gearbox, 9: Brake disc, 10: Coupling, 11: Service crane,
12: Generator, 13: Meteorological sensors, 14: Yaw bearing, 15: Yaw gear, 16: Yaw
ring, 17: Tower, 18: Nacelle bedplate, 19: Canopy, 20: Oil filter, 21: Oil filter,
22:Generator fan, 23: Oil cooler, 25: Rotor lock, 26: Hub controller box.

Fig. 15: Nacelle components of the Siemens SWT-2.3-82 VS variable speed wind
turbine. Source: Siemens.

TECHNICAL SPECIFICATIONS

Operational
data
Cut in wind 3 – 5 m/s
speed
Nominal 13 - 14 m/sec
power at
about
Cut out 25 m/s
wind speed
Maximum 55 m/s (standard version)
wind gust 60-80 m/s (special version)
 Rotor

Type 3 bladed horizontal axis

Position Upwind
Diameter 82.4 m
Swept area 5,300 m²
Synchronous 6-18 rpm
rotor speed
Regulation Pitch regulation
Rotor tilt 6 degrees

Rotor Blade

Type Self supporting

Blade length 40 m
Tip chord 0.80 m
Root chord 3.1 m
Aerodynamic NACA 63.xxx, FFAxxx
profile
Material Glass Reinforced Epoxy (GRE)
Surface gloss Semi matt, <30 / ISO2813
Surface color Light gray, RAL 7035

Aerodynamic
Brake
Type Full span pitching
Activation Active, fail safe

Load
supporting
parts
Hub Nodular cast iron
Main Spherical roller bearing
bearings
Main shaft Alloy steel
Nacelle Steel
bedplate

Transmission
system
Coupling hub Flange
shaft
Coupling Shrink disc
shaft gearbox
Gearbox type 3 stage planetary helical
Gearbox ratio 1:91
Gearbox Splash / forced lubrication
lubrication
Oil volume About 400 liters
Gearbox Separate oil cooler
cooling
Gearbox PEA 4456
designation
Gearbox Winergy AG
manufacturer
Coupling gear Double flexible coupling
generator
Mechanical
Brake
Type Fail safe disc brake
Position High speed shaft
Number of 2
calipers
Electrical
Generator
Type Asynchronous
Miminal 2,300 kWe
power
Protection IP 54
Cooling Integrated heat exchanger
Insulation F
class
Generator AMA 500L4 BAYH
designation
Canopy
Type Totally enclosed
Material Steel
Yaw
System
Type Active
Yaw Externally geared slew ring
bearing
Yaw drive Eight electric gear motors
Yaw brake Passive friction brake
Controller
Type Microprocessor
SCADA WPS via modem
system
Controller WTC 3.0
 designation
Tower
Type Cylindrical and/or tapered tubular
Hub height 80 m or site specific
Corrosion Painted
protection
Surface Silk matt, 30-34/ ISO 2813
gloss
Surface Light gray, RAL 7035
color
Masses
Rotor 54 t
Nacelle 82 t
excluding
rotor
Tower (89 158 t
m)

ENERCON WIND TURBINES

The Enercon E-70 wind turbine is suitable for sites with high wind speeds, with
2.3 MW of rated power output. With numerous steel and precast concrete tower versions
it is designed to ensure maximum yield in the upper power range. It is characterized by a
gearless or direct drive system eliminating the weak link of the gearbox in modern wind
machines.
The rotor hub is not manufactured of cast steel which has been replaced by
modern spheroidal graphite cast iron.

DIRECT DRIVE SYSTEM

The drive system has fewer rotating components compared with other systems,
reducing mechanical stress and increasing the technical service life of the equipment.
The maintenance and service costs for the wind turbine are lower because of the fewer
wearing parts and the absence of need for gear oil change, resulting in reduced
operational costs.
The rotor hub and annular generator are directly connected to each other as a
fixed unit without gears. The rotor unit is mounted on a fixed axle or axle pin.
Compared with conventional geared systems that have a large number of bearing points
in a moving drive train, such drive system has only two slow moving roller bearings, a
configuration made possible by the low speed of the direct drive.
The rotor hub is not made of cast steel anymore and has been replaced by modern
spheroidal graphite cast iron. It is also used in the manufacturing of other major
components such as the blade adaptors, the axle pins and the main carriers.
The cast components are drawn at the foundries on a three dimensional Computer
Aided Design (CAD) system and calculated using the finite element method to test the
strain increases at the critical points. During the entire prototype phase, the designer tests
and optimizes performance. In order to guarantee the identification and traceability of
each cast component, each part is given a specific barcode, from which the serial number
can be obtained in the event of quality issues. Cast components are not released for
further steps in the manufacturing process until comprehensive quality testing has taken
place, thus guaranteeing high quality standards in the cast component supply sector.

Fig. 16: The Enercon direct drive system has few rotating components, eliminating
the gearbox and increasing its design lifespan. Source: Enercon.

Fig. 17: Enercon E-112 wind turbine.

The Enercon E-112 turbine was upgraded, so that instead of generating 4.5
megawatts, it now produces 6 megawatts, enough to supply power to 4,000 homes in
Germany. It is named the E-112 because it has a rotor diameter of 112 meters or about
367 feet. The gearless drive system does not require any oil to operate. The tips of the
turbine's blades are tilted to reduce noise emissions.

Fig. 18: Enercon E-126, 7 MW wind turbine. These turbines are equipped with a
number of new features: an optimized blade design with a spoiler extending down to
the hub, and a precast concrete base.

The Enercon E-126 has a rated capacity 6 MW and 20 million kW.hr/year. That
is enough to power about 5,000 households of 4 in Europe. For the USA, 938 kW.hr is
needed per home per month, yielding 11,256 kW.hr per year per house, suggesting that
1,776 American homes could be powered by one wind turbine.
The rotor blade length is 126 meters or 413 feet. These turbines are equipped
with new features: an optimized blade design with a spoiler extending down to the hub,
and a pre cast concrete base.
In the Enercon design, no gearbox is used and the generator is housed just at the
widest part of the nose cone. It takes up the entire width of the nacelle to generate power
more efficiently, and provide longer service life with less wear.
Like small wind turbines, these have inverters instead of synchronous generators,
that is to say, a separate controller that converts the AC electrical power generated into
something the grid can be fed with. This means that the rotor can rotate at more optimal
and varied speeds.
Also, like small turbines, the E-126 does not shut right off at a predetermined
speed due to gusts or just very high wind speeds. It simply throttles down by turning the
blades slightly away from the wind so as to continue to generate power though at a lower
production rate. Then the instant the wind is more favorable, it starts back up again.
Many smaller wind turbines do something similar except that they have no blade pitch
control, and they use the technique of side furling where the whole machine, excepting
the tail, turns sideways to catch less wind but continue operating.
Due to the elevated hub height and the new blade profile, the performance of the
E-126 is expected to by far surpass that of the E-112.

Fig. 19: Enercon E-70 2.3 MW wind turbine. The bottom of the turbine is painted
in green to blend with the green surroundings. Source: Enercon.
Fig. 20: Nacelle of the Enercon E-70 wind turbine is shaped as an artistic liquid
drop. Source: Enercon.

Fig. 21: Number of rotations in E-70 turbine with direct drive compared with
conventional turbines. The generator of an E-70 undergoes the same number of
rotations in 20 years as the generators in conventional wind turbines in three
months. Source: Enercon.
 ANNULAR GENERATOR

The annular generator is of primary importance in the gearless system design of

the E-70 wind turbine. It offers the advantages of totally avoiding the gearbox
components, a lower wear caused by a slow machine rotation, low stress due to the high
level of speed variability, the incorporation of yield optimized control and the high level
of grid compatibility.
Combined with the rotor hub, it provides an almost frictionless flow of energy,
while the gentle running of fewer moving components guarantees minimal material wear.
Unlike conventional asynchronous generators, the annular generator is subjected to
minimal mechanical wear, which makes it ideal for particularly heavy demands and a
long service life.
The annular generator is a low speed synchronous generator with no direct grid
coupling. The output voltage and frequency vary with the speed and are converted for
output to the grid by a DC link and inverter. This achieves a high degree of speed
variability.

Fig. 22: Annular generators assembly line. Source: Enercon.

 STATOR AND ROTOR

To enhance the service life time, the copper winding in the stator, the stationary
part of the annular generator, known as closed, single layer basket winding is produced in
the insulation class F to 155 °C. It consists of individual round wires that are gathered in
bundles and varnish insulated. The copper winding is done manually. In spite of
increasing automation in other manufacturing areas, preference has been given to manual
labor in this case since it ensures that the materials used are fully tested. A special
processing method allows continuous windings to be produced. Each wire strand is
continuous from start to finish.
The advantages of continuous winding are:
1. Prevents processing faults in the production of electrical connections.
2. Maintains the high quality copper wire insulating system.
3. Eliminates the contact resistance.
4. Eliminates weak points that are susceptible to corrosion or material fatigue.
The magnetic field of the stator winding is excited via pole shoes. These are
located on the disk rotor, the mobile part of the annular generator. Since the shape and
position of the pole shoes have a decisive influence on the noise emission of the annular
generator, Research and Development (RD) has dedicated particular attention to this
aspect. The result is an improved adaptation of the pole shoes to the slow rotation of the
annular generator with no significant noise being generated.

Fig. 23: Stator and rotor of E-70 wind turbine. Source: Enercon.

TEMPERATURE RESPONSE

The annular generator features optimized temperature control. The hottest areas
in the annular generator are constantly monitored by a large number of temperature
sensors. The sensors activation temperature is well below the constant temperature
resistance of the insulating materials used in the generator. This prevents temperature
overload. The maximum operating temperature in an annular generator is considerably
below the limit values of the processed materials.

Fig. 24: Temperature response in the annular ring generator. Source: Enercon.

QUALITY ASSURANCE

Annular generators are manufactured with close collaboration with the supplier
companies. The enameled copper wires are subjected to more testing than is specified in
the industrial standard and samples are archived, while surge voltage tests are performed
on the pole shoes and then documented in the computer system.

ROTOR BLADES DESIGN

The goals of the rotor blade concept are to maximize yield, reduce noise emission,
and minimize the induced stresses. The blades use the inner part of the rotor area and
considerably increase the energy yield. The rotor blades are less susceptible to
turbulence and provide an even flow along the entire length of the blade profile.
The blade tips have been optimized with regard to noise emission and energy
yield. Turbulence that occurs at the blade tips due to over pressure and under pressure is
effectively removed from the rotor plane. The entire length of the blade is utilized
without any loss of energy caused by turbulence.
 Fig. 25: Blade tip design eliminating noise emission. Source: Enercon.

The rotor blades offer higher efficiency due to the modified design, generate less
noise and have a longer life span due to their optimized tips, and offer easier transport
due to their streamlined geometry.
The rotor blades are manufactured with a vacuum infusion process using the
sandwich method. Glass fiber mats placed in the mold are vacuum impregnated with
resin via a pump and a hose system. This method eliminates the formation of air pockets
in the laminate.

Fig. 26: Layered composite construction of E-70 rotor blade. Source: Enercon.

To efficiently protect the rotor blade surface against the elements such as wind
and water, ultra violet (UV) radiation, as well as erosion and bending loads, the rotor
blade finish protection system includes gel coat, filler, edge protection and a top coating.
Solvent free two component polyurethane compounds are used in the entire system.
To effectively withstand wind stress over the entire usage period, the rotor blades
have an extremely large blade flange diameter. A double-row bolt connection specially
developed for large wind turbines provides additional strength by creating an even load
distribution. This is an important at sites with extreme winds and large stress
fluctuations.

Fig. 27: Load diagram on rotor blades. The load diagram indicates that the load F
is reduced by using a larger blade diameter D, suggesting an enhanced loading
capability. Source: Enercon.

SYSTEM MONITORING AND CONTROL

Fig. 28: System controls are located inside the structural tower protecting them
from the environmental conditions and from possible intrusion and vandalism.
 Source: Enercon.

State of the art microelectronics is used for the control of wind turbines. The
Main Processing Unit (MPU), the central element of the control system, constantly
registers information from the peripheral control elements, such as the yaw control and
active pitch control systems. Its function is to adjust the individual system parameters to
ensure that the wind turbines achieve maximum output under all weather conditions. The
functions of the control system include:
1. The constant evaluation of measurement data from wind sensor for adaptive nacelle
yaw control.
2. Variable speed for maximum wind turbine efficiency at all wind speeds, and
elimination of undesirable output peaks and high operating load.
3. Active pitch control system to obtain ideal angle of flow on the rotor blades ensures
maximum output and stress reduction on the entire wind turbine.
4. Monitor the brake system for maximum turbine reliability by means of three
independently operating pitch mechanisms with a standby power supply in the form of
batteries in case of supply failure
5. Tower and generator monitoring by means of vibration and acceleration sensors to
check tower oscillations.
6. Monitor the temperature and air gap sensors between rotor and stator ensure
dependable annular generator operation

GRID CONNECTION MONITORING

Ensuring proper power feed from the wind turbines into the grid requires grid
connection monitoring. Grid parameters such as voltage, current and frequency are
measured on the low voltage side between an inverter and the system transformer. The
measured values are continuously transmitted to the control system, enabling the turbine
to react immediately to changes in the grid voltage or frequency. If the defined limit
values of the system protection are exceeded, the wind turbine is reliably shut down and
service is informed.
 Fig. 29: Grid connection monitoring system. Source: Enercon.

As soon as the voltage and frequency return to within the permissible tolerances,
the wind turbine is automatically started up again avoiding prolonged downtimes.

MONITORING AND CONTROL SYSTEM

The Surveillance, Control and Data Acquisition (SCADA) monitoring and control
system has been a proven system for remote wind farm control and monitoring for many
years. Introduced in 1998, this system is now used in more than 6,500 wind turbines
worldwide. It offers a number of optional functions and interfaces to connect wind farms
to the grid while meeting demanding grid connection regulations.
Due to its modular design, expansion is simple and flexible and can be adapted to
electrical utilities specific applications.

POWER REGULATION AND ENERGY MANAGEMENT

If the cumulative nominal output of a wind farm is greater than the grid
connection capacity at the point of common coupling, the wind farm power regulation
system ensures that the capacity is used to the fullest at all times. If a wind turbine in the
wind farm generates less power, the other turbines are appropriately adjusted to run at a
higher capacity and take the slack. This is an optional energy management feature that
can be added to the monitoring and control system

Fig. 30: Energy management and power regulation. Without energy management,
the available grid capacity could not be fully exploited. The grid capacity is 80
percent of the cumulative rated power installed. Therefore this becomes the feed-in
limit without energy management. Source: Enercon.

VOLTAGE CONTROL

As an option, the monitoring and control system can be expanded to provide wind
farms with a voltage control feature. This feature, which is a mandatory requirement by
utilities in some countries, enables large wind farms to be integrated into relatively weak
grids. The reactive power range of the wind turbines is in this case is usually used to
control the voltage at the point of common coupling. Voltage can be controlled by the
grid operator according to some predefined conditions or via additional interfaces.
There are various requirements concerning wind farm voltage control. If a wind
farm is connected to a substation, automatic voltage regulators can be integrated into the
control concept. In large wind farms with respective cable lengths, a control system can
be used to improve reactive power demand for the contractually agreed point of common
coupling with centralized compensation equipment and decentralized wind turbines.

Fig. 31: Voltage control for a wind farm. Source: Enercon.

SYSTEM INTERFACES

In most countries, the integration of wind farms into the grid control systems and
connection to grid control stations are today standard requirements for wind farms.
Different optional modules that are added to the control system can act as interfaces
between the various systems. This enables the control system to communicate via analog
or digital interfaces depending on the requirements. Certain wind farm target values can
be preset and status messages or wind farm measurement values transmitted to the grid
operator. If desired the wind masts in a wind farm can be integrated into the permanent
data transfer system.

BOTTLENECK MANAGEMENT, FEEDING INTO WEAK GRIDS

Not all regions have sufficient transmission capacity available to manage each
low load and strong wind situation. A bottleneck management system offers the
possibility of connecting wind farms to this type of grid. Constant data exchange
between the wind farm and the grid operator ensures that transmission capacity is well
adapted to the highest permissible wind farm output.

Fig. 32: System interfaces and bottleneck management. The wind farm output can
be infinitely adjusted during bottlenecks at the grid operator’s request. Source:
Enercon.

SUBSTATIONS FOR WIND FARMS

Wind farms are increasingly feeding power into the grid via substations especially
constructed for this purpose. Remote monitoring and control of these substations are
often required in order to receive continuous information on switchgear assemblies and,
as the case may be, carry out switching operations.
The control system can incorporate special optional modules for remote
monitoring and control of switchgear units and entire substations.

MAIN CONTROL UNIT (MCU)

Individual wind farms functioning similar to conventional power plants have

successfully been in operation and integrated into existing grid structures for many years.
It is common to find several wind farms connected to a central point of common coupling
to form wind power plants. Since installed power output is high, these plants usually
feed power into high performance transmission grids. The MCU assumes centralized
open-loop and closed loop control of a wind power plant. It takes over typical
communication and data transfer tasks to grid control systems and load dispatching
centers fulfilling complex technical grid connection regulations for wind power plants.
The MCU comes a as module. Each application is customized with features best
suited to the project. Depending on requirements, the MCU has different interfaces to
connect to the grid control systems. Bottleneck management for wind power plants is yet
another feature part in addition to reactive power management, or the integration of
switchgear assemblies or entire substations into the wind power plant.
The typical requirements for wind power plants connection to the power grid are:
1. The wind turbines should be able to remain connected to the grid without power
reduction even if considerable voltage and frequency deviations occur.
2. If voltage dips occur due to grid problems, the wind turbines should remain connected
to the grid for a defined period.
3. Short circuit current feeding may be demanded during a grid failure.
4. After a fault has been remedied, a wind farm should resume power feed as quickly as
possible within a specified maximum time range.
5. Wind farms should be able to be operated with reduced power output without any time
restrictions.
6. For coordinated load distribution in the grid, the increase in power output (power
gradient), for example when the wind farm is started up, should be able to be restricted in
accordance with the grid operator’s specifications.
7. Wind farms should be able to contribute reserve energy within the grid. If the grid
frequency increases, the power output of a wind farm should be reduced.
8. If necessary, wind farms should be able to contribute to maintaining voltage stability in
the grid by supplying or accepting reactive power.
9. Wind farms should be able to be integrated in the grid control system for remote
monitoring and control of all wind turbines in the grid.
Fig. 33: The Main Control Unit (MCU) controls the grid connection of several wind
power plants.

STORM CONTROL

Some wind turbine designs are equipped with a special storm control system,
which enables reduced turbine operation in the event of extremely high wind speeds.
This prevents the otherwise frequent shutdowns and the resulting yield losses.
The diagram of a power curve of a wind turbine without storm control shows that
the wind turbine stops at a defined shutdown maximum wind speed V3.

Fig. 34: Power curve with (bottom) and without (top) storm control showing the
strong wind hysteresis effect. Source: Enercon.

In the case of a wind turbine without storm control this occurs at a wind speed of
about 25 m/s with 20 seconds mean time duration. The wind turbine only starts up again
when the average wind speed drops below the shutdown speed or possibly even lower
restart speed at V4 in the diagram. This is known as the strong wind hysteresis effect. In
gusty wind conditions, this may take a while, which means that considerable yield losses
are incurred.

TOWER CONSTRUCTION

The load dynamic design of materials and structure used in wind turbine towers
provide the best conditions for transport, installation and use. They must conform to the
international standards and codes such as ASA, DIN and Eurocode which assure quality
and safety norms.

Fig. 36: Steel tower foundation. Source: Enercon

Virtual 3D models of the tower designs are produced during the development
phase using the Finite Element Method (FEM). All possible stress on the wind turbine is
then simulated on the model. Accurate predictions concerning tower stability and service
life are not left to chance before building a prototype. Measurements on existing turbines
provide verification of the calculated data. The calculations are supported by results
produced by specially commissioned certification bodies, research institutes and
engineering firms.
The aesthetic aspect is also a decisive factor during tower development, which is
obvious in the finished product. The streamlined gradually tapered design offers a visibly
sophisticated aesthetic concept.

TUBULAR STEEL TOWERS

Tubular steel towers are manufactured in several individual tower sections

connected using stress reducing L flanges. Unlike the conventional flange connections
used in steel chimney construction, the welding seam of the L-flange is outside the stress
zone. The L flange approach presents several advantages:
1. It dispenses with complicated and costly welding work on site.
2. It offers quick, reliable assembly with the highest quality standard.
3. It allows full corrosion protection, applied under the best production engineering
conditions

Fig. 37: Tubular steel sections. Source: Enercon.

Due to their relatively small circumference, shorter tubular steel towers are
mounted on the foundations using a foundation basket, which consists of a double rowed
circular array of threaded steel bolts. A retainer ring, fitted to the tower flange
dimensions, is used to hold the individual bolts in position. When the foundation is
completed, the lower tower section is placed on the bolts protruding out of the concrete
surface and then bolted with nuts and washers.
 Fig. 38: Tubular steel sections connections. Source: Enercon.

A specially developed foundation connection system is used for taller steel

towers. A cylindrical structural element is set on the blinding layer and precisely aligned
with adjusting bolts. Once the foundation is completed, the tower is flanged together
with the foundation section
Tubular steel towers are subject to strict quality standards. Quality assurance
begins already in the design development stages to ensure that the prototype meets all
requirements before going into series production.

PRE CAST CONCRETE TOWER

 Fig. 39: Precast concrete tower sections.

Precast concrete structural towers are made using specially developed prestressed
steel reinforcement. The individual tower sections and foundation are fastened together
to form an inseparable unit with stay cables running through jacket tubes in the core of
the concrete tower wall. The tower sections themselves are manufactured entirely in the
precasting plant. Specially constructed steel molds assure manufacturing precision for
each individual concrete section. This manufacturing process minimizes dimensional
tolerances which assures a high degree of fitting accuracy.
Quality Assurance carries strict inspections and detailed procedural and work
instructions are available for each manufacturing sector ensuring that each individual
manufacturing stage as well as the materials used can be completely retraced

FOUNDATION CONSTRUCTION

The foundation transmits the wind turbine's dead load and wind load into the
ground. Circular foundations are favored. The advantages of rounded foundations can
be identified as:
1. The forces are equal in all wind directions, whereas asymmetrical foundation pressure
is possible with square bases or cross shaped foundations.
2. The circular design has proven to reduce the amount of reinforcement and concrete
required. The circular design reduces the size of the formwork area.
3. Backfilling the foundation with soil from the excavation pit is included in the structural
analysis as a load. This means that less reinforced concrete is needed for foundation
stability.
 Fig. 40: Pouring of reinforced concrete into a round foundation. Source: Enercon.

Depending on the site, the ground can only absorb a certain amount of
compressive strain so the foundation surfaces are adapted accordingly. Circular
foundations are designed based on this elementary realization and as a rule are installed
as shallow foundations. If necessary in soft soil a special deep foundation distributes the
load down to deeper load bearing soil strata. The piles, symmetrically arranged, are
slightly inclined so that the imagined extended pile center lines meet at a point above the
center of the foundation. This provides maximum force/load distribution over the entire
surface.

TECHNICAL SPECIFICATIONS

Rated power 2,300 kW

Rotor diameter: 71 m
Hub height: 58 - 113 m
Wind class (IEC) IEC/NVN I
Turbine concept Gearless, variable speed, variable
pitch control
Rotor
Type Upwind rotor with active pitch
control
 Direction of rotation Clockwise
Number of blades 3
Swept area 3,959 m2
Blade material Fiberglass reinforced with epoxy
resin, integrated lightning protection
Rotational speed: Variable, 6 - 21.5 rpm
Pitch control: Blade pitch system, one independent
pitching system per rotor blade with
allocated emergency supply
Drive train with generator
Hub Rigid
Main bearings Dual-row tapered/single-row
cylindrical roller bearings
Generator: Direct-drive synchronous annular
generator
Grid feeding ENERCON converter
Braking systems Three independent blade pitch
systems with emergency supply
Rotor brake
Rotor lock
Yaw control Active via adjustment gears, load-
dependent damping
Cut-out wind speed 28 - 34 m/s with storm control
Remote monitoring: SCADA

NORDEX WIND TURBINES

A rotor diameter of 80 m and an installed capacity of 2.5 MW characterize the
Nordex N80 as a choice for strong wind sites.
Using pitch control, the GL-1-certified machine is able to optimize the energy
yield at all wind speeds.
 Fig. 41: Erection of a Nordex N80/2500 wind turbine. Source: Nordex.

The machine offers low maintenance due to having no rotating hydraulics in the
hub, maintenance-free blade adjustment drives and easily accessible control cabinets.
It offers user friendly construction and access to the control system both from the
bottom of the tower and from the nacelle. It possesses a wide range of remote query
possibilities for the control system and converter.

CONTROL SYSTEM

The N80/2500 wind turbine is controlled by Nordex Control 2 (NC2), a

software/hardware system for managing the central wind power system components right
up to wind farms or the power station networks of non-centralized energy producers. The
software system continuously evaluates all operating and weather data measured and
ensures yield-optimized operation of the system. The system programs each system with
turbine and location-based parameters. The wind turbines are fitted with two
anemometers to record the wind data. The first one is used to manage the system and the
second one monitors the first device. If one device fails, the other takes over.
Each system is linked to a remote monitoring system for controlling the hardware
and software component. All data and signals are transmitted by ISDN and can be
viewed using an Internet browser. This ensures data monitoring as well as active remote
management at start-up, deactivation and wind tracking, for each turbine from the Nordex
service center in Rostock. The remote monitoring office works around the clock and is
automatically alerted in the event of any deviation in operating data from standard
parameters. The system is backed by an emergency power supply. Together with the
batteries fitted to the pitch system, the system is deactivated securely in the event of any
loss of power.
The turbine can be fitted with a condition monitoring system to ensure proactive
maintenance. This early warning system alerts the operator when a component needs to
be replaced in the foreseeable future. It is thus possible to avoid an unscheduled
shutdown.

Fig. 42: Control system display. Source: Nordex.

 Fig. 43: Nordex N80 2.5 MW Wind turbine. Source: Nordex.

TURBINE DESCRIPTION

1. The rotor blades are made of glass fiber reinforced plastic composite. The rotor is
pitch regulated.
2. The hub is made of cast iron.
3. The turbine frame is made of ductile cast iron. A superior material with regards to
strength, vibration and noise reduction features.
4. The rotor bearing is a solid double spherical roller bearing with a ductile cast iron
casing.
5. The rotor shaft is made of ductile cast iron.
6. The gearbox is a custom designed two stage planetary gears.
7. The disk brake is equipped with two brake calipers and located on the high speed shaft
of the gearbox.
8. The generator coupling is a flexible coupling.
9. The generator is a 2500 kW of rated power liquid cooled double fed asynchronous
generator.
10. The cooling radiator is a part of the gearbox cooling system.
11. The fan coolers for the generator cooling.
12. The wind measuring system consists of a redundant anemometer and wind vane,
which measures the wind conditions and gives signal to the turbine control system.
13. The control system monitors and controls the operation of the wind turbine.
14. The hydraulic system maintains and controls the hydraulic pressure to the disc brakes
and the yaw brake system.
15. The yaw drive consists of 2 planetary yaw gears, driven by frequency controlled
electrical motors.
16. The yaw bearing is a 4 point ball bearing with outer teething. In addition the turbine
is equipped with an active yaw disc brake system.
17. The nacelle cover is made of glass fiber reinforced plastic on a steel frame.
18. The tower is a tubular steel structure which can be delivered in various heights.
19. The pitch system consists of 3 independent pitch gears, driven by electrical motors.

Fig. 44: Nordex N80 2.5 MW wind turbine nacelle. Source: Nordex.

REPOWER WING TURBINES

The REpower 5M is variable speed wind turbine has a rated power of 5 MW and
a rotor diameter of 126 m. The 5M is one of the largest and most powerful wind turbines
in the world targeting offshore installations.
Wind farms with turbines of this capacity achieve outputs similar to conventional
power plants. This in turn places high demands on the control and regulation system
since optimized integration into the power grid becomes essential.
With a modular structure and logistical flexibility, it is is suitable for onshore and
offshore installation. The offshore version is specifically designed to withstand the
conditions of the high seas, including redundancy of key components to guarantee
maximum availability, effective protection against corrosion and permanent monitoring.

Fig. 45: The REpower 5M variable speed wind turbine. Source: REpower.

Fig. 46: REpower 5 MW wind turbine cutout showing a standard person inside the
nacelle. Source: Repower.
 Fig. 47: Components of REpower 5M wind turbine. Source: Repower.

Fig. 48: Offshore foundation installation of the REpower 5M wind turbine showing
the underwater foundation. Source: REpower.
 Fig. 49: REpower 5 MW wind turbine power curve. Source: Repower.

TECHNICAL SPECIFICATIONS

Rotor
Number of blades 3
Vane length 61.5 m
Rotor diameter 126 m
Rotor speed 6.9-12.1 T/min (+/- 15.0 percent)
Rotor area 12, 469 m2
Cut in wind speed 3 m/s
Rated capacity 5MW at 13 m/s
Cut out wind speed 31 m/s
Power control Active blade stalling

OFFSHORE TRANSFORMER

On the offshore transformer platform step up voltage takes place to transform the
power that has been collected to a higher voltage of 150 kV. This is necessary to limit
losses when transporting power over long distances.
 Fig. 50: Offshore transformer barge installation. Source: Repower.

GRID CONNECTION

Connection of the land cables to the public 150 kV electricity grid takes place at a
high voltage switching station.

Fig. 51: Onshore switching station for connection to the power grid. Source:
 Repower.

MULTIBRID OFFSHORE WIND TURBINES

DESCRIPTION

The Multibrid company specializes in large power wind turbines in the 5 MW

power range such as the M5000 turbine for offshore power applications. The company
develops and produces offshore turbines at Bremerhaven, a harbor site in Germany. The
M5000 is the first wind energy converter that has been exclusively designed for large
offshore wind farms. As a result of the continuous development process new solutions
were found that set new standards and are best adapted to fit the requirements of offshore
operation.
Since its foundation in 2000, the Multibrid company has been working on the
development and manufacture of the offshore wind energy converter Multibrid M5000.
It is affiliated with the Prokon Nord Group with a long experience in wind farm
technology. The maritime environment in Bremerhaven supports the consequential
orientation of the turbine’s technology towards offshore deployment with knowledge
about transportation and installation on the high seas.

PRODUCTION AND INSTALLATION

The Multibrid M5000 is produced directly at the Bremerhaven’s harbor. In this

way, ideal preconditions exist for the transport to the offshore wind farms. An in house
team of technicians installs all components of the nacelle and the hub, including the
sensitive components of the drive train. The turbine design is conceptualized in such a
way that for the installation at the offshore site only the smallest number of installation
steps is required. Besides the erection of the tower, just the nacelle and rotor have to be
mounted. The converter system, transformer and switchgear are already installed on the
tower ready for operation in order to reduce the installation risk at the offshore location to
a minimum.

SERVICE AND MAINTENANCE

To account for the weather related reduced accessibility of the offshore location,
particular attention has been paid to long service intervals. The use of maintenance
complex components has been avoided wherever possible. Where regular inspections are
required, as for the filter units, the maintenance cycles were considerably increased by
the sizing of these parts and the inclusion of redundancies. The plant’s condition can be
checked at all times by the monitoring of all turbine parts that are indispensable for
operation. This way, repairs on the high seas may be planned on a long term basis for
most operations.
 Fig. 52: Multibrid M5000 5 MW offshore wind turbine. Source: Multibrid.

TECHNICAL SPECIFICATIONS

General
Rated power 5 MW
Cut-in wind speed 4 m/s
Rated wind speed 12 m/s
Cut-out wind speed 25 m/s
Design life time 20 years
Type class IEC 1a/GL-TK 1 offshore

Gearbox
Type step-planetary gear, helical
Rated power 5,540 kW
Rated torque 3,575 kNm
Ratio 1:9.92

Rotor
Rotor diameter 116 m
Number of blades 3
Rotor area 10,568 m²
Rated speed 14.8 min-1
Tilt angle 5º
Cone angle -2º

Generator and converter

Generator type synchronous, permanent magnet
Rated generator power 5,315 kWe
Speed range 5.9 - 14.8 min-1 ± 10 %
Cooling Water cooled
Protection class IP 54
Converter type 4-quadrant-converter
Power factor of grid 0.9 inductive
0.9 capacitive

Tower
Type Tubular steel tower

Pitch system
Principle Electrical single pitch
Power control Blade angle and rotor speed control

Masses
Blade 16,500 kg
Hub 60,100 kg
Nacelle 199,300 kg

WEIGHT

In the development of the turbine the greatest importance was attached to the low
weight of nacelle and rotor. This simplifies the transport considerably and allows a safe
and fast installation, since the nacelle can be lifted as one complete unit on top of the
structural tower. The low nacelle weight ensures the use of highly cost effective
foundation structures.

RELIABILITY

Reliability is a decisive factor for the operation of offshore wind energy

converters, is an integral element of the concept. The low rotational speed level and the
small number of rotating parts and roller bearings reduce the risk of damage in the drive
train to a minimum. Additionally, all auxiliary aggregates and sensors that are
indispensable for the operation are installed in duplicate in order to avoid that a failure of
these parts will lead to a failure of the overall system.

SEALING

The permanent protection of the converter’s technology from the corrosive sea
atmosphere is the basic precondition for a long life time. Therefore nacelle and hub of
are hermetically sealed against the ambient air. An air treatment system filters the air
throughout all weather and operational conditions and provides that the plant’s interior is
not affected by corrosion through salt and humidity.

COMPACTNESS

The drive train evolved from the combination of the advantages of conventional
turbine concepts. The integration of the rotor bearing, gear system and generator allows
an extraordinary compact design and a very effective utilization of the main components.
This leads to short load paths from the rotor to the tower head. The compactness is not
an end in itself, but the result of a consequential implementation of the requirements on
offshore wind energy converters.

Fig. 53: Calculated power curve for the Multibrid M5000 wind turbine. Source:
Multibrid.

Fig. 54: Calculated energy yield curve for the Multibrid M5000. Source: Multibrid.
 ROTOR

The rotor blades are characterized by exceptionally high stiffness and low weight
due to the employment of carbon fiber girders. The aerodynamics of the rotor blades
were designed towards yield performance and provide low noise emission. Three
independent electrical blade pitch systems guarantee a highly dynamic blade angle
adjustment and maximum safety in case of failure. The blade pitch system is completely
located inside the closed rotor hub and thus protected against weather conditions.

Fig. 55: Rotor blade end of M5000 wind turbine. Source: Multibrid.

ROTOR BEARING, GEARBOX

A double tapered roller bearing in the TDO configuration transfers the rotor loads
from the hub into the machine housing. The bearing and the gearbox are arranged in
such a way that the dynamic rotor loads cannot have a harmful impact on the tooth
engagements. The planetary gear is driven by the hollow wheel and the planetary shafts
are fixed in a stationary cage. The shafts running on friction bearings as well as the gear
meshing can be easily lubricated.

Fig. 56: Rotor bearing and gearbox M5000 wind turbine. Source: Multibrid.
 GENERATOR AND CONVERTER

The stator of the permanent magnet synchronous generator is directly installed

into the main frame. The rotor is mounted on the output shaft of the gearbox and
therefore needs no further bearings. By using a permanent magnet technology, high
efficiency is achieved at nominal loads as well as at partial load operation. The generator
is connected to the grid via a 4Q converter, which allows maximum speed variability and
full compliance with grid connection codes.

Fig. 57: Rotor bearings, gearbox and generator assembly of M5000 wind turbine.
Source: Multibrid.

AIR VENTILATION

For offshore applications there is a need to include an air treatment system which
is located at the tower bottom. It takes in ambient air and separates water and salt
particles. An overpressure in the tower and nacelle is built up with the treated air and
secures a controlled volume flow through the turbine. With a pressure difference
monitoring system it is possible to eliminate any intrusion of untreated air. In addition,
the temperature in the nacelle is adjusted by variation of the air flow.
GAMESA WIND TURBINES
DESCRIPTION

A feature of this design is that the drive train and the main shaft are supported
with two spherical bearings transmitting the side loads to the frame through the bearing
housing. This approach prevents the gearbox from receiving additional loads reducing
faults and providing an adequate servicing capability.
The primary braking system uses aerodynamic full feathering. The secondary
braking system is a hydraulically activated disc brake mounted on the gearbox speed
shaft.
A total lightning protection system following the IEC 61024-1 standard conducts
any lightning discharge from both sides of the rotor blade tip down to the root joint and
across the nacelle and tower structure to a grounding system located in the foundation,
protecting the blade and sensitive electrical components from damage.

Fig. 58: Gamesa G52-850 kW wind turbine farm. Source: Gamesa.

CONTROL SYSTEM

The generator used is a doubly fed machine whose speed and power are
controlled using IGBT converters and Pulse Width Modulation (PWM) electronic
control. Such a system offers both active and reactive power control, low harmonic
content and minimal losses, increased efficiency and a long lifetime for the turbine.
 The control system allows real time operation and remote control of the wind
turbines, meteorological mast and the electrical substation by way of a satellite and
terrestrial network using the TCP/IP protocol with a world wide web (www) interface. A
modular design is adopted with control tools for active and reactive energy, noise,
shadows and wake effects.

Fig. 59: Gamesa G52 850 kW wind turbine. Source: Gamesa.

Fig. 60: Power curve of the Gamesa G52 850 kW wind turbine. Source: Gamesa.
 Table 2: Power curve data for the Gamesa G52-850 kW wind turbine.

Power Wind speed

[kW] [m/s]
27.9 4
65.2 5
123.1 6
203.0 7
307.0 8
435.3 9
564.5 10
684.6 11
779.9 12
840.6 13
848.0 14
849.0 15
850.0 16
850.0 17-25

POWER CURVE

The power curve for the Gamesa G52 850 kW wind turbine is generated based on
the NACA 63.xxx and FFA-W3 air foil profiles for an air density of 1.225 kg/m3.
The rotor blade is tip angle pitch regulated supplying a grid at 50 Hz frequency, at
10 percent turbulence intensity and a variable rotor rotational speed over the range 14.6-
30.8 rpm.
The grid connection uses doubly fed wind turbines and active crowbar and over
sized converter technologies. Low voltage ride through and dynamic regulation of the
active and reactive power are added capabilities.

TECHNICAL SPECIFICATIONS

Rotor
Rotor diameter 52 m
Number of blades 3
Length of blade 25.3 m
Airfoil type NACA 63.xxx and FFA-W3
Composition Glass fiber reinforced epoxy
Rotor area 2,124 m²
Rotational speed Variable: 14.6-30.8 rpm, 55m and 65 m
towers
Variable: 16.2-30.8 rpm, 44 m tower
Rotation Clockwise from front view
Rotor blade weight 1.9 t
Weight including hub 10 t
Top head mass 33 t
Gearbox
Type 1 planetary stage / 2 helical stages
Gear ratio 1:61.74, 50 Hz
1:74.5, 60 Hz
Cooling Oil pump with oil cooler
Oil heater 1.5 kW
Electrical Generator
Rated power 850 kWe
Number of poles 4
Rotational speed 900:1,900 rpm
rated: 1620 rpm
Type Doubly fed machine
Voltage 690 Volts, AC
Rated stator current 67 Ampères at 690 Volts
Frequency 50/60 Hz
Protection class IP 54
Power factor, Standard:0.95 CAP – 0.95 IND at partial
At generator output terminals, at low loads and 1 at nominal power.
voltage side before transformer input Optional: 0.95 CAP – 0.95 IND throughout
terminals. power range

PREDICTIVE MAINTENANCE

A predictive maintenance system is used for the early detection of sources of

malfunction and early deterioration in the turbine’s main components, is integrated with
the control system. This reduces the occurrence of major corrective measures, increases
the machine availability and working life, and allows for obtaining preferential terms in
insurance premiums.

NOISE CONTROL

The aerodynamic blade tip and mechanical components design minimizes noise
emissions. The noise emission is controlled according to chosen or regulatory criteria as
concerns date, time or wind direction.

ECOTÈCNIA WIND TURBINES

INTRODUCTION

Ecotècnia, is a Spanish manufacturer and operator of wind turbines and solar

energy products. It developed its first wind turbine in 1981, and designs, manufactures
and operates its own wind turbines and builds turnkey wind farms.
 MAIN FEATURES

The Ecotècnia 80 wind turbine of 2 MW nominal power has been designed

following the Class II specifications of standard IEC-61400-1, suitable for sites with a
mean annual wind speed of up to 8.5 m/s and an extreme gust speed with a 50 year
repetition frequency of 60 m/s. An efficient control system incorporating control
mechanisms associated with the structure has made it possible to attain a diameter of 80.5
m with a 2 MW wind turbine. It has a power flux or areal power of:

P 4 x 2,000 W
=Ap = = 392.96[ 2 ]
π D 4 π x80.5
2 2
m

and has been designed for optimal exploitation of Class III sites by incorporating active
damping mechanisms.
It has a characteristic mechanical design based on supporting the rotor directly on
the frame, separating the tasks of supporting it from those of torque transmission. The
drive train has a carefully studied design that includes controlled flexibility and torque
control in any situation. Combined with variable speed operation, this permits a
reduction of the number of cycles and extreme loads to which the drive train is subjected.

Fig. 61: Wind farm using ecotècnia wind turbines. Source: ecotècnia.

MECHANICAL DESIGN

This mechanical design concept, has been demonstrated its efficiency in

commercial wind turbines of lower power of 0.64, 0.75, 1.3 and 1.67 MW, of which over
1,000 units have been installed. The concept is based on the following features:
1. The rotor supported directly by the frame.
2. A flexible drive train and floating shaft are used.
3. The transmission of loads is directly to the structure.
4. The yaw system uses gliding pads.
 The design includes some important features:
1. A modular conception of the wind turbine.
2. An independent pitch control system in each blade.
3. A decentralized control system.
4. Use of built in predictive maintenance.
5. Use of active damping systems.
The optimization of the design process aims at greater cost effectiveness,
reliability, integration into the electrical grid, and environmental compatibility.
The gearbox, better protected, is subjected to much lower loads than in
conventional configurations, thus lengthening its working life.
The rotor, resting directly on the frame, is not supported by the gearbox, which
suggests that this component is not subjected to the great asymmetry of loads generated
on the rotor by the wind. The rotor being fixed; means that the gravity loads are
deflected to the tower and only the useful wind rotational loads are transmitted to the
drive train.
The length of the shaft gives the drive train considerable elasticity, thus
preventing load peaks on the gearbox. The positioning of the gearbox, separate from the
support structure, prevents it from being subjected to loads deriving from the behavior of
the latter, such as deformations or displacements of large masses.
In extreme situations, these loads can generate overloads not foreseen in the load
simulation and calculation stage.

Fig. 62: Ecotècnia wind turbines. Source: Ecotècnia.

 MODULAR DESIGN

The wind turbine is conceived in a modular form. The nacelle is made up of three
modules comprising the following components:
Module 1: Rotor, bearings and shaft.
Module 2: Mainframe, yaw system and housing support.
Module 3: Drive train.
These modules include both the mechanical components and the control systems,
thus allowing independent verification of their integrity and operation. Their
manufacturing process is also independent, and they are interchangeable.
These modules have reduced weight and reduced the external dimensions, thus
facilitating the transport operations. In addition, the modules can be assembled at the top
of the structural tower, thus reducing the requirements for assembly cranes and auxiliary
elements.
The modularity of the wind turbine offers several advantages:
1. Less need for a civil engineering infrastructure: access to the site with the nacelle is
made easier by having to transport only components weighing less than 30 tonnes.
2. Ease of transport: the modules have weights and dimensions which enable them to
adapt to standard transport procedures and containerization.
3. Lower requirement of cranes: due to the reduced weight of the modules, the wind
turbine can be hoisted with cranes of the same capacity as those currently used for
machines of less than 1 MW power. This also means lower infrastructure requirements at
the site.
4. A better exploitation of complex terrains due to ease of installation.

TECHNICAL SPECIFICATIONS

General characteristics
Type Wind turbine class II as per IEC-61400-1
Ecotèchnia 80 2.0
Nominal power 2 MW
Standard hub height 70 m
Power control system Variable speed with independent pitch control in each blade
Range of operating -10 to -40 oC
temperatures
Mean annual wind speed for 8.5 m/s
suitability
Maximum wind speed (mean 42.5 m/s
10’)
Extreme gust speed (IEC) 59.5 m/s
Instant stoppage speed 32 m/s
Turbulence intensity A
Rotor
Yaw Windward
Speed range 9.44-17.9 rpm
Number of blades 3
Rotor diameter 80.5 m
Cut in and cut out speed 3 m/s and 25 m/s
Swept area 5,090 m2
Rotor rotational speed 9.44-17.90 rpm at nominal power
Blade tip speed 80 m/s
Rotor weight including hub 53 t
Nacelle weight without hub 105 t
Blades manufacturer LM Glassfiber
Type of blades LM 37.3 II + 2.21 m lengthener
Nacelle
Yaw By means of guide shoes, with 4 motor reducers
Hub, shaft and bearings
Hub material Nodular cast iron EN-GJS400-18U-LT
Type of main bearings 2 conical roller bearings at front and rear, housed inside hub
Bearings manufacturer FAG or SKF
Transmission shaft material F.1252 UNE 36-012-75
Length of cylindrical shaft 4.17 m
Hub to shaft coupling system Contraction ring and elastic coupling
Gearbox
Type Planetary with parallel shafts
Manufacturer Winergy or equivalent
Gearing ratio 1:100.6
Mechanical power 2.225 MW
Nominal torque 1,190 kNm
Cooling system Active cooling by means of radiator with forced ventilation
Lubrication system Oil using active lubrication
Gearbox generator coupling Contraction rings and elastic coupling
Weight 35 t
Operational temperature 65 oC with ambient temperature 40 oC
Grid connection Asynchronous generator controlled by the rotor
Voltage drops Capacity to maintain operation during voltage drops
Generator
Type Induction with wound rotor. Rotor generator winding with
converter, based on IGBT technology, connected at the rotor
Manufacturer ABB, Siemens, or equivalent
Quantity 1
Nominal power 2,050 kWe
Rotational speed 1000 / 1800 rpm
Nominal voltage 690 V +/- 10 %
Grid connection Variable-speed
Power wave inverter Two directional, IGBT technology
Cos φ range at nominal 0.95 inductive/capacitive
power
Cooling system Air/air
Structural Tower
Type Tronco-conical steel tube
Bottom diameter 3.95 m for 70 m tower
Top diameter 2.13 m
Rust protection Class 4 as per standards ISO 9332, ISO 9224 and EN 10025
Height 70 m
Color RAL 7053
Control System
Type Control of torque and pass angle
Torque control Digital Signal Processor (DSP) and power electronics
Control of blade pass angle or Three independent microprocessor controlled systems, one for
pitch control each blade using electrical pitch control
Power control Vectorial control by the generator
Interconnection and Bus device Net and TCP/IP
communication protocols
Monitoring ARGOS system
Speed control Pitch control
Main brake Independent pitch control
Auxiliary brake Independent emergency system
Yaw system
Yaw speed 0.47 o/s
Type Active, with mechanical brake
Yaw motion 3 polymer gliding pads
Yaw motor 4 electrical motors and planetary type gears
Activation At variable frequency and torque control
Manufacturer Bonfiglioli or similar
Yaw brake 2 guide shoes acting as clamps by means of hydraulic safety
system
Brakes system
Main brake Aerodynamic by means of pitch rotation of the blades
Stop or parking brake Disc brake located on the high speed shaft
Weights
Nacelle including hub 64 t
Structural tower, 70 m height 126 t
Blade unit without lengheners 6.035 t

INDEPENDENT ROTOR PITCH CONTROL

The incorporation of independent pitch control into each rotor blade represents an
advance over the traditional wind turbine in terms of safety and regulation. The principle
is based on having three independent electrical pitch control systems, one for each blade.
 The functions of the pitch control are to carry out the commands of the central
control system, with which it is communicated by means of a digital bus. The
redundancy due to the existence of independent systems in the three blades ensures
greater safety, since one single blade in a downwind position is capable of maintaining
the rotor in a safe condition.
The advantages of incorporating the pitch control system are:
1. Control of the rotor speed within the regulation margin, maintaining the power
constant in the grid connection.
2. Reduction of extreme loads in the structure, enabling operation in strong winds with
the blades in closed position without the risk of gusts of wind causing extreme values of
operational loads. In the machine-stopped situation or storms, the loads in the support
structure and foundations are lower.
3. Elimination of the mechanical brake without loss of safety. The independent
activation ensures the braking of the wind turbine under any circumstance. A fault in one
of the pitch control systems is not critical for the structural safety of the wind turbine.
4. Start-up in low winds, by providing significant torque values at low turning speeds.
5. Better use of blades when dirty, by allowing the position of optimal aerodynamic
performance to be sought.
6. Active damping of the structure in the direction parallel to the rotor shaft. The use of
acceleration signals of the nacelle and their inclusion in the pitch control loop allows the
oscillations of the nacelle and tower structure to be actively damped, thus reducing
fatigue loads.

Fig. 63: The Ecotècnia rotor is directly supported by the structural tower. Source:
 Ecotècnia.

DECENTRALIZED CONTROL SYSTEM

The control system consists of a decentralized system formed by interconnected

elements which perform specialized functions:
1. Management control system which carries out the supervision of the systems of the
wind turbine and operation of activating elements and sensors.
2. Torque control system involving the vectorial control of the generator and its
synchronization with the grid.
3. Blade angle of attack control system.
4. Status monitoring system including the measurement of vibrations.
The effective control of the drive train is based on the capacity of injecting
electrical energy into the grid in a controlled manner within a wide range of rotational
speeds. This is based on a fast control system based on a Digital Signal Processor (DSP)
and power electronics capable of modeling the electromagnetic processes (vectorial
control of the electrical machine) of the interior of the generator in real time. This makes
it possible to feed constant power into the grid free of influence of speed variations in the
drive train.
The following advantages are achieved by means of the torque control system:
1. Increase in energy produced throughout the wind speed range: at low speeds, by
improving the aerodynamic performance of the rotor, and at high speeds by permitting
efficient control of the power, preventing the external influences of dirt on the blades and
changes in density and temperature.
2. Improved operational conditions.
3. Reduction of peaks and oscillations in the production of energy and reduction of
extreme loads in the drive train with transient-free interconnection.
4. Possibilities of control of the power delivered to the grid.
5. Dynamic control of the reactive power, allowing a contribution to regulation to the
grid. This implies improved characteristics for weak grids.
6. Lower environmental impact due to reduction of turning speed at low wind speeds.
7. Less risk of bird collision thanks to reduced frequency of blade tip passage, due to
reduced turning speed at low wind speeds.
Fig. 64: Power curve of the Ecotècnia A80, 2 MW wind turbine. Source: Ecotècnia.

PREDICTIVE MAINTENANCE

The integration into the wind farm control and monitoring systems of status
monitoring enables predictive maintenance to be carried out in an automated or in a
remote mode.
This predictive maintenance is based on monitoring the status and condition of the
machinery throughout the lifetime of the units. In general it is based on the measurement
of vibrations, allowing the monitoring of their operation on time scales of the order of the
lifetime of the complete system.
The integration into the control systems of fast vibration measurements and their
direct frequency processing permits the periodical collection of data to establish the
evolution of the status and to establish alarms or stoppages requiring an inspection of the
wind turbine.
The data analysis is separated into two frequency ranges:
1. Low-frequency range of up to 10 Hz, in which the behavior of the structure of the wind
turbine is analyzed. In this range the analysis is based on the modes of the wind turbine
itself, the aim being a permanent diagnosis of the correct status of the structure of the
wind turbine. This range includes also the low-speed rotary elements.
2. High-frequency range of 10-4,000 Hz, in which the rotary elements of the drive train
are analyzed. In this range the analysis is based on monitoring the multiple frequencies
of the turning speed, and in a variable-speed machine it requires special frequency
processing.

MITSUBISHI WIND TURBINES

 Mitsubishi wind turbines have a range of available ratings: 200 kW, 300 kW, 500
kW, 600 kW and 1 MW and a 2 MW design under development.
The characteristics of Mitsubishi wind turbine include:
1. Lightweight blades with full span pitch control and optimum blade profile for
maximum power performance.
2. Noise reduction technology in the rotor blade and the gearbox.

Fig. 65: The Mitsubishi MWT 1000, 1 MW wind turbine. Source: Mitsubishi.

TECHNICAL SPECIFICATIONS

Turbine
Type Blade pitch controlled
upwind type
Rated output 1 MW
Rotor diameter 57.0 m (Class 1)
61.4 m (Class 2)
Rotational speed 21.0 rpm
19.8 rpm
Number of blades 3 (GFRP)
Blade length 26.8 m
29.5 m
 Generator
Type Induction
Rated output 1 MWe
Voltage, phase and 690 V / 600 V
frequency 3 phase
50 Hz / 60 Hz
Tower
Type Monopo;e
Hub height 45 / 60 / 69 m
Control systems
Power regulation Pitch control
Yaw orientation Active yaw control
Safety Systems
Overspeed
Low governor oil pressure
Excessive nacelle vibration
Yaw disorder control
Generator over current
Controller disorder

JAPAN STEEL WORKS (JSW) GEARLESS WIND TURBINE

INTRODUCTION

Japan Steel Works (JSW) became involved in Wind Power Systems using its long
experience in industrial machinery and energy technology. Initially, it delivered 30 sets
of General Electric (GE) 1.5s wind turbines in Japan. Using the acquired operational
experience, JSW adopted the technology of permanent magnet gearless synchronous
generator wind turbines from Enercon in Germany and manufactures its own wind
turbine including the rotor blades and the tower.
 Fig. 66: Japan Steel Works (JSW) J82 permanent magnet synchronous generator
gearless wind turbine. The nacelle contains the transformer and the converter
instead of having them placed on the ground. Source: JSW.

JSW uses the SCADA remote monitoring and control system. It produces 34 and
40 meters length blades. Its production capacity is about 60 wind turbines sets per year
and delivers turnkey projects.
The CO2 reduction is estimated in comparison with an oil-fired power system as
0.704 kg-CO2/kWh.

Table 3: Estimated Annual Performance of the J82 Wind Turbine.

Average wind speed

[m/s]
6 7
Power generation 4,465 MWh 6,069 MWh
CO2 reduction 3,140 tons 4,270 tons
FEATURES OF JSW TURBINES

1. Efficiency: The direct gearless drive eliminates gear loss and the synchronous
generator with permanent magnet offers high efficiency compared with conventional
designs.
2. Reliability: The avoidance of the gearbox and the oil cooler eliminates a major cause
of down time. Compared with an asynchronous slip ring anchor generator, no abrasion
parts such as brushes are required, eliminating the need for frequent maintenance and
replacement.
3. Reduced noise level: The gearbox, which is the major source of noise claim, is
omitted.
4. Low maintenance cost: In addition to the high reliability, because there are no
equipment requiring oil lubrication, such as the gearbox, the main shaft and the brushes, a
reduction in maintenance cost is achieved.
5. Less influence on grid: The full conversion of the power using a converter and
transformer in the nacelle leads to several advantages for the power quality supplied to
the grid and the flexibility offered to the grid operator.

TECHNICAL SPECIFICATIONS

J82-2.0 / III J82-2.0 / II

Main Rated power 2 MW 2 MW
specifications Cut-in wind speed 3.0 m/s 3.5 m/s
Rated wind speed 12 m/s 13 m/s
Cut-out wind speed 20 m/s 25 m/s
IEC class S S
Extreme wind speed 70 m/s 70 m/s
according to IEC61400
class I
Average wind speed 7.5 m/s 8.5 m/s
Turbulence intensity 0.18 0.18
Rotor Material GFRE GFRE
Length of rotor blade 40 m 40 m
Diameter 82.6 m 82.6 m
Rated rotational speed 19 rpm 19 rpm
Rotational speed Variable Variable
Tower Hub height 65/80 m
Electrical Generator type Direct drive gearless permanent
specifications magnet synchronous generator
Nominal voltage 660 V
Transformer output voltage 6.6 or 22 kV
Voltage frequencies 50/60 Hz
Control Pitch system Variable speed control
Yaw system Active
Weight Rotor 42 tons 42 tons
 Nacelle 17 tons 18 tons
Subframe 15 tons 15 tons
Generator 48 tons 48tons
Tower 110 tons (Hub height 65 m)
160 tons (Hub height 80 m)

Fig. 67: J82 gearless turbine power curve. The estimated power generation is based
on the average annual wind speed at the hub height. Source: JSW.
 Fig. 68: Annual power generation capacity for the J82 gearless turbine. Source:
JSW.

TECHNOLOGY CHOICE CONSIDERATIONS

Numerous workable technology options exist in windmill designs. Some
manufacturers advocate a direct drive approach. These direct drive turbines have no
gearbox, which reduces the number of moving components and teeth problems as well as
the oil cooling system posing a fire hazard and an environmental spillage problems. The
generator is much larger than the gearbox models and if it failed, it would be costly to
repair or replace.
There are passive stall regulated models, compared with active pitch models.
Passive stall turbines automatically stall because of the blade aerodynamics, when the
wind speed exceeds about 14 m/s, slowing down the rotor, ensuring that the generator
output does not exceed the rated capacity of the turbine, causing it to overheat. Active
stall control and active pitch turbines have motors that adjust the blade pitch, and let the
wind pass through when the wind speed is high accomplishing the same purpose.
The manufacturers make claims about how their technology is simpler or superior
than each other. Direct drive manufacturers claim that eliminating the gearbox reduces
the maintenance cost. Passive stall manufacturers suggest that the simplicity of passive
stall, with no need to pitch the blades, reduces the probability of failure. The active pitch
manufacturers advocate that their technology eases some of the strain on the tower and
blades.
Experience shows that the different technologies work. What actually matters is
the availability of service in a given local area. Servicing wind turbines is a specialized
field, and factory training and updates are essential.
Parts of a wind turbine design are proprietary, particularly the controller and its
associated software. This includes the pitch algorithms, and the protection and control
system which ensure the safety of the turbine. Temperature sensors exist at many turbine
locations, shutting down the turbine if it overheats. The protection and monitoring
software measures voltages, and shuts down if the voltage drops too much, or if the
current is unbalanced which could damage the generator. An optical rotor speed sensor is
used to shut the turbine down if it spins too fast and gets into a runaway condition. A
flash detector in the transformer detects arcing or fire. The control system measures wind
direction, and the yaw motors adjust the nacelle to face the wind in the optimal direction.
Wind speed is measured to adjust the blade pitch to let some of the wind pass by if it is
too strong, and shut down the turbine in very high winds, to protect the structure. The
software manages automatic restarts if conditions improve. It logs events and even
places calls to the technical staff when problems are detected.
Parts availability in winds turbines operation is essential. Summoning parts from
distant locations can result in significant turbine downtime. Stocking an inventory of
spare parts requires a critical mass of installed wind turbines before it becomes
economically feasible. A critical mass of installed turbines is essential for allowing the
service technicians to be trained at diagnosing faults and making repairs. Third party
service organizations for wind turbines are needed in the future, but presently factory
trained engineers and technicians are in vogue.
According to these considerations, when a turbine design is chosen it is advisable
that it should include a 5-10 years warranty, with availability guarantees from the
supplier.