A national laboratory of the U.S.

Department of Energy Office of Energy Efficiency & Renewable Energy

National Renewable Energy Laboratory

Innovation for Our Energy Future

Low Wind Speed Turbine Project Phase II: The Application of Medium-Voltage Electrical Apparatus to the Class of Variable Speed Multi-Megawatt Low Wind Speed Turbines
June 15, 2004 April 30, 2005
W. Erdman and M. Behnke
Behnke, Erdman & Whitaker (BEW) Engineering San Ramon, California

Subcontract Report
NREL/SR-500-38686 November 2005

NREL is operated by Midwest Research Institute Battelle

Contract No. DE-AC36-99-GO10337

Low Wind Speed Turbine Project Phase II: The Application of Medium-Voltage Electrical Apparatus to the Class of Variable Speed Multi-Megawatt Low Wind Speed Turbines
June 15, 2004 April 30, 2005
W. Erdman and M. Behnke
Behnke, Erdman & Whitaker (BEW) Engineering San Ramon, California NREL Technical Monitor: A. Laxson
Prepared under Subcontract No. TAM-4-33200-03

Subcontract Report
NREL/SR-500-38686 November 2005

National Renewable Energy Laboratory

1617 Cole Boulevard, Golden, Colorado 80401-3393 303-275-3000 www.nrel.gov Operated for the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy by Midwest Research Institute Battelle Contract No. DE-AC36-99-GO10337

NOTICE This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. Available electronically at http://www.osti.gov/bridge Available for a processing fee to U.S. Department of Energy and its contractors, in paper, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831-0062 phone: 865.576.8401 fax: 865.576.5728 email: mailto:[email protected] Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 phone: 800.553.6847 fax: 703.605.6900 email: [email protected] online ordering: http://www.ntis.gov/ordering.htm This publication received minimal editorial review at NREL

Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste

TableofContents Section 1 2 Page ExecutiveSummary.......................................................................................................................11 IntroductionandScopeofStudy...............................................................................................21 2.1 ProjectTeamandParticipants..............................................................................................21 2.2 PremiseoftheStudy...............................................................................................................21 2.3 DefinitionsofLVandMVClasses ......................................................................................23 2.4 ElectricalSystemandTurbineArchitectureConsiderations.........................................24 2.4.1 TurbineElectricalSystem...........................................................................................24 2.4.1.1 GeneratorandDriveTrainEfficiency.....................................................27 2.4.1.2 GeneratorRectifierandInverterSystem(Converter)..........................29 2.4.1.3 TowerPendantCables .............................................................................210 2.4.1.4 PadmountTransformerandMainBreaker .........................................214 2.4.2 TurbineArchitectureforCOEModel....................................................................214 2.5 WindEnergyMarketsConsideredinthisStudy ...........................................................215 2.6 MaterialsCostingVolumeAssumption...........................................................................216 2.7 TransmissionFaultRideThroughRequirements..........................................................216 2.7.1 RecentTransmissionRideThroughRequirements ...........................................216 2.7.2 ImpactofRideThroughRequirementsonElectricalSystem..........................219 2.8 References...............................................................................................................................221 3 ElectricalSystemBillofMaterialLVVoltageSourceInverterTopology...................31 3.1 SectionOrganization ..............................................................................................................32 3.2 ElectricalSystemBOMfor3.0MWLVTurbine ..............................................................32 3.2.1 ConverterSystemfor3.0MWLVTurbine ............................................................33 3.2.2 ConverterSystemDiagramfor3.0MWLVTurbine...........................................33 3.2.3 ConverterPricingSpreadsheetfor3.0MWLVTurbine.....................................34 3.2.4 ConverterMaterialBreakdownandBOMfor3.0MWLVTurbine ................35 3.2.5 LineMatrixfor3.0MWLVTurbine .......................................................................36 3.2.6 LineFilterfor3.0MWLVTurbine ..........................................................................37 3.2.7 ConverterSubpanelfor3.0MWLVTurbine ........................................................38 3.2.8 PassiveRectifierfor3.0MWLVTurbine ...............................................................39 3.3 ElectricalSystemBOMfor5.0MWLVTurbine ............................................................310 3.3.1 ConverterSystemfor5.0MWLVTurbine ..........................................................310 3.3.2 ConverterSystemDiagramfor5.0MWLVTurbine.........................................311 3.3.3 ConverterPricingSpreadsheetfor5.0MWLVTurbine...................................312 3.3.4 ConverterMaterialBreakdownandBOMfor5.0MWLVTurbine ..............312 3.3.5 LineMatrix5.0MWLVTurbine............................................................................313 3.3.6 LineFilterfor5.0MWLVTurbine ........................................................................313 iii

TableofContents Section Page 3.3.7 ConverterSubpanelfor5.0MWLVTurbine ......................................................314 3.3.8 PassiveRectifierfor5.0MWLVTurbine .............................................................314 3.4 ElectricalSystemBOMfor7.5MWLVTurbine ............................................................314 3.4.1 ConverterSystemDiagramfor7.5MWLVTurbine.........................................315 3.4.2 ConverterPricingSpreadsheetfor7.5MWLVTurbine...................................317 4 ElectricalSystemBillofMaterialMVVoltageSourceInverterTopology .................41 4.1 SectionOrganization ..............................................................................................................41 4.2 ElectricalSystemBOMfor3.0MWMVTurbine.............................................................41 4.2.1 ConverterSystemfor3.0MWMVTurbine...........................................................42 4.2.2 ConverterSystemSchematicandPricingfor3.0MWMVTurbine.................42 4.2.3 ConverterSystemMaterialBreakdownandBOMfor3.0MWMV Turbine .........................................................................................................................43 4.2.4 LineMatrixfor3.0MWMVTurbine ......................................................................44 4.2.5 Chopperfor3.0MWMVTurbine ...........................................................................45 4.2.6 LineFilterfor3.0MWMVTurbine.........................................................................47 4.2.7 ConverterSubpanelfor3.0MWMVTurbine.......................................................47 4.2.8 PassiveRectifierfor3.0MWMVTurbine..............................................................48 4.3 ElectricalSystemBOMfor5.0MWMVTurbine.............................................................49 4.3.1 ConverterSystemfor5.0MWMVTurbine...........................................................49 4.3.2 ConverterSystemSchematicandPricingfor5.0MWMVTurbine.................49 4.3.3 ConverterMaterialBreakdownandBOMfor5.0MWMVTurbine .............410 4.3.4 LineMatrixfor5.0MWMVTurbine ....................................................................411 4.3.5 Chopperfor5.0MWMVTurbine .........................................................................413 4.3.6 LineFilterfor5.0MWMVTurbine.......................................................................414 4.3.7 ConverterSubpanel5.0MWMVTurbine...........................................................415 4.3.8 PassiveRectifierfor5.0MWMVTurbine............................................................415 4.4 ElectricalSystemBOMfor7.5MWMVTurbine...........................................................417 4.4.1 ConverterSystemfor7.5MWMVTurbine.........................................................417 4.4.2 ConverterSystemPricingfor7.5MWMVTurbine ..........................................418 4.4.3 ConverterMaterialBreakdownandBOMfor7.5MWMVTurbine .............418 4.4.4 LineMatrixfor7.5MWMVTurbine ....................................................................419 4.4.5 Chopperfor7.5MWMVTurbine .........................................................................419 4.4.6 LineFilterfor7.5MWMVTurbine.......................................................................420 4.4.7 ConverterSubpanelfor7.5MWMVTurbine.....................................................420 4.4.8 PassiveRectifierfor7.5MWMVTurbine............................................................421 4.5 References...............................................................................................................................421

iv

TableofContents Section 5 Page ElectricalSystemBillofMaterialsMV,CurrentSourceInverterTopology ..............51 5.1 SectionOrganization ..............................................................................................................51 5.2 ElectricalSystemBOMfor3.0MWMVTurbine.............................................................51 5.2.1 ConverterSystemfor3.0MWMVTurbine...........................................................52 5.2.2 ConverterMaterialBreakdownandBOMfor3.0MWMVTurbine ...............52 5.2.3 LineMatrixfor3.0MWMVTurbine ......................................................................54 5.2.4 LineFilterfor3.0MWMVTurbine.........................................................................55 5.2.5 ConverterSubpanelfor3.0MWMVTurbine.......................................................56 5.2.6 ControlledRectifierfor3.0MWMVTurbine .......................................................56 5.3 ElectricalSystemBOMfor5.0MWMVTurbine.............................................................57 5.3.1 ConverterSystemfor5.0MWMVTurbine...........................................................58 5.3.2 ConverterMaterialBreakdownandBOMfor5.0MWMVTurbine ...............58 5.3.3 LineMatrixfor5.0MWMVTurbine ......................................................................59 5.3.4 LineFilterfor5.0MWMVTurbine.......................................................................511 5.3.5 ConverterSubpanelfor5.0MWMVTurbine.....................................................511 5.3.6 ControlledRectifierfor5.0MWMVTurbine .....................................................512 5.4 ElectricalSystemBOMfor7.5MWMVTurbine...........................................................513 5.4.1 ConverterSystemfor7.5MWMVTurbine.........................................................514 5.4.2 ConverterMaterialBreakdownandBOMfor7.5MWMVTurbine .............514 5.4.3 LineMatrixfor7.5MWMVTurbine ....................................................................516 5.4.4 LineFilterfor7.5MWMVTurbine.......................................................................516 5.4.5 ConverterSubpanelCostingfor7.5MWMVTurbine .....................................516 5.4.6 ControlledRectifierCostingfor7.5MWMVTurbine ......................................517 6 ComparisonofCOEEstimatesandConclusions ..................................................................61 6.1 CostComparisons,AEP,andCOEEstimatesfortheStudy..........................................61 6.2 SummaryofConclusions ......................................................................................................64 6.2.1 CapitalCostDiscussion..............................................................................................64 6.2.2 AEPEstimates ..............................................................................................................65 6.2.3 COEEstimates..............................................................................................................65 Appendix A COE Details Using 2005 Dollars for Components Included within Study .. A-1 Appendix B COE Details Using 2002 Dollars for Components Included within Study ...B-1 Appendix C Cable Termination Study ................................................................................. C-1 Appendix D Application Specification ................................................................................. D-1

1 Executive Summary
Kilowatt(kW)ratingsofmodernwindturbineshaveprogressedrapidlyfrom50kWto1,800kW overthepast25years,with3.0to7.5megawatt(MW)turbinesexpectedinthenext5years.The premiseofthisstudyissimple:Therapidgrowthofwindturbinepowerratingsandthe

correspondinggrowthinturbineelectricalgenerationsystemsandassociatedcontrolsare quicklymakinglowvoltage(LV)electricaldesignapproachescostineffective.
Thisreportprovidesdesigndetailandcomparesthecostofenergy(COE)betweencommercialLV classwindpowermachinesandemergingmediumvoltage(MV)classmultimegawattwind technology.Thekeyfindingisthata2.5%reductionintheCOEcanbeachievedbymovingfromLV toMVsystems.Thisisaconservativeestimate,witha3%to3.5%reductionbelievedtobeattainable oncepurchaseorderstosupporta250turbine/yearproductionlevelareplaced. Thisevaluationconsiderscapitalcostsaswellasinstallation,maintenance,andtrainingrequirements forwindturbinemaintenancepersonnel.Subsystemsinvestigatedincludethegenerator,pendant cables,variablespeedconverter,andpadmounttransformerwithswitchgear.Converter developmentisemphasizedbecausesignificantsavingscanberealizedhereviaengineering.Both currentsourceandvoltagesourceconverter/inverterMVtopologiesarecomparedagainsttheirlow voltage,voltagesourcecounterpartsatthe3.0,5.0,and7.5MWlevels. Supplementaryconclusionsdetailedwithininclude: PerceivedtechnicalriskassociatedwiththeMVconverter/inverterinnovationsismitigated bythefactthatsuchtechnologyisalreadycommoninmotordriveapplications. ThereisasubstantialreductioninthecostofpendantcablesfortheMVsystemscomparedto LVsystems. Transmissionridethroughrequirementswillbeasignificantdriverinthearchitectureof newsystems.Voltagesourcesystemsmorenaturallymeetthisrequirement,butcurrent sourcesystemswithstraightforwardmodificationswillalsomeettherequirements. ThereislittleornocostdifferencebetweenLVandMVgeneratorsorpadmount transformers. AlthoughcomponentefficiencieswithinLVandMVdesignsdiffer,theoverallefficiencies arethesame. Installationcostsarecomparableforbothsystemdesigns.Withlowvoltage,manysimple terminationsareperformedbylesshighlytrainedcraft;fewerterminationsaremadeat mediumvoltagebyskilledcraftata10%wagepremium. LVvs.MVelectricalequipmentmaintenancedifferencesaremoredifficulttoassessatthis stageandareperhapsjustapush.Regardless,theCOEevaluationsarenotsensitivetosuch minorelements.Ingeneral,MVdesignswithsubstantiallyfewerpartsarelikelytorequire fewerunscheduledvisits,albeitwithmoreexpensivelabor.

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2 Introduction and Scope of Study

Behnke,Erdman&WhitakerEngineering,Inc.(BEWEngineering)ofSanRamon, California,preparedthisreportinsupportoftheLowWindSpeedTurbineProjectPhase IIprojectsforTheNationalRenewableEnergyLaboratory(NREL).Thereportdocuments thecostofenergy(COE)impactsthatresultfromtheuseofMVelectricalapparatuson multimegawattclasswindturbines. 2.1 Project Team and Participants

Dr.WilliamErdman,PrincipalInvestigator,andMichaelR.Behnke,PrincipalEngineer,of BEWEngineeringInc.ledthisstudy.ClipperWindpowerprovidedwindturbine applicationrequirements,andDeWolfEngineeringprovideddetailsonmagneticsand mechanicalstructures. ThecompanieslistedinTable21providedsignificanttechnical,operationsand maintenance,andcostinputtothisstudy.Thesecompanieswereaskedtoparticipate becauseoftheirwindenergyhistoryandexperienceandbecauseoftheiruniqueexpertise andproductofferings,asnotedintherightcolumn. Table21CompaniesConsulted Expertise
PowerSemiconductors ElectricalControlApparatusandSwitchgear PadmountTransformers Magnetics LowandMediumVoltageConductors LowandMediumVoltageGenerators PowerSemiconductors Magnetics ThermalManagement PowerSemiconductorCustomBusBar ElectricalControlApparatusandSwitchgear

Company
ABB

ArevaT&D MagTranEquipmentCorp. OkoniteInc. PotenciadeMexico PowerexInc. QualityTransformer RTheta Rotech SquareD

2.2

Premise of the Study

Thepremiseofthisstudyissimple:Therapidgrowthofwindturbinepowerratingsand thecorrespondinggrowthinturbineelectricalgenerationsystemsandassociatedcontrols arequicklymakinglowvoltageelectricaldesignapproachescostineffective.Thisstudy

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 examinestheuseofMVequipmentonmultimegawattturbinesincontrastto,andasan alternativeto,lowvoltageclasssystems. Figure21showsthegrowthofwindturbineratingsfrom1980to2010essentiallythe historyofmodernwindenergysystems.Thelogscaleyaxisamplifiestherapidrisein powerratingoverthisperiod.Thefigurerepresentscommercialturbinesinutilityscale, landbased,andoffshorewindfarms.Anonexhaustivesampleofrepresentative commercialturbinesisalsoshown.In2005,forexample,atypicallandbasedturbinewould havearatingof1.5MWto1.8MW,andoffshoreturbineswouldhavearatingof3.6to5.0 MW.Turbinesonascaleof7.5MWarebeingconsideredforfutureoffshoreprojects.A reviewofresearchturbineswouldsuggestthatsingleprototypeturbinesofagivenkW ratingaretypicallyinstalled2to3yearsaheadofthetimeperioddepictedbythedata showninthefigure. This30yearhistoryhelpstoexplainthepreferenceforLVequipment,aspurchasing proceduresandoperationalandmaintenanceprocessesareskewedtowardthisequipment class.Italsoexplainsinpartthecontinualreluctanceofturbinemanufacturersandwind plantoperatorstomovetowardMVsolutions.Aperceivedincreaseintechnicalriskrelated tosystemdesign(particularlywithvariablespeedturbines)anduncertaintyregarding increasedoperationalandmaintenancecostsareoftencitedasreasonstonotintroduceMV equipment.
10000 Multi-brid

Enercon E-112

GE 3.6 Vestas V80 Turbine Rating, kW 1000 NEG-Micon 600 Micon 900 Enercon E-40 100 Vestas V27 Kenetech 56-100 Kenetech 56-50 10 1980 GE 1.5

1985

1990

1995 Year

2000

2005

2010

Figure21Windturbineratinggrowth19802010

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 Inthisstudy,wedeterminedthatthemostcosteffectiverangeforLVequipmenttopsoutat about750kW.Thisconclusionisconsistentwiththemajorindustrialswitchgearanddrive suppliers(Figure22).DeterminingthesweetspotforLVequipmentisofcourseanever changing,complicatedtaskbecauseofproductrequirements,productdemand,introduction ofnewpowersemiconductortechnology,andotherfactors.This750kWratingisatthetop oftherangeforreadilyproduced,readilyavailableswitchgear,conductors,andpower semiconductorsbeforeparallelingofcomponentsbegins.

Siemens med voltage Siemens low voltage

Allen-Bradley med voltage Allen-Bradley low voltage

ABB med voltage ABB low voltage 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Power rating, kW

Figure22Samplestandarddriveproductofferings 2.3 Definitions of LV and MV Classes

DefinitionsofthreephaseLVandMVclassesareregionalandarebasedonapplicable standards.AsummaryoftheNorthAmericanandEuropeanmarkets,theappropriate standards,andthecorrespondingdefinitionsisgiveninTable22. Table22Regionalvoltageclassifications RelevantStandard Definition ANSIC84.1 Lowvoltage,below600V o 208V,120/240V,480V,575V Mediumvoltage,above600V,below35kV o 2.4kV,4.16kV,6.9kV,12.47kV, 13.8kV,21kV,34.5kV IEC60038 Lowvoltage,below1000V o 220V,400V,690V Mediumvoltage,above1000V,below35kV o 3.3kV,6.6kV,11kV,22kV,33kV

Region North America

Europe

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 Inrecentyears,regionalvoltageclassdistinctionshaveblurred.Asthekilowattratingof turbineshasincreased,forexample,Europeanmanufacturershaveinstalled690volt(V) electricalsystemsintheUnitedStates.Withthisapproach,however,therearehiddencosts associatedwithinstallationandmaintenance.Inmanycases,commoninspectionstandards simplydontaddressthisvoltageasitfallsintoagreyarea(i.e.,somewherebetweenlow andmediumvoltage)andissubjecttowidelyvaryinginterpretationsbytheauthoritywith jurisdictionfrominstallationtoinstallation.Forthisreason,certificationandinspection becomelengthyandcostlywhencomparedtowelldefinedandmorecommonlyused electricalsystemvoltages.Fromanoperationstandpoint,inventoriesmustincreaseto accountfor1000Vratedswitchgearandapparatusthatarenotreadilyavailablethrough U.S.distributionchannels. Despitethesehiddencosts,thedecisiontoinstallthesenonstandard,marginallyhigher voltageelectricalsystemsisdrivenbythefactthatincreasingturbinesizesarenolonger wellsuitedtostrictlydefinedLVsystems. MVequipmentistypicallypartofalmosteveryutilityscalewindplanttoday.Historically, windplantcollectionsystemshaveoperatedat12.47kVand13.8kVinNorthAmerica,but morerecentlycollectionsystemsarebeinginstalledat34.5kV.Maintenanceonthe collectionsystemisoftenperformedbypersonnelwithhigherelectricalqualificationsthan thatrequiredforworkingontheLVturbine,atanestimatedbasepaydifferentialofabout 10%1 . 2.4 Electrical System and Turbine Architecture Considerations

ThisstudyusesexistingturbinearchitecturetoarriveattheCOEforLVandMVsystems. Thearchitectureoftheturbineandcorrespondingelectricalsystemisdescribedbelow. 2.4.1 Turbine Electrical System TurbinecomponentsidentifiedinredinFigure23aretheprimaryfocusofthisstudy. Thesecapitalcostitems,whichwillbesubjectedtotradeoffstudies,includethefollowing: o Generator o Towerpendantcables(includingfestooncables)
1

Basedontwosources:California2005prevailingwagedataforContraCostaCountyshowthefullyloaded, straighttimerateforajourneymancablespliceras9.5%higherthanthatofaninsidewireman;also,a March25,2005consultationwithaPacificGas&Electricseniorelectricalsubstationengineerindicatedthe laborcostformediumvoltagelinemenwasabout10%more,roughly$5/hr,thanforlowvoltage technicians.

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 o Converter,whichcomprises o Generatorrectifier(uptowerordowntower) o Invertersystem o Padmounttransformerandswitchgear. Totheextenttheseelectricalitemsareusedonanentireuniverseofturbinearchitectures i.e.,stallregulated,variablepitch,twobladed,threebladed,etc.theresultsofthisstudy arequitegeneralandarewidelyapplicabletomanyturbines.

25

Figure23Windturbinekeycomponents,withelectricalsystemunderconsiderationinred

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 2.4.1.1 Generator and Drive Train Efficiency Aclassicalsynchronousgeneratorwithsinusoidaldistributedwindingsisusedwitheachof theturbinesystemspresentedinthisstudy.Bothwoundfieldandpermanentmagnettype machinesareacceptable;intheCOEestimates,thewoundfieldmachineisused.Further,it isassumedthatthewoundfieldmachineisexcitedwithconstantmainfieldcurrentsothat aconstantVolts/Hz(opencircuit)isachieved.Therearenoassumeddamperwindings;the generatoriswoundasathreephasemachine,andasynchronousreactanceof33%is selected.Theselectionofthisreactanceisconsistentwithreferences[1],[2],[3].Further,itis assumedthepowercurveisoperatingoveraspeedrangeof1.6:1.Withthisspeedrange andwiththesynchronousreactanceat33%andthegeneratorconnectedtoasixpulse rectifier,theoperatingDCgeneratorvoltagefortheLVsystemisasshowninFigure24, below.MVgeneratorswillhavesimilarshapeandrelationshipandwillbescaled appropriately.
1600
Rated power, 1120 rpm

1400

1200 Voltage, volts

1000

800

600
Cut-in windspeed, 700 rpm Rated overspeed, 1276 rpm

400 600

700

800

900

1000 Speed, rpm

1100

1200

1300

1400

Figure24GeneratorDCbusvoltageovera1.6:1operatingpowercurve. Theselectionofasynchronousgeneratorisbasedonmanyrequirements;however,oneof themostcompellingreasonstousethisgeneratortypeistherecentintroductionof transmissionsystemridethroughrequirements(seeSection2.6).Withthesenew requirements,itisimportanttomovetheDCbusregulationfunctionfromtheutilitysideof

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 theconvertertothegeneratorside.Thesynchronousgeneratorallowsforthis configuration. Itisfurtherassumedthatallgeneratorswilluseaformwoundinsulationsystembecauseof theruggednessandaddedlifeexpectancythisbringstothegenerator.Otheradvantagesof preformedinsulationsystemsarebetterendturnbracingandtheabilitytowithstand higherrateofchangeofvoltage(dv/dt).Thecostimpactofthisdecisionreallyonlybearson theLVdesignsinwhichthecaseforarandomwoundgeneratorcouldbemade(butusually notinthesekWclasses).Therandomwoundmachinewouldbelessexpensivethanthe formwoundmachine,butrandomwoundinsulationsystemscannotbeexpectedtohave anadequatelifeexpectancy.Forthemostpart,thewindenergyindustryhassettledon formwoundgenerators,andweusethisassumptioninthisstudy. Lastly,thereisalwaysacomplicatedtradeoffingeneratorselectionbetweeninitialcapital costandefficiency.Thistradeoffisnotundertakeninthisstudyasitwillnotimpactthe comparisonbetweenLVandMVsystems;i.e.,a97%fullloadefficientgeneratorcanbe achievedinlowvoltageormediumvoltage.COEcalculationsusethetotaldrivetrain efficiencyshowninFigure25.
94 92 90 88 Efficiency 86 84 82 80 78 76 74 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Losses Include Gearbox, Generator, Power Converter, Pendant Cable, Padmount Transformer

Drive Train Input Power

Figure25DriveTrainEfficiencyCurve

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 2.4.1.2 Generator Rectifier and Inverter System (Converter) Inthisstudy,asixpulserectifierisassumedforallconverterconfigurationsandturbine powerratings2 .Beyondthepassiverectifierportionofthegenerator,theexactcircuit topologydependsontheselectedvoltagelevelandtypeofinvertersystem,eithervoltage sourceorcurrentsource.Threetypesofsystemsareunderconsideration(Figure26).

Figure26Systemsunderconsideration TheLVsysteminFigure26(a)allowstheDCbusvoltagetofluctuateoverthe200Vrange (approximately)showninFigure24.Thesystemisextremelysimple,butitdoesrequire thattheinverterwithstandthehighestvoltagecorrespondingtotheunloaded,maximum speedoftheturbine.InLVsystemsupto575V,thissmallpenaltyisoffsetbythesimplicity ofthedesign. TheMVsystemshowninFigure26(b)usesathreelevel(ormultilevel),neutralpoint clamped,voltagesourceinverter.Thistypeofinvertersystemhasbecomeverypopularin

2

Theuseofatwelvepulserectifierwithasixphasegeneratorisanoptionandevenlikelyat7.5MW.Such ageneratorwouldhavenearlythesameactivematerialbutwithstatorandrotorpolepitchappropriatefor sixphases.TheuseofsuchageneratorandrectifierwouldnotsubstantiallyaffectCOEestimates.Ong,C., DynamicSimulationofElectricMachinery:UsingMatlab/Simulink,PrenticeHall,1998.

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 MVsystemsinotherapplications[4],anditsoperationisdiscussedinreferences[5],[6]. ThissystemusesaboostchopperonthegeneratorsidetosteptheDCvoltageuptoits requiredlevelforoperatingtheinverter.Thechopperin(b)extendsthespeedrangeofthe generatordowntonearzeroRPM.Also,becauseoftheridethroughrequirements (discussedinSection2.6),theutilitycannotbecountedontoregulatetheDCbusvoltage,so thechopperservesthisfunctionaswell. Both(a)and(b)arevoltagesourceinvertersand,assuch,theyoperateinamodeatwhich theDCbusmustbeabovethepeakoftheAClinelinevoltage.Whenautilitylinevoltage dipoccurs,theseinvertersnaturallydealwiththedropinvoltagebecausetheDCtoAC requirementisnotviolated.Theseinverterscanseamlesslyandgracefullysupplycurrentto autilityfaultandduringthevoltagerecovery.Thevoltagesourceinverterspower semiconductordevicesareeitherinsulatedgatebipolartransistors(IGBTs)withflyback diodesorasymmetricalgatecontrolledthyristordevices[7],[8]. TheMVsysteminFigure16(c)usesacurrentsourceinverter.Thisisfundamentally differentfromthevoltagesourcecase.ProperoperationofthissystemrequiresthattheDC busvoltagebelowerthanthepeakoftheAClinelinevoltage.Forthisreason,thissystem naturallyextendsthespeedrangeofthegeneratorrightdowntozerospeed.Duringaride throughevent,however,theAClinelinevoltagedropssubstantially,andtheDCbus voltagemustbereducedoranuncontrolledfaultcurrentwilloccur.Thephasecontroller rectifiershownonthegeneratoronlybecomesactiveduringthisdipintheutilityvoltage.In normaloperationthecontrolledrectifierisfiredatazerodegreedelayangle,anditlooks likeapassiverectifierinthismodeofoperation.Symmetricalgatecontrolledthyristor devicesarerequiredforcurrentsourceinverters[7],[8]. 2.4.1.3 Tower Pendant Cables Figure27showsa600Vand5/8kVclassofconductor,eitherofwhichwouldbe acceptablefortowerpendantcables.

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Figure27Towerpendantcables(left),600Vclasslowvoltageand(right)5/8kVclassMV conductors. TheLVcableshownontheleftinFigure27hastwoparts,thecoatedcopperconductorand asimpleinsulationsystem.Inthiscasetheinsulationconsistsofablackpigmented ethylenepropylenebaseinsulatingcompound.Thecableisratedat90C,isflame retardant,andissuitableforindoorandoutdoorapplications.Theconductorisrelatively easytoterminateandinstall.Conductorsofthistypeareavailableinsizesrangingfrom14 gaugeto1000MCM.Atlargercontemporarypowerlevelsinthe3.0to7.5MWrange,the chiefdisadvantageofthiscableissimplyitsweightandvolume. TheMVcableinFigure27ismorecomplex.Thesecableshaveacoatedcopperconductor andavarietyofinsulationlayers.Directlycoveringtheconductorisastrandscreencoated (ethylenepropylenecompound)insulator.Thisiscoveredbyanotherinsulatinglayerof ethylenepropylenecompound.Asecondcoatedstrandingscreenisthenshown.Asolid coppertapeshieldisthenshownoverthetopoftheinsulatingscreen.Finally,aPVCjacket providesresistancetooils,acids,chemicals,andmechanicaldamage.Terminatingthis conductorismorecomplicatedandrequiresmoreskillthanthatneededforLVcables.Care mustbetakentoavoidpointsorsharpturnsthatcouldresultinhighEfieldsandresultant dielectricbreakdown.TheseconductorsareavailableinthesamesizesastheLVcables. WhiletheterminationsoftheseMVcablesaremoredifficultthantheLVcableandare usuallyperformedbyhigherskilledlabor,therearefarfewerterminationstomakeina giventurbinesize.Thetotalcostimpactoninstallationandmaintenanceofthesecablesis minorandcoveredintheCOEmodelsinsubsequentsections.Figure28compareslow andMVtowerpendantcablesforthesmallerturbineunderconsideration,3.0MWand5.0 MW.

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 Asalastpoint,rigidaluminumbusswasconsideredasanalternativeforthecoppertower pendantcables.Theserigidbussalternativesarecitedasbeinglowercostbecauseofthe reducedamountoflaborrequiredforinstallation.Ouranalysisshowsnosignificantcost advantageforeitherandgiventheavailabilityofMVbuildingcable,thecableapproachis expectedtoyieldsignificantcertificationadvantages.Forthesereasons,inthisstudy standardbuildingcableisusedratherthanrigidbuss.

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Figure28LVvs.MVtowerpendantcables,3.0MWand5.0MW

213

 2.4.1.4 Padmount Transformer and Main Breaker ThepadmounttransformersusedintheLVandMVcomparativestudiesarequitesimilar tothepadmounttransformersusedonturbinesinthepast.Atypicalpadmounttransformer wouldbeoilfilled,closedcontainer,witha34.5kVprimaryforthecollectionsystemand either575Vor2400/4160/6900Vfortheturbineconnection.Bothvoltageclasstransformers areassumedtohaveawyewyewindingforsolidgroundingoftheneutral(s).Typical impedanceswillbeinthe4%7%range. Themainbreakerforthetransformerwillbelocatedinthepadmounttransformeror separatelyintheconvertercabinet(s).AnexampleofthesizeandweightofanLVbreaker vs.MVmainbreakerat3.0MWand5.0MWisshowninFigure29.ThemainLVbreakeris substantiallylarger,heavier,andmorecostlythantheMVcounterpart.

5-kV Vacuum Circuit Breaker

(Same Frame Size for 3.0 and 5.0 MW)

600-V Air Circuit Breaker

(Frame Size for 3.0 and 5.0 MW)

21 17

19 16 160 lbs. 15 35 293 lbs.

Figure29LVandMVmaincircuitbreakers. 2.4.2 Turbine Architecture for COE Model ForpurposesofCOEcalculations,abaselineturbinewasusedandscaledfordifferentMW classmachinesbasedon[9]and[10].Theassumptionsusedinthebaselineareshownin Table23andTable14.Thesecharacteristicswereusedtodevelopthebaselineturbineand powerratingderivativesthereof.Inadditiontotheabovementionedcapitalequipment items,theimpactofMVelectricalsystemsoninstallationcostsandelectricaloperationand maintenancecostwillbeconsidered.

214

 Table23Baselineturbineassumptions Characteristic Value NumberofBlades 3 GeneralConfigurations Upwind Fullspanpitch Rotorhub RotorSolidity 2%5% VariableSpeedOperation MaximumPower Coefficient=0.47 AirDensity 1.225kg/m3 AnnualMeanWindSpeed 5.8m/s,6.7m/s VerticalWindShear PowerExponent=0.143 RatedWindSpeed 1.5xannualaverage@ hubheight CutOutWindSpeed 3.5xannualaverage@ hubheight Table24Baselineturbine,sizerelatedoperationalassumptions Rating Characteristics 1.5MW 3.0MW 5.0MW 7.5MW RotorDiameter,m 69 98 126 155 DesignTipSpeedRatio 7.0 7.0 7.0 7.0 TheoreticalOperatingMinimumRPM 13.9 9.8 7.6 6.2 RatedRPM 22.2 15.6 12.2 9.9 MaximumOperatingRPM(1.07Rated) 23.8 16.7 13.0 10.5 PESystemTripRPM(1.14Rated) 25.3 17.8 13.9 11.2 SafetySystemActivationRPM(1.2Max) 28.5 18.7 14.6 11.8 MaximumOverSpeedDesignRPM(1.3Max) 30.9 20.3 15.8 12.8 HubHeight,m 65 91 117 144 CutInWindSpeed,m/s 3 3 3 3 CutOutWindSpeed,m/s 26 26 26 26 2.5 Wind Energy Markets Considered in this Study

TheprincipalmarketconsideredinthisstudyisNorthAmerica.Manyoftheconclusions expressedhereinareextensibletoEuropeandtherestoftheworld,andwhereappropriate, wementionsuchextensions.Oneoftheimportantandinterestingdiscussionsregarding geographicjurisdictionisthedefinitionoflowandmediumvoltage,asthisdiffersfrom 215

 regiontoregion.Worldwideclassificationsofvoltageclassandrelevantstandardswere delineatedinSection1.3. 2.6 Materials Costing Volume Assumption

Allcostingperformedinthisstudyassumesannualproductionof250turbines.Further,itis assumedthatthisisamatureturbineproductionwithatleast150previouslycompleted units. 2.7 Transmission Fault Ride-Through Requirements

Overthepast2years,therehasbeenasubstantialchangeinhowtransmissionoperators dealwithwindplantsinterconnectedtothepublicelectricaltransmissionsystem.Inthe earlyhistoryofwindplants,interconnectingutilitiesrequiredthatturbines(andwind plants)dropofflineinthepresenceofsystemfaultsandcorrespondingvoltagedips.As windplantsbegintorepresentahigherpercentageofgenerationonagiventransmission system,theviewofwindplantsasautilitynuisancehaschangedtothatofasystem resourcewhoseoperationmustbemaintainedthroughtransmissionsystemtransients.This changeinperspectivehasprecipitatednewrequirementsforhowawindplantshould operateduringtransientconditionsthatwouldpreviouslyresultintheplanttripping offline.Theseridethroughrequirementscontinuetoevolveandhavesignificantimpact onthedesignoftheturbineandplantelectricalsystems,particularlyforvariablespeed turbines. 2.7.1 Recent Transmission Ride-Through Requirements Beginninginearly2003,theGermanutilityandtransmissionoperatorE.ONinstituteda ridethroughrequirementfornewlyinstalledturbines.Thestandardrequiredthatturbines ridethrough,ratherthantripoff,fortransmissionfaultsaccordingtothevoltageprofile showninFigure210.Therequirementwasnotfullydeveloped,andithasbeenassumed thattheridethroughrequirementpertainedtothreephasesymmetricalfaultstheworst conditionfromastabilitystandpointforthetransmissionoperator.Theinitialrequirement didnotmentionnonsymmetricalfaultsanddidnotspecifywhetherthewindplantshould feedthefaultorstopsupplyingcurrentduringthefaultevent.Laterin2003,some ambiguitieswereaddressed,anditbecameclearthatfeedingthefaultwasintended[11].

216


Minimum Required Wind Plant Response to Emergency Low Voltage, E.ON 1.1 1.0 0.9 0.8 V/Vnominal 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 -1 0 0.15 1 Time (seconds) 2 3 4

Fault Initiation

Wind Plant Required to Remain On-line

Wind Plant Not Required to Remain On-line

Figure210E.ONinitialrequirementsforwindturbineridethroughposedin2003 In2004,thetransmissionoperatorinSpain,RedElctricadeEspaa,proposedasimilar,but modifiedcurvetothatproposedbyE.ON.ThecurveshowninFigure211becamea requirementforwindturbinesinstalledinSpaininFebruary2005,anditisapplicableto threephasesymmetricalfaultsandnonsymmetricalfaults[12].

217


Minimum Required Wind Plant Response to Emergency Low Voltage, Spain 1.1 1.0 0.9 0.8 V/Vnominal
Fault Initiation Wind Plant Required to Remain On-line

0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 -1

Wind Plant Not Required to Remain On-line

0 0.5

7 8 9 10 Time (seconds)

11

12

13

14

15

16

17

Figure211Spanishridethroughrequirementsproposedinspring2004 InFebruary2005,theFederalEnergyRegulatoryCommission(FERC)proposeditsown ridethroughrequirements(Figure212).Theserequirementshavebeenreleasedfor commentandshouldbefinalizedbytheendof2005.Clearly,theFERCproposed requirementsaremorestringentthaneitheroftheEuropeanrequirementsbecauseofthe extendedtimeperiod(625ms)atverylowACvoltage(15%ofnominal).

218


Minimum Required Wind Plant Response to Emergency Low Voltage, FERC 1.1 1.0 0.9 0.8 V/Vnominal 0.7
Fault Initiation

0.6 0.5 0.4 0.3 0.2 0.1 0.0 -1

Wind Plant Required to Remain On-line

Wind Plant Not Required to Remain On-line

0.62

1 Time (seconds)

Figure212FERCridethroughrequirements 2.7.2 Impact of Ride-Through Requirements on Electrical System Theridethroughrequirementsmentionedabovehaveasignificantimpactontechnology selectioninbothlowandMVwindturbinesystems.Simpleitemssuchascontrolboard powersupplyholdupduringthetransmissionfaultsbecomeimportant.Theabilityof electricalpitchsystemstooperateundertheseLVconditionscanalsobeproblematicandfor whichthissystemridethroughrequirementcanbeasignificantcostdriver. Ridethroughrequirementshavethelargestimpactongeneratorandvariablespeed convertertechnologyselection.Inrecentyears,apopularapproachtoprovidingvariable speedoperationhasbeentoutilizeadoublefedgeneratorwithapartiallyratedconverter systemconnectedtothegeneratorrotor.Thisapproachhasbeenusedsomewhateffectively despiteoftencitedandobviousdrawbacks3 .Oneoftheprincipaladvantagesofthis approachisthatitallowstheuseofLVconvertersandtechnologytoprovidethevariable speedfeature,evenonlargeturbines.
3

Drawbacksincludeslipringassembliesandassociatedmaintenanceandlargebearingcurrentsduetorotor PWMexcitation.

219

 Theproblemwiththedoublyfedapproachrelativetotheridethroughrequirementsisthat itdoesnotentirelydecouplethegeneratoroperationfromtheutilitysystem,asthestator circuitremainsdirectlyconnectedtotheutility.Becauseofthisdirectconnection, uncontrolledstatordynamicsoccurduringthetransmissionfaultandveryhighvoltages canoccurontherotorcircuit.ThisfaultconditionjeopardizestheLVconverterandrequires additionalprotectivecircuitryintheformofacrowbar.Thesestatortransientsthatoccur duringatransmissionfaultandtheconsequentialfiringofthecrowbarhavealsobeencited asamaincauseofgearboxproblemsasseveretorquetransientsonthedrivetraincanoccur [13],[14],[15]. Figure213comparesasimplifiedschematicrepresentationofadoublyfed,partial conversionsystemtoafullconversionsystem.Completedecouplingbetweenthegenerator andutilityisclearinthelattercase.Afullpowerconversionsystemthatcompletely decouplesthegeneratorfromtheutilitygridisapreferredapproachtomeettheride throughrequirements,astheresultingtorqueandcurrenttransientsduringatransmission faultaremorereadilycontrolled.Furthermore,extensivecostanalyseshaveshownno advantagetothepartiallyfedsystemoverafullpowerconversionsystemwhenallcostsof ownershipareincluded.Forthesereasons,onlyfullconversionsystemsareconsideredin thisstudy. Doubly Fed Generator Utility W(t)

Synchronous Generator Utility W(t) Figure213Doublyfedandfullconversionsystemschematics

220

 2.8 References 1 Dubois,M.R.ReviewofElectromechanicalConversioninWindTurbine.Report EPP00.R03,Delft,Netherlands,TUDELFT,April2000. 2 Grauers,A.DesignofDirectDrivenPermanentMagnetGeneratorsforWind Turbines.Ph.DDissertation.Gttenborg,Sweden:ChalmersUniversityofTechnology, 1996. 3 Poore,R.;Lettenmaier,T.AlternativeDesignStudyReport:WindPACTAdvanced WindTurbineDriveTrainDesignsStudyNovember1,2000February28,2002. NationalRenewableEnergyLaboratory,NREL/SR50033196,August2003. 4 Yamaguchi,Y.,etal.A6kV/5kAReverseConductingGCT.IEEEIASAnnual Meeting,Chicago,IL,October1991. 5 Nabae,A.;Takahashi,I.;Akasi,H.ANewNeutralPointClampedPWMInverter. IEEEIASAnnualMeeting,Seattle,WA,October1990. 6 Yuan,X.,etal.FundamentalsofaNewDiodeClampingMultiLevelIndicator.IEEE TransactiononPowerElectronics,July2000. 7 IntegratedGateCommutatedThyristorsApplicationNotes,ApplyingIGCTGate Units,ABB,December2002.. 8 Motto,E.PowerSemiconductorTechnologyforHighPower(1MVA+)Applications. PresentationattheNationalRenewableEnergyLaboratoryPowerElectronicsMeeting, January2002.. 9 AlternativeDesignStudyReports,WindPACTAdvancedWindTurbineDriveTrainDesign Study(Draft),GlobalEnergyConcepts,NRELSubcontract#YAM13020901,July2002.. 10Malcolm,D.J.;Hansen,A.C.WindPACTTurbineRotorDesignStudyJune2000June2002, NationalRenewableEnergyLaboratory,NREL/SR50032495,August2002. 11GridCode:Highandextrahighvoltage,E.ONNetzGmbH,Bayreuth,Germany,1August 2003. 12ProcedimientosdeOperacin12.2.Instalacionesconectadasalareddetransporte: requisitosmnimosdediseo,equipamiento,funcionamientoyseguridadypuestaen servicio.RedElctricadeEspaa.11022005. 13Poller,M.DoublyFedInductionMachineModelsforStabilityAssessmentofWind Farms.DigsilentCorp,Gormaringen,Germany,2003. 14Akhmatov,V.AdvancedSimulationofWindmillsintheElectricPowerSupply. ElectricPowerandEnergySystems,22,2000. 15Hudson,R.,etal.LatestDevelopmentsinPowerElectronicConvertersforMegawatt ClassWindTurbinesEmployingDoublyFedGenerators.PCIM,Europe,2003.

221

3 Electrical System Bill of Material LV Voltage-Source Inverter Topology

ThissectiondetailstheelectricalsystemBillofMaterial(BOM)forthe3.0,5.0,and7.5MW turbinesusingaNorthAmerican,LV,575Velectricalsystem.Beyondtheentireelectrical systemcost,whichisusedforCOEcomparisonpurposes,theconverterforeachofthe turbineratingsisdetailedout.The3.0MWconverterispresentedinthegreatestdetail, showingbothsimplifiedschematicsandfullcostedBOMs.The5.0and7.5MWsystemsare describedusingthesamemethod,butbecausethesesystemssimplyrepresentmore parallelingofthesame3.0MWcomponents,theyarepresentedinsomewhatlessdetailto minimizeoverlapandrepetitionfromthe3.0MWsystem.Asnotedintheprevioussection, themostcommonmethodofdesigningamultiMWconverterinvolvesparallelingenough LVvoltagesourceinverterstoachievethedesiredrating.Thegenericdesignforallthree systemsisshowninFigure31.
LV Diode-IGBT Drive System Overview
+ Padmount Transformer 575V Secondary -

+ Generator

N Parallel Drives + -

+ -

System MW 3.0 5.0 7.5

N Drives 4 8 10

kW/Drive 750 625 750

Figure31GenericLVconvertersystemdiagram

31

 3.1 Section Organization

Thesectionisorganizedasfollows. Section3.2: AnelectricalsystemBOMispresentedthatrepresentsthecosting ofallelectricalsystemcomponentsunderconsiderationandas describedintheintroductionofSection1. Section3.2.12.2.3: Converterpricing.Theconverterassemblyisselectedfordetailing becauseitiscustomengineered,hasasignificantcostimpacton theelectricalsystem,andhasthemostopportunityforreducing cost.Subsectionsunderthisassemblyincludeasystemdiagram andapricespreadsheet.Thespreadsheetincludesmaterialcosts, directlaborcosts,indirectcosts,andgrossmarginforthe convertermanufacturer.Withthisinformation,theconverter appearsinthehighestlevelelectricalsystemBOMasapurchased item. Sections3.2.43.2.8: TheseincludearolledupconverterBOMalongwithsubassembly BOMbreakdowns,inthefollowingorder: o Completeassembly o IGBTmatrixsubassembly o Linefiltersubassembly o Subpanelsubassembly o Rectifiersubassembly Sections3.33.4 Followtheabovepatternfor5.0and7.5MWsystemswithcertain redundantsubassemblydrawingsandsubassemblyBOMs excluded. Thegeneratorisnotdetailedinthisstudy.ThecostoftheMVgeneratorisessentiallythe sameastheLVgeneratorwhenformwoundinsulationsystemsareusedthroughout.A slightadderforthehighervoltageinsulationsystems(4160V,6900V)isreflectedwhere appropriateintheBOM. 3.2 Electrical System BOM for 3.0-MW LV Turbine

Table31liststheelectricalsystemBOMforthe3.0MW,LVturbine.Thematerialcost totalizedatthebottomofthetablewillbecomparedwiththeMVdesignsintheCOE modelsofSection5.

32

 Table313.0MWLVelectricalsystemBOM
# Item Description 3.0 MW, 105 Deg. C rise, 6 pole, open drip-proof, flange mounted, 33% reactance, wye connected, form wound, 97% F.L. efficiency 3249 ft. of 2kV, 90 deg C., 350 MCM,normal stranding 573 ft., 2 kV, high stranded, 313 MCM DLO Voltage source inverter per attached included BOM's 3MVA, Oil filled padmount, outdoor rated, 34.5 kV primary, 575 V wye secondary Total Cost Cost

1 2 3 4 5

Generator Tower Pendant Cables Tower Pendant Cables (festooning) LV Inverter Transformer and Switchgear

$ $ $ $ $ $

114,000 18,932 3,712 139,275 34,318 310,237

3.2.1 Converter System for 3.0-MW LV Turbine The3.0MW,LVvariablespeedconvertersystemconsistsofparalleledpassiverectifierand IGBTinverterassemblies.Asdiscussedearlier,alimitof750kWrepresentsthemaximum costeffectiveapproachtoLVconvertersineachassembly.Forthisreason,four750kW converters,operatinginparallel,areusedinthe3.0MWturbine.Thisconfigurationis showninthesimplifiedschematicofFigure32.Notethatonecontrolboardcontrolsall fourconverters.Linefilterandswitchgeararenotincludedinthissimplifiedfigure;these aredescribedinmoredetailinsubsequentfiguresandsubsections. 3.2.2 Converter System Diagram for 3.0-MW LV Turbine ThefigurebelowshowstheparalleledstructureoffourLVconvertersusedtobuildupa 3.0MWcompleteconvertersystem.

33

LV Diode-IGBT Drive 3.0-MW System

Padmount Transformer 575V Secondary + -

+ 3.0-MW Generator

Control & Communication Board + -

+ -

Figure32Convertersystemdiagramfor3.0MWLVturbine 3.2.3 Converter Pricing Spreadsheet for 3.0-MW LV Turbine Theconverterpricingspreadsheetbelowdelineatestotalmaterialcosts,directfixedand variablecosts,andagrossmarginrangingfrom20%to30%fortheconvertermanufacturer. Inadditiontothematerialcostsdetailedinsubsequentsections,anadditional$1328mustbe addedfortheonecontrolboardnotidentifiedinanyassemblyorsubassemblyBOM.Other importantfootnotesareincludedatthebottomofthespreadsheet.Attentionshouldbe giventofootnote#4.Thisistheannualizedcostofbuildingconvertersregardlessofthe quantitiesbuilt(thereforeitisadirectfixedcost).Thisincludesmanufacturingspace,rent, utilities,andworkfloorsupervision.Thisnumberwillvarydependingontheconverter MWratingmostlybecauseofutilitybillings.

34

 Table32Converterpricingspreadsheetfor3.0MWLVturbine
3.0-MW LV Synchronous Machine Drive Direct Variable Materials (2) Direct Variable Labor (3) Direct Fixed Costs Total Direct Costs (4) Gross Margin Sales Price
(1)

$ $ $ $ $

95,856.54 6,871.43 1,728.00 104,455.97 20% 130,569.96

$ $ $ $ $

95,856.54 6,871.43 1,728.00 104,455.97 25% 139,274.62

$ $ $ $ $

95,856.54 6,871.43 1,728.00 104,455.97 30% 149,222.81

(1) Annual production = 250 Turbines (2) Includes 3% freight in (3) Assumes 70% utilization and 30% fringe benefits (4) Includes $120k rent, $200k capital equip, $27k utility and $85k supervision (annual cost) (5) Gross Margin = (Sales Price - Direct Cost)/Sales Price

3.2.4 Converter Material Breakdown and BOM for 3.0-MW LV Turbine AsintroducedinSection3.1,materialcostforoneconvertermainassemblyislistedbelow, withsubassemblydetailsshowninthesubsequentfoursections.TheQuotedcolumnis includedtoshowfixedquotedcostsfromthevariousselectedvendors.AYindicatesan offtheshelfcomponentforwhichaquotewasobtained.N/Aindicatesacustom subassemblyforwhichcostsestimateswerepreparedbytheprojectteamanddetailed separately.

35


LV Diode-IGBT Converter
9 5 + 3-Phase Line Filter 1 2 3 4 7 8 Enclosure Gate Drive Board Line Side Subpanel 1 2 6 Generator Padmount Transformer 575V Secondary

N Included in Converter BOM N Not Included in Converter BOM

Control Board & Communication Controls up to 4 Inverters (Included in System BOM)

To Turbine Communication

Figure33Converterdiagramfor3.0MWLVturbine

Table333.0MWLVConverterBOM
LV 750 kVA Converter BOM Item # Qty Description 1 1 Circuit Breaker, 1000A, 600VAC, 3-P, Line 2 1 Fuse, 800A, 600VAC, 3-Pole 3 1 Contactor, 800A, 600VAC, 3-Pole, Line 4 1 Line Filter, 3 Phase 5 1 Assy, IGBT Matrix, 3-Phase, Line 6 1 Diode Bridge 7 1 Sub Panel 8 1 Enclosure 9 4 Current Transducers, Line TOTAL: Quoted Y Y Y N/A N/A N/A N/A Y Y Unit Cost 1,500.00 120.00 1,300.00 6,340.00 7,293.00 2,463.00 2,038.40 1,100.00 195.00 Ext Cost 1,500.00 120.00 1,300.00 6,340.00 7,293.00 2,463.00 2,038.40 1,100.00 780.00 22,934.40

3.2.5 Line Matrix for 3.0-MW LV Turbine Theinvertermatrixforthe3.0MWconverterisdiagramedbelow.Itisasixelement,IGBT based,twolevelinverterusing2.5kVsilicondevices.

36

Figure34Linematrixschematic,3.0MWLVturbine

Table34Linematrixcosting,3.0MWLVturbine
LV 750 kVA Line Matrix BOM Item # 1 2 3 4 5 6 7 8 Qty 12 24 6 1 1 1 1 1 Description Resistor, Balance, 10k, 25W Capacitor, 8200uF, 450Vdc IGBT, 1200A, 2500V Gate Drive Board, Hex Assy, Laminated Bus Heatsink Cooling Fan Fiber Optic Harness TOTAL: Quoted Y Y Y Y Y Y Y Y Unit Cost 3.00 47.00 510.00 325.00 1,000.00 1,176.00 450.00 118.00 Ext Cost 36.00 1,128.00 3,060.00 325.00 1,000.00 1,176.00 450.00 118.00 7,293.00

3.2.6 Line Filter for 3.0-MW LV Turbine Thelinefilterforthe3.0MWconverterisshownbelowandconsistsofaninductiveand capacitiveelement.ThepadmounttransformerleakageinductancehelpstoformaTsection lowpassfilter.

37

Figure35Linefilterschematic,3.0MWLVturbine

Table35Linefiltercosting,3.0MWLVturbine
LV 750 kVA Line Filter BOM Item # Qty Description 1 1 Reactor, PWM, 600uH, 3 Phase Resistor, Stainless, 3 phase, 0.1 /Phase 2 3 3 1 Capacitor, 20.8 kVAR, 3 Phase, 575V 4 1 Enclosure TOTAL: Quoted Y Y Y Y Unit Cost 5,500.00 33.00 141.00 600.00 Ext Cost 5,500.00 99.00 141.00 600.00 6,340.00

3.2.7 Converter Subpanel for 3.0-MW LV Turbine Thesubpanelismadeupofmanysmallcomponentsusedintheconverter.Thesubpanelis aconvenientapproachtomountingandmanagingthevariouscomponents.

38

 Table36Convertersubpanelcosting,3.0MWLVturbine
LV 750 kVA Sub-Panel BOM Item # Qty Description 1 1 Fab, Panel, Power Distribution 2 1 Switch, Disconnect, 80A, 600V, 2p 3 2 Circuit Breaker, 30A, 600V, 3-P 4 3 Fuse, 30A, 600V 5 3 Fuseblock, 100A, 600V 6 2 Capacitor, Electrolytic, 300uF, 250V 7 1 Assy, Harness, Main 8 1 Circuit Breaker, 20A, 600V 9 1 Circuit Breaker, 2A, 600V 10 4 SSR, 12A, 200Vdc, MOSFET OUT 11 250 350 MCM 2000V Cable 12 1 Transformer, Control, 4kVA 1ph TOTAL: Quoted Y Y Y Y Y Y Y Y Y Y Y Y Unit Cost 50.00 180.00 120.80 5.00 5.00 15.00 300.00 93.80 70.00 17.00 2.50 350.00 Ext Cost 50.00 180.00 241.60 15.00 15.00 30.00 300.00 93.80 70.00 68.00 625.00 350.00 2,038.40

3.2.8 Passive Rectifier for 3.0-MW LV Turbine TherectifierusedintheLVsystemisasimplepassivesixelementdesign(Figure2.6).The sixrectifiersaremountedonaheatsink,andacoolingfanisusedtomanagetherelatively smalllossesassociatedwiththissubassembly.

Figure36Passiverectifier,3.0MWLVturbine

39

 Table37Passiverectifiercosting,3.0MWLVturbine
LV 750 kVA Diode Bridge BOM Item # Qty Description 1 6 Diode, 1200A, 2400V, Fast Recovery 2 1 Heatsink, Clamps, Terminations 3 1 Cooling Fan and Switchgear TOTAL: Unit Cost 238.00 710.00 325.00 Ext Cost 1,428.00 710.00 325.00 2,463.00

Quoted Y Y Y

3.3

Electrical System BOM for 5.0-MW LV Turbine

Table38belowliststheelectricalsystemBOMforthe5.0MWLVturbine.Thematerialcost totalizedatthebottomofthetablewillbecomparedwiththeMVdesignintheCOEmodels ofSection5. Table385.0MWLVelectricalsystemBOM

# Item Description 5.0 MW, 105 Deg. C rise, 6 pole, open drip-proof, flange mounted, 33% reactance, wye connected, form wound, 97% F.L. efficiency 8354 ft. of 2kV, 90 deg C., 300 MCM, normal stranding 1474 ft., 2 kV, high stranded, 313 MCM DLO Voltage source inverter per attached included BOM's 5MVA, Oil filled padmount, outdoor rated, 34.5 kV primary, 575 V wye secondary Total Cost Cost

1 2 3 4 5

Generator Tower Pendant Cables Tower Pendant Cables (festooning) LV Inverter Transformer and Switchgear

$ $ $ $ $ $

164,000 48,681 9,546 265,128 45,911 533,266

3.3.1 Converter System for 5.0-MW LV Turbine The5.0MWLVvariablespeedconvertersystemconsistsofapassiverectifierandIGBT invertersystem.Asdiscussedearlier,alimitof750kWrepresentsthemaximumcost effectiveapproachtoLVconverters.Inthe5.0MWsystem,eightx625kW,operatingin parallel,areused.ThisconfigurationisshowninthesimplifiedschematicofFigure37. Notethattherearenowtwocontrolboards,eachcontrollingfourconverters.Whileitis preferabletouseonecontrolboard,thecontrolofeightconvertersisbeyondtheI/O capabilityandprocessingpower,whichcouldbeexpected.Thetwocontrolboardcosts needtobeaddedtosubsequentBOMsasthesearenotincludedatanyassemblyor subassemblylevelbelow.Thiscostis$2657.Figuresoflinefilterandswitchgeararenot

310

 included;thesearethesameasdiscussedinthe3.0MWsectionofthisreport.Theadjusted costing,however,isprovidedinthesectionsbelow. 3.3.2 Converter System Diagram for 5.0-MW LV Turbine

LV Diode-IGBT Drive 5.0-MW System

+ + -

Control & Communication Board + + + + 5.0-MW Generator

Padmount Transformer 575V Secondary

Control & Communication Board + + Inverter Rectifier

Figure37Convertersystemdiagram,5.0MWLVturbine

311

3.3.3 Converter Pricing Spreadsheet for 5.0-MW LV Turbine Thetablebelowshowsthebuildupofcostingforthe5.0MWconvertersystem. Table39Converterpricingspreadsheet,5.0MWLVturbine

5.0-MW LV Synchronous Machine Drive Direct Variable Materials (2) Direct Variable Labor (3) Direct Fixed Costs Total Direct Costs (4) Gross Margin Sales Price
(1)

$ $ $ $ $

183,267.08 13,742.86 1,836.00 198,845.93 20% 248,557.42

$ $ $ $ $

183,267.08 13,742.86 1,836.00 198,845.93 25% 265,127.91

$ $ $ $ $

183,267.08 13,742.86 1,836.00 198,845.93 30% 284,065.62

(1) Annual production = 250 Turbines (2) Includes 3% freight in (3) Assumes 70% utilization and 30% fringe benefits (4) Includes $120k rent, $200k capital equip, $54k utility and $85k supervision (annual cost) (5) Gross Margin = (Sales Price - Direct Cost)/Sales Price

3.3.4 Converter Material Breakdown and BOM for 5.0-MW LV Turbine Thematerialcostingoftheconverterisbrokendownfurtherasshownbelow.Notethatthe schematicsandfiguresassociatedwitheachBOMarenotincludedinthissectionastheyare identicaltothosecorrespondingfiguresinthe3.0MWconvertersection.Forexample,the invertertopology,thelinefilter,etc.areschematicallythesameasinthe3.0MWsystem,but thecomponentvaluesareoptimizedinaccordancewiththereducedratingof625kW. ThesedifferentcomponentscanbeidentifiedintherespectiveBOMsbelow. Table3105.0MWLVConverterBOM
LV 625 kVA Converter BOM Item # Qty Description 1 1 Circuit Breaker, 1000A, 600VAC, 3-P, Line 2 1 Fuse, 700A, 600VAC, 3-Pole 3 1 Contactor, 700A, 600VAC, 3-Pole, Line 4 1 Line Filter, 3 Phase 5 1 Assy, IGBT Matrix, 3-Phase, Line 6 1 Diode Bridge 7 1 Sub Panel 8 1 Enclosure 9 4 Current Transducers, Line TOTAL: Quoted Y Y Y N/A N/A N/A N/A Y Y Unit Cost 1,200.00 120.00 1,200.00 5,840.00 7,293.00 2,463.00 1,913.40 1,100.00 195.00 Ext Cost 1,200.00 120.00 1,200.00 5,840.00 7,293.00 2,463.00 1,913.40 1,100.00 780.00 21,909.40

312

 3.3.5 Line Matrix 5.0-MW LV Turbine Costingforthe5.0MWLVturbinelinematrixincludingallpowersemiconductorsandDC linkcapacitorsandotherequipmentisprovidedbelow. Table311Linematrixcosting,5.0MWLVturbine

LV 625 kVA Line Matrix BOM Item # Qty Description 1 12 Resistor, Balance, 10k, 25W 2 24 Capacitor, 8200uF, 450Vdc 3 6 IGBT, 1200A, 2500V 4 1 Gate Drive Board, Hex 5 1 Assy, Laminated Bus 6 1 Heatsink 7 1 Cooling Fan 8 1 Fiber Optic Harness TOTAL: Quoted Y Y Y Y Y Y Y Y Unit Cost 3.00 47.00 510.00 325.00 1,000.00 1,176.00 450.00 118.00 Ext Cost 36.00 1,128.00 3,060.00 325.00 1,000.00 1,176.00 450.00 118.00 7,293.00

3.3.6 Line Filter for 5.0-MW LV Turbine Thelinefilterforthe5.0MWturbineisdescribedandcostedbelow. Table312LinefilterBOM,5.0MWLVturbine

LV 625 kVA Line Filter BOM Item # Qty Description 1 1 Reactor, PWM, 800uH, 3 Phase Resistor, Stainless, 3 phase, 0.1 /Phase 2 3 3 1 Capacitor, 20.8 kVAR, 3 Phase, 575V 4 1 Enclosure TOTAL: Quoted Y Y Y Y Unit Cost 5,000.00 33.00 141.00 600.00 Ext Cost 5,000.00 99.00 141.00 600.00 5,840.00

313

3.3.7 Converter Subpanel for 5.0-MW LV Turbine The5.0MWturbinesubpanelhasthesamecomponentsmountedonitasinthe3.0MW case. Table313Convertersubpanelcosting,5.0MWLVturbine

LV 625 kVA Sub-Panel BOM Item # Qty Description 1 1 Fab, Panel, Power Distribution 2 1 Switch, Disconnect, 80A, 600V, 2p 3 2 Circuit Breaker, 30A, 600V, 3-P 4 3 Fuse, 30A, 600V 5 3 Fuseblock, 100A, 600V 6 2 Capacitor, Electrolytic, 300uF, 250V 7 1 Assy, Harness, Main 8 1 Circuit Breaker, 20A, 600V 9 1 Circuit Breaker, 2A, 600V 10 4 SSR, 12A, 200Vdc, MOSFET OUT 11 250 262 MCM 2000V Cable 12 1 Transformer, Control, 4kVA 1ph TOTAL: Quoted Y Y Y Y Y Y Y Y Y Y Y Y Unit Cost 50.00 180.00 120.80 5.00 5.00 15.00 300.00 93.80 70.00 17.00 2.00 350.00 Ext Cost 50.00 180.00 241.60 15.00 15.00 30.00 300.00 93.80 70.00 68.00 500.00 350.00 1,913.40

3.3.8 Passive Rectifier for 5.0-MW LV Turbine Therectifierforthe5.0MWLVturbineisidenticaltothe3.0MWdesignandiscosted below. Table314Passiverectifiercosting,5.0MWLVturbine

LV 625 kVA Diode Bridge Rectifier BOM Item # Qty Description 1 6 Diode, 1200A, 2400V, Fast Recovery 2 1 Heatsink, Clamps, Terminations 3 1 Cooling Fan and Switchgear TOTAL: Quoted Y Y Y Unit Cost 238.00 710.00 325.00 Ext Cost 1,428.00 710.00 325.00 2,463.00

3.4 Electrical System BOM for 7.5-MW LV Turbine The7.5MWLVvariablespeedconvertersystemconsistsofapassiverectifierandIGBT inverter.Justasinthe3.0MWcasestudy,the7.5MWturbineusesahighlyparalleled750 kWconvertermodulestructuretoachievetherequired7.5MW.Inthissystem,ten750kW convertersareusedtoachievetheturbinesrating.Thisconfigurationisshowninthe simplifiedschematicofFigure38.Notethatthreecontrolboardsarenowusedonthe turbine,twocontrolboardscontrollingfourconverterseachandathirdcontrolboard

314

 controllingonlytwoconverters.Thecostforthethreecontrolboardsis$3985,whichmust beaddedtomaterialcosts.Theadditionofmultiplecontrolboardscomplicates communicationwithturbinecontrolsystems.Itisnecessaryfortheboardstoflageachother intheeventofafaultcondition.Matrix,linefilter,subpanel,andswitchgeararenot includedasfiguresorBOMsinthissectionbecausetheyareidenticaltotheassemblies mentionedinthe3.0MWdiscussion. Table3157.5MWLVelectricalsystemBOM

# Item Description 7.5 MW, 105 Deg. C rise, 6 pole, open drip-proof, flange mounted, 33% reactance, wye connected, form wound, 97% F.L. efficiency 12,846 ft. of 2kV, 90 deg C., 300 MCM, normal stranding 2267 ft., 2 kV, high stranded, 313 MCM DLO Voltage source inverter per attached included BOM's 5MVA, Oil filled padmount, outdoor rated, 34.5 kV primary, 575 V wye secondary Total Cost Cost

1 2 3 4 5

Generator Tower Pendant Cables Tower Pendant Cables (festooning) LV Inverter Transformer and Switchgear

$ $ $ $ $ $

241,000 74,857 14,677 345,858 62,445 738,837

3.4.1 Converter System Diagram for 7.5-MW LV Turbine Theconvertersystemdiagramforthe7.5MWLVturbineisshowninFigure3.8.

315

LV Diode-IGBT Drive 7.5-MW System

+ + Control & Communication Board

+ + Padmount Transformer 575V Secondary Inverter + + Control & Communication Board

7.5-MW Generator Rectifier

+ + + + Control & Communication Board

Figure38Convertersystemdiagram,7.5MWLVturbine

316

 3.4.2 Converter Pricing Spreadsheet for 7.5-MW LV Turbine Pricingforthehighlyparalleled7.5MWLVturbineisshownbelow.Thecostingincludes threecontrolboardsforatotalcostadderof$3985. Table316Converterpricingspreadsheet,7.5MWLVturbine
7.5-MW LV Synchronous Machine Drive Direct Variable Materials (2) Direct Variable Labor (3) Direct Fixed Costs Total Direct Costs (4) Gross Margin Sales Price
(1)

$ $ $ $ $

240,324.75 17,178.57 1,890.00 259,393.32 20% 324,241.65

$ $ $ $ $

240,324.75 17,178.57 1,890.00 259,393.32 25% 345,857.76

$ $ $ $ $

240,324.75 17,178.57 1,890.00 259,393.32 30% 370,561.89

(1) Annual production = 250 Turbines (2) Includes 3% freight in (3) Assumes 70% utilization and 30% fringe benefits (4) Includes $120k rent, $200k capital equip, $67.5k utility and $85k supervision (annual cost) (5) Gross Margin = (Sales Price - Direct Cost)/Sales Price

317

4 Electrical System Bill of Material MV Voltage-Source Inverter Topology

AsinSection3,thissectiondetailstheelectricalsystemBOMforthe3.0,5.0,and7.5MW turbines.Inthiscase,however,aNorthAmericanMVelectricalsystemisassumedinstead oftheconventional575Vconfiguration.Thevoltagesusedare2,400Vat3.0MW,4,160Vat 5.0MW,and6,900Vat7.5MW.ThesevoltageswereselectedtokeeptheAClinecurrentsat about700ampsforallthreeturbines,whichcostingeffortsdemonstrateprovidethemost costeffectiveMVequipment. Buildingonthebaselineelectricalsystem,inthissectiontheMVconvertersarepricedoutin detail.Theconvertersforthe5.0and7.5MWturbinesshareathreelevel,neutralpoint clamp,voltagesourceinvertertopology.Thistopologyisnowwellunderstood[1],[2]and hasnumerousadvantagesathighervoltages.The3.0MWturbineconverterusesa6 elementvoltagesourceinverterusing6.6kVpowersemiconductors. Inadditiontothechangesintheinvertersection,aboostconverterisaddedintheDClink betweenthegeneratorrectifierandtheinverter.ThechopperallowsawideDCbus operatingrange,asprovidedintheLVcase,withoutexceedingthevoltagelimitofavailable powersemiconductors.Thechopperhasanotheradvantageinthatitextendstheoperating speedrangeofthegenerator,andthiswiderrangecorrespondstoabouta0.3%increasein theenergycaptureoftheMVturbine.However,thisisoffsetbyaslightlylowerefficiency duetotheboostcircuit.Adetailedanalysisofthenetgainsorlossesduetotheseeffectsis notperformedinthisstudy.Theconvertertopologiesaredetailedbelow.

4.1 Section Organization

ThissectionisarrangedtoparallelthedevelopmentoftheLVcasesinSection3.Specifically, Sections4.2,4.3,and4.4detailcostsandmaterialsforthe3.0,5.0,and7.5MWelectrical systems,respectively.ThesubsectionsthenfollowthesameorderaswasusedinSection2 costingandpricing.

4.2 Electrical System BOM for 3.0-MW MV Turbine

Table41liststheelectricalsystemBOMforthe3.0MWMVturbine.Thematerialcost totalizedatthebottomofthetablewillbecomparedwiththeLVdesignintheCOEmodels ofSection5.

41

 Table413.0MWMVelectricalsystemBOM
# Item Description 3.0 MW, 105 Deg. C rise, 6 pole, open drip-proof, flange mounted, 33% reactance, wye connected, form wound, 97% F.L. efficiency 812 ft. of 5kV shielded, 90 deg C., 600 MCM,normal stranding 143 ft., 5 kV, high stranded, 600 MCM DLO Voltage source inverter per attached included BOM's 3MVA, Oil filled padmount, outdoor rated, 34.5 kV primary, 2400 V wye secondary Total Cost Cost

1 2 3 4 5

Generator Tower Pendant Cables Tower Pendant Cables (festooning) LV Inverter Transformer and Switchgear

$ $ $ $ $ $

114,000 7,578 1,471 110,494 34,212 267,755

4.2.1 Converter System for 3.0-MW MV Turbine The3.0MWMVvariablespeedconvertersystemconsistsofapassiverectifier,generator, boostchopper,andthreelevelIntegratedGateCommutatedThyristor(IGCT)inverter system.IncontrasttothehighlyparalleledarchitectureoftheLVsystem,theMVelectrical systemconsistsofasinglegeneratoroutputandasingleconvertersystem. 4.2.2 Converter System Schematic and Pricing for 3.0-MW MV Turbine Pricingforthe3.0MWMVturbineisprovidedinthespreadsheetbelow.Thestructureof the3.0MWmachineincludesmaterialcostforacontrolboardinthefundamentalconverter inthenextsection,sonocontrolboardcostadderisrequired(unliketheLVcase). Table42PricingSpreadsheetfor3.0MWMVTurbine
3.0-MW MV Voltage Source Synchronous Machine Drive Direct Variable Materials (2) Direct Variable Labor (3) Direct Fixed Costs Total Direct Costs (4) Gross Margin Sales Price
(1)

$ $ $ $ $

79,146.23 1,996.43 1,728.00 82,870.66 20% 103,588.32

$ $ $ $ $

79,146.23 1,996.43 1,728.00 82,870.66 25% 110,494.21

$ $ $ $ $

79,146.23 1,996.43 1,728.00 82,870.66 30% 118,386.66

(1) Annual production = 250 Turbines (2) Includes 3% freight in (3) Assumes 70% utilization and 30% fringe benefits (4) Includes $120k rent, $200k capital equip, $27k utility and $85k supervision (annual costs) (5) Gross Margin = (Sales Price - Direct Cost)/Sales Price

42

 4.2.3 Converter System Material Breakdown and BOM for 3.0-MW MV Turbine AbasicdiagramandmaterialcostoftheMVconvertermainassembliesareshownbelow, withsubassemblydetailsshowninthesubsequentfoursections.Asintheprevioussection, costsforcomponentsandsubassembliesarebasedonvendorquotationsorprojectteam estimates,asidentifiedintheQuotedcolumn.
MV Voltage Source 3.0-MW Diode-IGCT Converter
1 Padmount Transformer 2200V Secondary 2 3 4 5 6 7 3.0-MW Generator + Gate Drive Board Chopper Side 10 11 Enclosure

3-Phase Line Filter Gate Drive Board

+ -

Subpanel 9

Line Side Matrix Control Board & Communication

N N

Included in Converter BOM Not Included in Converter BOM To Turbine Communication

Figure413.0MWMVconverterdiagram Table433.0MWMVconverterBOM
3.0-MW MV Diode-IGCT Converter BOM Item # Qty Description 1 1 Circuit Breaker, 800A, 2400VAC, 3-P, Line 2 1 Fuse, 800A, 2400VAC, 3-Pole 3 1 Contactor, 800A, 2400VAC, 3-Pole, Line 4 1 Line Filter, 3 Phase 5 3 Current Transducers 900A 6 1 Assy, IGCT Matrix, 3-Phase, Line 7 1 Assy, Diode-IGCT Chopper 8 1 Diode Bridge 9 1 Sub Panel 10 1 Control Board 11 1 Enclosure TOTAL: Quoted Y Y Y N/A Y N/A N/A N/A N/A Y Y Unit Cost 3,106.00 2,798.00 2,715.00 28,150.00 93.20 17,074.00 12,254.00 4,236.00 2,878.40 1,350.00 2,000.00 Ext Cost 3,106.00 2,798.00 2,715.00 28,150.00 279.60 17,074.00 12,254.00 4,236.00 2,878.40 1,350.00 2,000.00 76,841.00

43

 4.2.4 Line Matrix for 3.0-MW MV Turbine Thelinesideinvertermatrixforthe3.0MWconverterisshownbelow.Thematrixuses asymmetricalIGCTdevicesratedat6.6kV.Costingforthelinesideinvertermatrixis shownbelowthefilter.

Medium Voltage Diode-IGCT Drive 3.0-MW 3-Phase IGCT Line Side Matrix

A B C

1 6 Parallel Resistor Strings

2 12 Parallel Capacitor Strings 7 Gate Drive Board

Typical

5 * Note Heatsink Not Shown 6 * Note Cooling Fan Not Shown

Fiber Optic Harness

To Turbine Control Board

Figure42Linematrixschematic,3.0MWMVturbine

44

 Table44Linematrixcosting,3.0MWMVturbine
3.0-MW MV Diode-IGCT Matrix BOM Item # Qty Description 1 72 Resistor, Balance, 10k, 25W 2 144 Capacitor, 8200uF, 450Vdc 3 6 IGCT, 1200A, 6.6kV 4 1 Assy, Laminated Bus 5 1 Heatsink 6 1 Cooling Fan 7 1 Fiber Optic Harness TOTAL:

Quoted Y Y Y Y Y Y Y

Unit Cost 3.00 47.00 962.00 1,200.00 2,500.00 500.00 118.00

Ext Cost 216.00 6,768.00 5,772.00 1,200.00 2,500.00 500.00 118.00 17,074.00

4.2.5 Chopper for 3.0-MW MV Turbine Asmentionedabove,theMV,voltagesourceinverterusesachoppertoregulatetheDC bus.Recallthatbusvoltageregulationisintentionallymovedtothegeneratorsideforride throughrequirementpurposes.ThechopperalsoextendsthespeedrangeoftheMVdesign.

45

MV Diode-IGCT Drive 3.0-MW Chopper

1 4

3 2

6 7

* Note Heatsink Not Shown * Note Cooling Fan Not Shown

Typical

Gate Drive Board

Fiber Optic Harness

To Turbine Control Board

Figure433.0MWMVchopperdiagram Table453.0MWMVchopperBOM
3.0-MW MV Diode-IGCT Chopper BOM Item # Qty Description 1 Inductor, Chopper, 1mH 900Adc 1 2 2 IGCT, 1200A, 6.6kV 3 1 Diode, Chopper, 1200A, 6.6kV 4 1 Assy, Laminated Bus 5 1 Fiber Optic Harness 6 1 Heatsink 7 1 Cooling Fan TOTAL: Quoted Y Y Y Y Y Y Y Unit Cost 5,600.00 962.00 412.00 1,200.00 118.00 2,500.00 500.00 Ext Cost 5,600.00 1,924.00 412.00 1,200.00 118.00 2,500.00 500.00 12,254.00

46

 4.2.6 Line Filter for 3.0-MW MV Turbine Thelinefilterforthe3.0MWinverterissimilartothatusedintheLVcase.Thefilteris diagrammedandcostedbelow.

MV Diode-IGCT Drive 3.0-MW 3-Phase Line Side Filter
Inverter Side A B C 2 1 3 Grid Side A B C

4 Enclosure

Figure44Linefilterschematic,3.0MWMVturbine Table46Linefiltercosting,3.0MWMVturbine
3.0-MW MV Diode-IGCT Filter BOM Item # Qty Description 1 Reactor, PWM, 6mH, 700A, 3 Phase, 2400V 1 2 3 Resistor, Stainless, 3 phase, 0.1 /Phase 3 1 Capacitor, 100 kVAR, 3 Phase, 4160V 4 1 Enclosure TOTAL: Quoted Y Y Y Y Unit Cost 24,000.00 500.00 1,850.00 800.00 Ext Cost 24,000.00 1,500.00 1,850.00 800.00 28,150.00

4.2.7 Converter Subpanel for 3.0-MW MV Turbine ThesubpaneldesignintheMVcaseisidenticaltothatusedintheLVcase.Thesubpanelis costedbelow.

47

 Table47Convertersubpanelcosting,3.0MWMVturbine
Quoted Y Y Y Y Y Y Y Y Y Y Y Y Y Unit Cost 500.00 50.00 180.00 120.80 5.00 5.00 15.00 300.00 93.80 70.00 17.00 3.86 350.00 Ext Cost 500.00 50.00 180.00 241.60 15.00 15.00 30.00 300.00 93.80 70.00 68.00 965.00 350.00 2,878.40

3.0-MW MV Diode-IGCT Subpanel BOM Item # Qty Description 1 1 Xfmr, 3 phase Isolation, 2400:240, 5kVA 2 1 Fab, Panel, Power Distribution Switch, Disconnect, 80A, 600V, 2p 3 1 4 2 Circuit Breaker, 30A, 600V, 3-P 5 3 Fuse, 30A, 600V 3 Fuseblock, 100A, 600V 6 7 2 Capacitor, Electrolytic, 300uF, 250V 1 Assy, Harness, Main 8 9 1 Circuit Breaker, 20A, 600V 10 1 Circuit Breaker, 2A, 600V 4 11 SSR, 12A, 200Vdc, MOSFET OUT 12 250 350 MCM 2000V Cable 13 1 Transformer, Control, 4kVA 1ph
TOTAL:

4.2.8 Passive Rectifier for 3.0-MW MV Turbine ThepassiverectifierfortheMVconverterissimilartotheLVdesign.Itusesaheatsinkand fanassemblytoremovetherathersmalllossesgivenoffbythesixelements.

MV Diode-IGCT Drive 3.0-MW 3-Phase Diode Bridge

A B C 1

2 * Note Heatsink Not Shown 3 * Note Cooling Fan Not Shown

Figure45Passiverectifier,3.0MWMVturbine

48

 Table48Passiverectifiercosting,3.0MWMVturbine
3.0-MW MV Diode-IGCT Diode Bridge Rectifier BOM Item # Qty Description 1 6 Diode, 1200A, 6.6kV, Fast Recovery 2 1 Heatsink, Clamps, Terminations 3 1 Cooling Fan and Switchgear TOTAL: Quoted Y Y Y Unit Cost 418.00 1,372.00 356.00 Ext Cost 2,508.00 1,372.00 356.00 4,236.00

4.3 Electrical System BOM for 5.0-MW MV Turbine

Table49liststheelectricalsystemBOMforthe5.0MWMVvoltagesourceinverter turbine.ThematerialcosttotalizedatthebottomofthetablewillbecomparedwiththeMV designintheCOEmodelsofSection5. Table495.0MWMVElectricalSystemBOM
# Item Description 5.0 MW, 105 Deg. C rise, 6 pole, open drip-proof, flange mounted, 33% reactance, wye connected, form wound, 97% F.L. efficiency 8354 ft. of 5kV shielded, 90 deg C., 500 MCM, normal stranding 184 ft., 5 kV, high stranded, 500 MCM DLO Voltage source inverter per attached included BOM's 5MVA, Oil filled padmount, outdoor rated, 34.5 kV primary, 4160 V wye secondary Total Cost Cost

1 2 3 4 5

Generator Tower Pendant Cables Tower Pendant Cables (festooning) LV Inverter Transformer and Switchgear

$ $ $ $ $ $

164,000 7,795 1,513 146,167 41,354 360,829

4.3.1 Converter System for 5.0-MW MV Turbine The5.0MWMVvariablespeedconvertersystemconsistsofapassiverectifier,generator, boostchopper,andthreelevelIGCTinvertersystem.Incontrasttothehighlyparalleled architectureoftheLVsystem,theMVelectricalsystemconsistsofasinglegeneratoroutput andasingleconvertersystem. 4.3.2 Converter System Schematic and Pricing for 5.0-MW MV Turbine Thepricingforthe5.0MWconverterisasfollows.

49

 Table410Convertersystempricingspreadsheet,5.0MWMVturbine
5.0-MW Permanent Magnet Drive Direct Variable Materials (2) Direct Variable Labor Direct Fixed Costs (3) Total Direct Costs Gross Margin (4) Sales Price
(1)

$ $ $ $ $

105,689.74 2,135.71 1,800.00 109,625.46 20% 137,031.82

$ $ $ $ $

105,689.74 2,135.71 1,800.00 109,625.46 25% 146,167.28

$ $ $ $ $

105,689.74 2,135.71 1,800.00 109,625.46 30% 156,607.79

(1) Annual production = 250 Turbines (2) Includes 3% freight in (3) Assumes 70% utilization and 30% fringe benefits (4) Includes $120k rent, $200k capital equip, $45k utility and $85k supervision (annual cost) (5) Gross Margin = (Sales Price - Direct Cost)/Sales Price

4.3.3 Converter Material Breakdown and BOM for 5.0-MW MV Turbine Thematerialcostingoftheconverterisbrokendownfurtherasshownbelow.
MV Voltage Source 5.0-MW Diode-IGCT Converter
1 Padmount Transformer 4160V Secondary 2 3 4 5 6 7 5.0-MW Generator + Gate Drive Board Chopper Side 10 11 Enclosure

3-Phase Line Filter

+ Gate Drive Board Line Side Matrix Control Board & Communication

Subpanel

N N

Included in Converter BOM Not Included in Converter BOM To Turbine Communication

Figure465.0MWMVconverterdiagram

410

 Table4115.0MWMVconverterBOM
5.0-MW MV Diode-IGCT Converter BOM Item # Qty Description 1 1 Circuit Breaker, 800A, 5kVAC, 3-Pole, Line 2 1 Fuse, 800A, 5kVAC, 3-Pole 3 1 Contactor, 800A, 5kVAC, 3-Pole, Line 4 1 Line Filter, 3 Phase 5 3 Current Transducers 900A 6 1 Assy, IGCT Matrix, 3-Phase, Line 7 1 Assy, Diode-IGCT Chopper 8 1 Diode Bridge 9 1 Subpanel 10 1 Control Board 11 1 Enclosure TOTAL: Quoted Y Y Y N/A Y N/A N/A N/A N/A Y Y Unit Cost 3,106.00 2,798.00 2,715.00 28,150.00 450.00 32,602.00 18,714.00 6,948.00 2,878.40 1,350.00 2,000.00 Ext Cost 3,106.00 2,798.00 2,715.00 28,150.00 1,350.00 32,602.00 18,714.00 6,948.00 2,878.40 1,350.00 2,000.00 102,611.40

4.3.4 Line Matrix for 5.0-MW MV Turbine The5.0MWlinesideinverterusesamultilevel(threelevel),neutralpointclampedinverter systemtosupplycurrenttothe4160Vpadmounttransformer.Thisinverterstructurehas theadvantagethatthesemiconductoronlyneedstoblockhalfofthetotalDCbusvoltage. Alsothemultilevelvoltageoutputhasasmallerharmoniccontentthanthetwolevel inverterandassuch,theoutputfilterrequirementsarereduced.

411

MV Diode-IGCT Drive 5.0-MW 3-Phase IGCT Line Side Matrix

A B C

1 6 Parallel Resistor Strings

2 12 Parallel Capacitor Strings 8 Gate Drive Board

Typical

6 * Note Heatsink Not Shown 7 * Note Cooling Fan Not Shown

Fiber Optic Harness

To Turbine Control Board

Figure47Linematrixschematic,5.0MWMVturbine Table412Linematrixcosting,5.0MWMVturbine
5.0-MW MV Diode-IGCT Matrix BOM Item # Qty Description 120 Resistor, Balance, 10k, 25W 1 240 Capacitor, 8200uF, 450Vdc 2 12 IGCT, 1200A, 6.6kV 3 Diode, Freewheel, 1200A, 10kV 4 6 5 1 Assy, Laminated Bus Heatsink 6 1 7 1 Cooling Fan Fiber Optic Harness 8 1
TOTAL:

Quoted Y Y Y Y Y Y Y Y

Unit Cost 3.00 47.00 962.00 850.00 1,200.00 2,500.00 500.00 118.00

Ext Cost 360.00 11,280.00 11,544.00 5,100.00 1,200.00 2,500.00 500.00 118.00
32,602.00

412

 4.3.5 Chopper for 5.0-MW MV Turbine Achopperisusedinthe5.0MWconverterforthesamereasonsthatwerediscussedinthe 3.0MWsection.Pleasenote,however,thatbecauseofthehigherDCvoltagehere, semiconductorsareappliedinaseriesconfigurationinthechopper.

MV Diode-IGCT Drive 5.0-MW Chopper

Typical

Gate Drive Board

6 5 Fiber Optic Harness 7

* Note Heatsink Not Shown * Note Cooling Fan Not Shown

To Turbine Control Board

Figure485.0MWMVchopperdiagram

413

 Table4135.0MWMVchopperBOM
5.0-MW MV Diode-IGCT Chopper BOM Item # Qty Description Inductor, Chopper, 1mH 900Adc 1 1 2 6 IGCT, 1200A, 6.6kV Diode, Chopper, 1200A, 6.6kV 3 2 Assy, Laminated Bus 4 1 6 1 Fiber-Optic Harness Heatsink 7 1 Cooling Fan 8 1 TOTAL: Quoted Y Y Y Y Y Y Y Unit Cost 7,800.00 962.00 412.00 1,200.00 118.00 2,500.00 500.00 Ext Cost 7,800.00 5,772.00 824.00 1,200.00 118.00 2,500.00 500.00 18,714.00

4.3.6 Line Filter for 5.0-MW MV Turbine Thelinefilterforthe5.0MW,multilevelinverterisshownandcostedbelow.

MV Diode-IGCT Drive 5.0-MW 3-Phase Line Side Filter
Inverter Side A Grid Side A

B C

B C

4 Enclosure

Figure49Linefilterschematic,5.0MWMVturbine

414

 Table414Linefiltercosting,5.0MWMVturbine
5.0-MW MV Diode-IGCT Filter BOM Item # Qty Description Reactor, PWM, 6mH, 700A, 3 Phase, 4160V 1 1 Resistor, Stainless, 3 phase, 0.1 /Phase 2 3 Capacitor, 100 kVAR, 3 Phase, 4160V 3 1 4 1 Enclosure TOTAL: Quoted Y Y Y Y Unit Cost 24,000.00 500.00 1,850.00 800.00 Ext Cost 24,000.00 1,500.00 1,850.00 800.00 28,150.00

4.3.7 Converter Subpanel 5.0-MW MV Turbine Thesubpanelcomponentsandcostingforthe5.0MWturbineareasshownbelow. Table415Convertersubpanelcosting,5.0MWMVturbine

5.0- MW MV Diode-IGCT Sub-Panel BOM Item # Qty Description 1 1 Xfmr, 3 phase Isolation, 4160:240, 5kVA Fab, Panel, Power Distribution 2 1 3 1 Switch, Disconnect, 80A, 600V, 2p 4 Circuit Breaker, 30A, 600V, 3-P 2 Fuse, 30A, 600V 5 3 Fuseblock, 100A, 600V 6 3 7 Capacitor, Electrolytic, 300uF, 250V 2 Assy, Harness, Main 8 1 Circuit Breaker, 20A, 600V 9 1 10 Circuit Breaker, 2A, 600V 1 11 SSR, 12A, 200Vdc, MOSFET OUT 4 12 250 350 MCM 2000V Cable 13 Transformer, Control, 4kVA 1ph 1 TOTAL: Quoted Y Y Y Y Y Y Y Y Y Y Y Y Y Unit Cost 500.00 50.00 180.00 120.80 5.00 5.00 15.00 300.00 93.80 70.00 17.00 3.86 350.00 Ext Cost 500.00 50.00 180.00 241.60 15.00 15.00 30.00 300.00 93.80 70.00 68.00 965.00 350.00 2,878.40

4.3.8 Passive Rectifier for 5.0-MW MV Turbine Thepassiverectifierforthe5.0MW,MVconvertersystemisshownbelow.Notetheseries connecteddioderectifiers.LossesaremanagedbyaheatsinkandfansimilartotheLVcase. Lossesareminimalintherectifiercircuit.

415


MV Diode-IGCT Drive 5 .0-MW 3-Phase Diode Bridge

A B C

2 3

4 * Note Heatsink Not Shown 5 * Note Cooling Fan Not Shown

Figure410Passiverectifierdiagram,5.0MWMVturbine Table416Passiverectifiercosting,5.0MWMVturbine
5.0-MW MV Diode-IGCT Diode Bridge Rectifier BOM Item # Qty Description 12 Diode, 1200A, 6.6kV, Fast Recovery 1 12 Resistor 2 3 12 Capacitor Heatsink, Clamps, Terminations 1 4 5 1 Cooling Fan and Switchgear TOTAL: Quoted Y Y Y Y Y Unit Cost 418.00 12.00 5.00 1,372.00 356.00 Ext Cost 5,016.00 144.00 60.00 1,372.00 356.00 6,948.00

416

4.4 Electrical System BOM for 7.5-MW MV Turbine

The7.5MWMVconvertersystemconsistsofapassiverectifier,chopper,andIGCTinverter system.Table417liststheelectricalsystemBOMforthe7.5MWMVvoltagesource inverterturbine.Thematerialcosttotalizedatthebottomofthetablewillbecomparedwith theLVdesignintheCOEmodelsofSection5. Table4177.5MWMVElectricalSystemBOM
# Item Description 7.5 MW, 105 Deg. C rise, 6 pole, open drip-proof, flange mounted, 33% reactance, wye connected, form wound, 97% F.L. efficiency 1285 ft. of 5/8kV shielded, 90 deg C., 500 MCM, normal stranding 227 ft., 5/8 kV, high stranded, 500 MCM DLO Voltage source inverter per attached included BOM's 7.5MVA, Oil filled padmount, outdoor rated, 34.5 kV primary, 6900 V wye secondary Total Cost Cost

1 2 3 4 5

Generator Tower Pendant Cables Tower Pendant Cables (festooning) LV Inverter Transformer and Switchgear

$ $ $ $ $ $

248,312 9,589 1,862 191,218 51,050 502,031

4.4.1 Converter System for 7.5-MW MV Turbine Materialcostingforthisconverterisdetailedbelow.Notethattheschematicsandfigureare notincludedinthissectionastheseareidenticaltothecorrespondingsubassembliesinthe 5.0MWconvertersection;thearchitectureoftherectifier,chopper,andinverterisidentical tothe5.0MWcase.Oneimportantpointregardingthe7.5MWsystemisthatitoperatesat 6,900V.Systemsoperatingatthisvoltageleveltypicallyusethree6.6kVpower semiconductorsinseriestoachievethenecessaryblockingvoltagemargin.Inthiscosting exercise,theuseoftwo10kVIGCTsisassumed.Thesedevicesaremuchmoreina developmentstagethanthosediscussedtothispointinthereport.Assuch,thecostingof thisconverterandthecommercialavailabilityofsuchpartsremainsarisk.Development IGCTdeviceshavebeenbuiltatthesevoltagelevels,andtheiroperationinmultilevel invertersat6900Varediscussedin[3],[4].Further,thewidebandgapmaterials,suchas siliconcarbide,areidealcandidatesforthehighervoltagedevices.

417

 4.4.2 Converter System Pricing for 7.5-MW MV Turbine Table418Pricingspreadsheetfor7.5MWMVConverterSystem

7.5-MW Permanent Magnet Drive Direct Variable Materials Direct Variable Labor (2) (3) Direct Fixed Costs Total Direct Costs Gross Margin (4) Sales Price
(1)

$ $ $ $ $

139,025.69 2,497.86 1,890.00 143,413.55 20% 179,266.94

$ $ $ $ $

139,025.69 2,497.86 1,890.00 143,413.55 25% 191,218.07

$ $ $ $ $

139,025.69 2,497.86 1,890.00 143,413.55 30% 204,876.50

(1) Annual production = 250 Turbines (2) Includes 3% freight in (3) Assumes 70% utilization and 30% fringe benefits (4) Includes $120k rent, $200k capital equip, $68k utility and $85k supervision (annual costs) (5) Gross Margin = (Sales Price - Direct Cost)/Sales Price

4.4.3 Converter Material Breakdown and BOM for 7.5-MW MV Turbine

MV Voltage Source 7.5-MW Diode-IGCT Converter
1 Padmount Transformer 6900V Secondary 2 3 4 5 6 7 7.5-MW Generator + Gate Drive Board Chopper Side 10 11 Enclosure

3-Phase Line Filter

+ Gate Drive Board Line Side Matrix Control Board & Communication

Subpanel 9

N Included in Converter BOM N Not Included in Converter BOM To Turbine Communication

Figure4117.5MWMVturbineconverterdiagram

418

 Table4197.5MWMVturbineconverterBOM
7.5-MW MV Diode-IGCT Converter BOM Item # Qty Description 1 1 Circuit Breaker, 800A, 10kVAC, 3-Pole, Line Fuse, 800A, 10kVAC, 3-Pole 2 1 3 1 Contactor, 800A, 10kVAC, 3-Pole, Line Line Filter, 3 Phase 4 1 Current Transducers 900A 5 3 Assy, IGCT Matrix, 3-Phase, Line 6 1 Assy, Diode-IGCT Chopper 7 1 8 1 Diode Bridge Subpanel 9 1 10 1 Control Board 11 1 Enclosure TOTAL: Quoted Y Y Y N/A Y N/A N/A N/A N/A Y Y Unit Cost 4,327.00 3,964.00 4,168.00 29,150.00 450.00 49,986.00 24,010.00 10,228.00 4,443.40 1,350.00 2,000.00 Ext Cost 4,327.00 3,964.00 4,168.00 29,150.00 1,350.00 49,986.00 24,010.00 10,228.00 4,443.40 1,350.00 2,000.00 134,976.40

4.4.4 Line Matrix for 7.5-MW MV Turbine AschematicfortheLinematrixcanbeseenunderthe5.0MWdiscussion. Table420Linematrixcosting,7.5MWMVturbine

7.5-MW MV Diode-IGCT Matrix BOM Item # Qty Description 192 Resistor, Balance, 10k, 25W 1 384 Capacitor, 8200uF, 450Vdc 2 12 IGCT, 1200A, 10kV 3 12 Diode, Freewheel, 1200A, 10kV 4 Assy, Laminated Bus 5 1 6 1 Heatsink Cooling Fan 7 1 Fiber-Optic Harness 8 1 TOTAL: Quoted Y Y Y Y Y Y Y Y Unit Cost 3.00 47.00 1,312.00 850.00 1,800.00 3,000.00 500.00 118.00 Ext Cost 576.00 18,048.00 15,744.00 10,200.00 1,800.00 3,000.00 500.00 118.00 49,986.00

4.4.5 Chopper for 7.5-MW MV Turbine Theschematicforthechopperisthesameasinthe5.0MWcostingsection.Costdifferences reflectthedifferentvaluesrequiredfor7.5MWoperation.

419

 Table4217.5MWMVchopperBOM
7.5-MW MV Diode-IGCT Chopper BOM Item # Qty Description Inductor, Chopper, 1mH 900Adc 1 1 IGCT, 1200A, 10kV 2 4 Diode, Chopper, 1200A, 10kV 3 2 Assy, Laminated Bus 4 1 Fiber-Optic Harness 5 1 Heatsink 6 1 Cooling Fan 7 1 TOTAL: Quoted Y Y Y Y Y Y Y Unit Cost 12,000.00 1,312.00 672.00 1,800.00 118.00 3,000.00 500.00 Ext Cost 12,000.00 5,248.00 1,344.00 1,800.00 118.00 3,000.00 500.00 24,010.00

4.4.6 Line Filter for 7.5-MW MV Turbine Costingforthe7.5MWlinefilterisgivenbelow. Table422Linefiltercosting,7.5MWMVturbine

7.5-MW MV Diode-IGCT Filter BOM Item # Qty Description 1 1 Reactor, PWM, 6mH, 700A, 3 Phase, 6900V 2 3 Resistor, Stainless, 3 phase, 0.1 /Phase 3 1 Capacitor, 100 kVAR, 3 Phase, 6900V 4 1 Enclosure TOTAL: Quoted Y Y Y Y Unit Cost 24,000.00 500.00 2,850.00 800.00 Ext Cost 24,000.00 1,500.00 2,850.00 800.00 29,150.00

4.4.7 Converter Subpanel for 7.5-MW MV Turbine Thecomponentsmountedandwiredonthe7.5MWconverterarethesameasinthe5.0 MWcase.

420

 Table423Convertersubpanelcosting,7.5MWMVturbine
7.5-MW MV Diode-IGCT Subpanel BOM Item # Qty Description 1 1 Xfmr, 3 phase Isolation, 6900:240, 5kVA 2 1 Fab, Panel, Power Distribution 3 1 Switch, Disconnect, 80A, 600V, 2p 4 2 Circuit Breaker, 30A, 600V, 3-P 5 3 Fuse, 30A, 600V 6 3 Fuseblock, 100A, 600V 7 2 Capacitor, Electrolytic, 300uF, 250V 8 1 Assy, Harness, Main 9 1 Circuit Breaker, 20A, 600V 10 1 Circuit Breaker, 2A, 600V 11 4 SSR, 12A, 200Vdc, MOSFET OUT 12 250 350 MCM 15kV Cable 13 1 Transformer, Control, 4kVA 1ph TOTAL: Quoted Y Y Y Y Y Y Y Y Y Y Y Y Y Unit Cost 1,500.00 50.00 180.00 120.80 5.00 5.00 15.00 300.00 93.80 70.00 17.00 6.12 350.00 Ext Cost 1,500.00 50.00 180.00 241.60 15.00 15.00 30.00 300.00 93.80 70.00 68.00 1,530.00 350.00 4,443.40

4.4.8 Passive Rectifier for 7.5-MW MV Turbine Thepassiverectifierusestwo10kVdioderectifiersinseriesforeachelement. Table424Passiverectifiercosting,7.5MWMVturbine

7.5-MW MV Diode-IGCT Diode Bridge Rectifier BOM Item # Qty Description 12 Diode, 1200A, 10kV 1 12 Resistor 2 12 Capacitor 3 Heatsink 4 1 5 1 Cooling Fan TOTAL: Quoted Y Y Y Y Y Unit Cost 672.00 12.00 5.00 1,604.00 356.00 Ext Cost 8,064.00 144.00 60.00 1,604.00 356.00 10,228.00

4.5 References 1 Yuan,X.,etal.FundamentalsofaNewDiodeClampingMultiLevelIndicator.IEEE TransactiononPowerElectronics,July2000. 2 IntegratedGateCommutatedThyristorsApplicationNotes.ApplyingIGCTGate Units.ABB,December2002.. 3 Eicher,S.,etal.The10kVIGCTANewDeviceforMediumVoltageDrives. ProceedingsofIEEEIndustryApplicationsSociety,Rome,2000. 4 Lyons,J.,etal.InnovationIGCTMainDrives.ProceedingsofIEEEIndustry ApplicationsSociety,Rome,2000.

421

5 Electrical System Bill of Materials MV, Current-Source Inverter Topology

Inthissection,allturbinesuseanMV,currentsourceinvertertosupplypowerbacktothe lowsideMVconnectiononthepadmounttransformer.Unlikevoltagesourceinverters,the currentsourceinverterrequirestheDCbusvoltagetoremainbelowthepeakoftheAC line.Duringridethroughevents,therectifiedgeneratorvoltage,whichsetstheDCbus voltage,iswellabovethefaultedAClinevoltageandcanleadtouncontrolledcurrentsand afaultcondition.Topreventthissituation,acontrolledrectifierisplacedonthegenerator. ThecontrolledrectifierkeepstheDCbusvoltagebelowthepeakoftheAClineforallline conditions.Acurrentsourceinverterwithacontrolledrectifierallowsformaintainedunit operationduringutilityfaultridethroughconditions.Anotherbeneficialeffectofthe requirementthattheDCbusvoltagebelessthanthepeakoftheAClineisthatthe generatorcanoperatedowntonearzerospeed.Acurrentsourceinverterdesignthus extendsthespeedrangeoftheturbinedrivetrainandslightlyincreasestheenergycapture overtherestrictedspeedrangecase. AsinSection4,NorthAmericanMVelectricalsystemsareassumed.Thespecificvoltages usedare2,400Vat3.0MW;4,160Vat5.0MW;and6,900Vat7.5MW.Thesevoltageswere selectedtokeeptheAClinecurrentsatabout700ampsforallthreeturbines;thisisthemost costeffectiveMVsizing.

5.1 Section Organization

ThissectionisorganizedinthesamewayasSections2.0and3.0.Deviationsfromthesetwo sectionsarepointedout.

5.2 Electrical System BOM for 3.0-MW MV Turbine

Table51liststheelectricalsystemBOMforthe3.0MW,MVturbine.Thematerialcost totalizedatthebottomofthetablewillbecomparedwiththeLVdesignintheCOEmodels ofSection5.

51

 Table513.0MWMVelectricalsystemBOM
# Item Description 3.0 MW, 105 Deg. C rise, 6 pole, open drip-proof, flange mounted, 33% reactance, wye connected, form wound, 97% F.L. efficiency 812 ft. of 5kV shielded, 90 deg C., 600 MCM,normal stranding 143 ft., 5 kV, high stranded, 600 MCM DLO Voltage source inverter per attached included BOM's 3MVA, Oil filled padmount, outdoor rated, 34.5 kV primary, 2400 V wye secondary Total Cost Cost

1 2 3 4 5

Generator Tower Pendant Cables Tower Pendant Cables (festooning) LV Inverter Transformer and Switchgear

$ $ $ $ $ $

114,000 7,578 1,471 83,660 34,212 240,921

5.2.1 Converter System for 3.0-MW MV Turbine The3.0MWMVvariablespeedconvertersystemconsistsofageneratorcontrolledrectifier andcurrentsourceIGCTinvertersystem.Theelectricalsystemconsistsofasinglegenerator outputandsingleconvertersystem.Thisisincontrasttothehighlyparalleledarchitecture oftheLVsystem,whichuses625kWor750kWconvertermodules. Table52Pricingspreadsheetfor3.0MWMVturbine
3.0-MW Synchronous Machine Drive

Direct Variable Materials (2) Direct Variable Labor (3) Direct Fixed Costs Total Direct Costs (4) Gross Margin Sales Price

(1)

$ $ $ $ $

58,881.39 2,135.71 1,728.00 62,745.11 20% 78,431.38

$ $ $ $ $

58,881.39 2,135.71 1,728.00 62,745.11 25% 83,660.14

$ $ $ $ $

58,881.39 2,135.71 1,728.00 62,745.11 30% 89,635.87

(1) Annual production = 250 Turbines (2) Includes 3% freight in (3) Assumes 70% utilization and 30% fringe benefits (4) Includes $120k rent, $200k capital equip, $27k utility and $85k supervision (annual costs) (5) Gross Margin = (Sales Price - Direct Cost)/Sales Price

5.2.2 Converter Material Breakdown and BOM for 3.0-MW MV Turbine Abasicdiagramandmaterialcostsoftheconvertermainassemblyareshownbelow,with subassemblydetailshowninthesubsequentfoursections.Firmquotationsforidentified componentsareidentifiedintheQuotedcolumn,withthebalanceofsubassemblies estimatedbytheprojectteamanddetailedseparately.

52

MV Current Source 3.0-MW Diode-IGCT Drive Topology

1 Padmount Transformer 2400V Secondary 2 3 4 5 6 + 3-Phase Line Filter Overvoltage Protection Subpanel Line Side Matrix Control Board & Communication 2 7 3.0-MW Generator

8 10 Enclosure 9

N N

Included in Converter BOM Not Included in Converter BOM To Turbine Communication

Figure513.0MWMVconverterdiagram Table533.0MWMVconverterBOM
3.0-MW MV Diode-IGCT Converter BOM Item # 1 2 3 4 5 6 7 8 9 10 Unit Cost 3,106.00 2,798.00 2,715.00 8,150.00 100.00 24,538.00 8,046.00 4,163.40 1,350.00 2,000.00 Ext Cost 3,106.00 2,798.00 2,715.00 8,150.00 300.00 24,538.00 8,046.00 4,163.40 1,350.00 2,000.00 57,166.40

Qty 1 1 1 1 3 1 1 1 1 1

Description Circuit Breaker, 800A, 2400VAC, 3-P, Line Fuse, 800A, 2400VAC, 3-Pole Contactor, 800A, 2400VAC, 3-Pole, Line Line Filter, 3 Phase Current Transducers 900A Assy, IGCT Matrix, 3-Phase, Line Assy, Active Rectifier Subpanel Control Board Enclosure TOTAL:

Quoted Y Y Y N/A Y N/A N/A N/A Y Y

53

 5.2.3 Line Matrix for 3.0-MW MV Turbine Thelinesideinvertermatrixisshownbelowandconsistsofsixsymmetrical,6.6kVIGCT devices.TheexistenceofthelargeDClinkreactorpresentspotentialovervoltage conditions.Toprotectagainstthisovervoltagecondition,theprotectioncircuitconsistingof passivediodes,capacitor,andtransientsuppressorisadded.Thisisshownintheschematic below.Thediodesareratedwellbelowthemainconverterdeviceratings.
MV Diode-IGCT Drive 3.0-MW 3-Phase IGCT Line Side Matrix
10 9 8 7

3 A 1 B C Overvoltage Protection

2 4 5

* Note Bus Fixture Assy Not Shown * Note Heatsink Not Shown * Note Cooling Fan Not Shown Fiber-Optic Harness To Turbine Control Board

Figure52Linematrixschematic,3.0MWMVturbine

54

 Table54Linematrixcosting,3.0MWMVturbine
3.0-MW MV Diode-IGCT Matrix BOM Item # 1 2 3 4 5 6 7 8 9 10 Unit Cost 6,000.00 500.00 1,800.00 2,500.00 500.00 118.00 332.00 47.00 3.00 75.00 Ext Cost 6,000.00 500.00 10,800.00 2,500.00 500.00 118.00 3,320.00 470.00 30.00 300.00
24,538.00

Qty 1 1 6 1 1 1 10 10 10 4

Description Inductor, Link, 2mH, 800A Assy, Bus Fixture IGCT, 1200A, 6600V Heatsink Cooling Fan Fiber-Optic Harness Diode, Overvoltage Protection, 6600V, 200A Capacitor, 8200uF, 450Vdc Resistor, Balance, 10k, 25W MOV, 1000V
TOTAL:

Quoted Y Y Y Y Y Y Y Y Y Y

5.2.4 Line Filter for 3.0-MW MV Turbine ThelinefilterforthecurrentsourceinverterisshowninFigure43.Notethatthe componentsarearrangedinadualityarrangementwhencomparedtothevoltagesource inverter;i.e.,parallelcapacitorsareconnectedtotheoutputoftheinverterandthenaseries inductortothetransformer.

Figure53Linefilterschematic,3.0MWMVturbine

55

 Table55Linefiltercosting,3.0MWMVturbine
3.0-MW MV Diode-IGCT Filter BOM Item # 1 2 3 4 Unit Cost 4,000.00 500.00 1,850.00 800.00 Ext Cost 4,000.00 1,500.00 1,850.00 800.00 8,150.00

Qty 1 3 1 1

Description Reactor, Line, 200uH, 750A, 3 Phase, 2400V Resistor, Stainless, 3 phase, 0.1 /Phase Capacitor, 100 kVAR, 3 Phase, 4160V Enclosure TOTAL:

Quoted Y Y Y Y

5.2.5 Converter Subpanel for 3.0-MW MV Turbine Thecurrentsourceinvertersubpanelcontainsthesamecomponentsandelementsasthe voltagesourceinverter.Costingforthesubpanelisprovidedbelow. Table56Convertersubpanelcosting,3.0MWMVturbine

3.0-MW MV Diode-IGCT Sub-Panel BOM Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 Unit Cost 1,500.00 50.00 180.00 120.80 5.00 5.00 15.00 300.00 93.80 70.00 17.00 5.00 350.00 Ext Cost 1,500.00 50.00 180.00 241.60 15.00 15.00 30.00 300.00 93.80 70.00 68.00 1,250.00 350.00 4,163.40

Qty 1 1 1 2 3 3 2 1 1 1 4 250 1

Description Xfmr, 3 phase Isolation, 2400:240, 5kVA Fab, Panel, Power Distribution Switch, Disconnect, 80A, 600V, 2p Circuit Breaker, 30A, 600V, 3-P Fuse, 30A, 600V Fuseblock, 100A, 600V Capacitor, Electrolytic, 300uF, 250V Assy, Harness, Main Circuit Breaker, 20A, 600V Circuit Breaker, 2A, 600V SSR, 12A, 200Vdc, MOSFET OUT 350 MCM 15kV Cable Transformer, Control, 4kVA 1ph TOTAL:

Quoted Y Y Y Y Y Y Y Y Y Y Y Y Y

5.2.6 Controlled Rectifier for 3.0-MW MV Turbine Thecontrolledrectifierisuniquetothecurrentsourceinverter.Theoperationisquite simple.Duringnormalrunningconditions,thecontrolledrectifierisfiredatazerodegree delayangle;thisisequivalenttopassiverectifieroperation.Underatransmissionride throughevent,however,therectifierisphasedbacktoreducetheDCbusvoltagetoprevent uncontrolledcurrentflow.Thecontrolledrectifieruses6.6kVSCRdevicesandappropriate triggeringandcontrolboardsubassemblies.

56


MV Diode-IGCT Drive 3.0-MW 3-Phase Controlled Rectifier
+

2 3 4

1 * Note Bus Fixture Assy Not Shown A * Note Heatsink Not Shown * Note Cooling Fan Not Shown B C

5 Fiber-Optic Harness To Turbine Control Board

Figure54Controlledrectifier,3.0MWMVturbine Table57Controlledrectifiercosting,3.0MWMVturbine
3.0-MW MV Diode-IGCT Controlled Rectifier BOM Item # Qty Description SCR, 800A, 6600V 6 1 Bus Fixture Assy 2 1 3 1 Heatsink, Clamps, Terminations Cooling Fan and Switchgear 4 1 Fiber-Optic Harness 5 1 TOTAL: Quoted Y Y Y Y Y Unit Cost 832.00 1,208.00 1,372.00 356.00 118.00 Ext Cost 4,992.00 1,208.00 1,372.00 356.00 118.00 8,046.00

5.3 Electrical System BOM for 5.0-MW MV Turbine

Table 58 lists the electrical system BOM for the 5.0MW, MV turbine. The material cost totalizedatthebottomofthetablewillbecomparedwiththeLVandMVdesigns inthe COEmodelsofSection5.

57

 Table585.0MWMVelectricalsystemBOM
# Item Description 5.0 MW, 105 Deg. C rise, 6 pole, open drip-proof, flange mounted, 33% reactance, wye connected, form wound, 97% F.L. efficiency 8354 ft. of 5kV shielded, 90 deg C., 500 MCM, normal stranding 184 ft., 5 kV, high stranded, 500 MCM DLO Voltage source inverter per attached included BOM's 5MVA, Oil filled padmount, outdoor rated, 34.5 kV primary, 4160 V wye secondary Total Cost Cost

1 2 3 4 5

Generator Tower Pendant Cables Tower Pendant Cables (festooning) LV Inverter Transformer and Switchgear

$ $ $ $ $ $

164,000 7,795 1,513 115,240 41,354 329,902

5.3.1 Converter System for 5.0-MW MV Turbine The5.0MWMVvariablespeedconvertersystemconsistsofageneratorcontrolledrectifier andcurrentsourceIGCTbasedinvertersystem.Theelectricalsystemconsistsofasingle generatoroutputandsingleconvertersystem.Thehighervoltage(i.e.,4160V)system requiresseriesconnectionofpowersemiconductors.Pricingforthe5.0MWconverter systemisprovidedinthissection. Table59Convertersystempricingspreadsheet,5.0MWMVturbine
5.0-MW Synchronous Machine Drive Direct Variable Materials (2) Direct Variable Labor Direct Fixed Costs (3) Total Direct Costs (4) Gross Margin Sales Price
(1)

$ $ $ $ $

82,466.33 2,163.57 1,800.00 86,429.90 20% 108,037.38

$ $ $ $ $

82,466.33 2,163.57 1,800.00 86,429.90 25% 115,239.87

$ $ $ $ $

82,466.33 2,163.57 1,800.00 86,429.90 30% 123,471.29

(1) Annual production = 250 Turbines (2) Includes 3% freight in (3) Assumes 70% utilization and 30% fringe benefits (4) Includes $120k rent, $200k capital equip, $45k utility and $85k supervision (annual costs) (5) Gross Margin = (Sales Price - Direct Cost)/Sales Price

5.3.2 Converter Material Breakdown and BOM for 5.0-MW MV Turbine Abasicdiagramandmaterialcostsofthe5.0MWconvertermainassemblyareshownin Figure45.

58

MV Current Source 5.0-MW Diode-IGCT Drive Topology

5.0-MW Generator

1 Padmount Transformer 4160V Secondary

6 +

3-Phase Line Filter Overvoltage Protection Subpanel Line Side Matrix

8 10 Enclosure 9

Control Board & Communication

N N

Included in Converter BOM Not Included in Converter BOM To Turbine Communication

Figure555.0MWMVconverterdiagram Table5105.0MWMVconverterBOM
5.0-MW MV Diode-IGCT Converter BOM Item # Qty Description Circuit Breaker, 800A, 5kVAC, 3-Pole, Line 1 1 Fuse, 800A, 5kVAC, 3-Pole 2 1 3 1 Contactor, 800A, 5kVAC, 3-Pole, Line Line Filter, 3 Phase 4 1 Current Transducers 900A 5 3 Assy, IGCT Matrix, 3-Phase, Line 6 1 Assy, Active Rectifier 7 1 Subpanel 8 1 9 1 Control Board 10 1 Enclosure TOTAL: Quoted Y Y Y N/A Y N/A N/A N/A Y Y Unit Cost 3,106.00 2,798.00 2,715.00 9,150.00 100.00 41,008.00 13,474.00 4,163.40 1,350.00 2,000.00 Ext Cost 3,106.00 2,798.00 2,715.00 9,150.00 300.00 41,008.00 13,474.00 4,163.40 1,350.00 2,000.00 80,064.40

5.3.3 Line Matrix for 5.0-MW MV Turbine The5.0MWlinesideinvertermatrixisshowninFigure46.Theconfigurationisidenticalto the3.0MWsystem;however,notetheuseoftwo6.6kVsymmetricalIGCTsinseries.Also, 59

 intheovervoltageprotectioncircuit,6.6kVdiodesareinseriestoachievethenecessary blockingvoltagecapability.
MV Diode-IGCT Drive 5.0-MW 3-Phase IGCT Line Side Matrix
10 9 8 7

A 1 B C

Overvoltage Protection

2 4 5

* Note Bus Fixture Assy Not Shown * Note Heatsink Not Shown * Note Cooling Fan Not Shown Fiber-Optic Harness To Turbine Control Board

Figure56Linematrixschematic,5.0MWMVturbine

510

 Table511Linematrixcosting,5.0MWMVturbine
5.0-MW MV Diode-IGCT Matrix BOM Item # Qty Description 1 1 Inductor, Link, 2mH, 800A Assy, Bus Fixture 2 1 12 IGCT, 1200A, 6600V 3 Heatsink 4 1 Cooling Fan 5 1 Fiber-Optic Harness 6 1 20 Diode, Overvoltage Protection, 6600V, 200A 7 14 Capacitor, 8200uF, 450V Electrolytic 8 14 Resistor, Balance, 10k, 25W 9 10 6 MOV, 1000V TOTAL: Quoted Y Y Y Y Y Y Y Y Y Y Unit Cost 8,000.00 500.00 1,800.00 2,500.00 500.00 118.00 332.00 47.00 3.00 75.00 Ext Cost 8,000.00 500.00 21,600.00 2,500.00 500.00 118.00 6,640.00 658.00 42.00 450.00 41,008.00

5.3.4 Line Filter for 5.0-MW MV Turbine Thelinefilterforthe5.0MWconverteriscostedbelow.Aschematicisnotincludedasthe circuitisthesameasinthe3.0MWcase. Table512Linefiltercosting,5.0MWMVturbine

5.0-MW MV Diode-IGCT Filter BOM Item # Qty Description 1 1 Reactor, Line, 200uH, 750A, 3 Phase, 2400V Resistor, Stainless, 3 phase, 0.1 /Phase 2 3 3 1 Capacitor, 100 kVAR, 3 Phase, 7200V Enclosure 4 1 TOTAL: Quoted Y Y Y Y Unit Cost 4,000.00 500.00 2,850.00 800.00 Ext Cost 4,000.00 1,500.00 2,850.00 800.00 9,150.00

5.3.5 Converter Subpanel for 5.0-MW MV Turbine Thesubpanelcostsinthe5.0MWcasearethesameasinthe3.0MWcase.

511

 Table513Convertersubpanelcosting,5.0MWMVturbine
5.0-MW MV Diode-IGCT Sub-Panel BOM Item # Qty Description 1 1 Xfmr, 3 phase Isolation, 2400:240, 5kVA 2 1 Fab, Panel, Power Distribution 3 1 Switch, Disconnect, 80A, 600V, 2p 4 2 Circuit Breaker, 30A, 600V, 3-P 5 3 Fuse, 30A, 600V 6 3 Fuseblock, 100A, 600V 7 2 Capacitor, Electrolytic, 300uF, 250V 8 1 Assy, Harness, Main 9 1 Circuit Breaker, 20A, 600V 10 1 Circuit Breaker, 2A, 600V 11 4 SSR, 12A, 200Vdc, MOSFET OUT 12 250 350 MCM 15kV Cable 13 1 Transformer, Control, 4kVA 1ph TOTAL: Quoted Y Y Y Y Y Y Y Y Y Y Y Y Y Unit Cost 1,500.00 50.00 180.00 120.80 5.00 5.00 15.00 300.00 93.80 70.00 17.00 5.00 350.00 Ext Cost 1,500.00 50.00 180.00 241.60 15.00 15.00 30.00 300.00 93.80 70.00 68.00 1,250.00 350.00 4,163.40

5.3.6 Controlled Rectifier for 5.0-MW MV Turbine Aschematicforthecontrolledrectifierinthe5.0MWconverterisprovidedbelowto emphasizetheseriesdevicerequirementsinthisportionofthecircuit.

512


MV Diode-IGCT Drive 5.0-MW 3-Phase Controlled Rectifier
+ 1 2 3 4 * Note Bus Fixture Assy Not Shown * Note Heatsink Not Shown * Note Cooling Fan Not Shown A B 5 6 C

7 Fiber-Optic Harness To Turbine Control Board

Figure57Controlledrectifier,5.0MWMVturbine Table514Controlledrectifiercosting,5.0MWMVturbine
5.0-MW MV Diode-IGCT Controlled Rectifier BOM Item # Qty Description 12 SCR, 800A, 6600V 1 Bus Fixture Assy 2 1 3 1 Heatsink Cooling Fan 4 1 12 Balancing Resistor 5 12 Balancing Capacitor 6 Fiber-Optic Harness 7 1 TOTAL: Quoted Y Y Y Y Y Y Y Unit Cost 832.00 1,208.00 1,604.00 356.00 12.00 5.00 118.00 Ext Cost 9,984.00 1,208.00 1,604.00 356.00 144.00 60.00 118.00 13,474.00

5.4 Electrical System BOM for 7.5-MW MV Turbine

Table416liststheelectricalsystemBOMforthe7.5MW,MVturbine.Thematerialcost totalizedatthebottomofthetablewillbeusedtocompareLVandMVdesignsintheCOE modelsofSection5.

513

 Table5157.5MWMVelectricalsystemBOM
# Item Description 7.5 MW, 105 Deg. C rise, 6 pole, open drip-proof, flange mounted, 33% reactance, wye connected, form wound, 97% F.L. efficiency 1285 ft. of 5/8kV shielded, 90 deg C., 500 MCM, normal stranding 227 ft., 5/8 kV, high stranded, 500 MCM DLO Voltage source inverter per attached included BOM's 7.5MVA, Oil filled padmount, outdoor rated, 34.5 kV primary, 6900 V wye secondary Total Cost Cost

1 2 3 4 5

Generator Tower Pendant Cables Tower Pendant Cables (festooning) LV Inverter Transformer and Switchgear

$ $ $ $ $ $

248,312 9,589 1,862 136,885 51,050 447,698

5.4.1 Converter System for 7.5-MW MV Turbine Materialcostingforthisconverterisdetailedbelow.Notethattheschematicsandfigure,as wellassubassemblyBOMs,arenotincludedinthissectionastheyareidenticaltothe correspondingsubassembliesinthe3.0MWconvertersection(bothsystemsuse750kW convertermodules).Forexample,theinvertertopology,thelinefilter,subpanel,etc.are identicaltothe3.0MWsystemandarecostedthesame. Table516Convertersystempricingspreadsheet,7.5MWMVturbine
7.5-MW Synchronous Machine Drive
Direct Variable Materials (2) Direct Variable Labor (3) Direct Fixed Costs Total Direct Costs (4) Gross Margin Sales Price
(1)

$ $ $ $ $

98,700.16 2,163.57 1,800.00 102,663.73 20% 128,329.67

$ $ $ $ $

98,700.16 2,163.57 1,800.00 102,663.73 25% 136,884.98

$ $ $ $ $

98,700.16 2,163.57 1,800.00 102,663.73 30% 146,662.48

(1) Annual production = 250 Turbines (2) Includes 3% freight in (3) Assumes 70% utilization and 30% fringe benefits (4) Includes $120k rent, $200k capital equip, $45k utility and $85k supervision (annual costs) (5) Gross Margin = (Sales Price - Direct Cost)/Sales Price

5.4.2 Converter Material Breakdown and BOM for 7.5-MW MV Turbine Abasicdiagramandmaterialcostsoftheconvertermainassemblyareshownbelow,with subassemblydetailshowninthesubsequentfoursections.Firmquotationsforidentified componentsareidentifiedintheQuotedcolumn.

514

MV Current Source 7.5-MW Diode-IGCT Drive Topology

1 Padmount Transformer 6900V Secondary 2 3 4 5 6 + 3-Phase Line Filter Overvoltage Protection Subpanel Line Side Matrix Control Board & Communication 2 7 7.5-MW Generator

8 10 Enclosure 9

N N

Included in Converter BOM Not Included in Converter BOM To Turbine Communication

Figure587.5MWMVconverterdiagram Table5177.5MWMVturbineconverterBOM
7.5-MW MV Diode-IGCT Converter BOM Item # 1 2 3 4 5 6 7 8 9 10 Unit Cost 4,327.00 3,964.00 4,168.00 9,150.00 100.00 49,268.00 17,135.00 4,163.40 1,350.00 2,000.00 Ext Cost 4,327.00 3,964.00 4,168.00 9,150.00 300.00 49,268.00 17,135.00 4,163.40 1,350.00 2,000.00 95,825.40

Qty 1 1 1 1 3 1 1 1 1 1

Description Circuit Breaker, 800A, 5kVAC, 3-Pole, Line Fuse, 800A, 5kVAC, 3-Pole Contactor, 800A, 5kVAC, 3-Pole, Line Line Filter, 3 Phase Current Transducers 900A Assy, IGCT Matrix, 3-Phase, Line Assy, Active Rectifier Subpanel Control Board Enclosure TOTAL:

Quoted Y Y Y N/A Y N/A N/A N/A Y Y

515

 5.4.3 Line Matrix for 7.5-MW MV Turbine Aschematicofthelinematrixforthe7.5MWconvertersystemisnotincludedhere,butitis includedinthe5.0MWsectionofthisreport.The7.5MWsystemusestwoseriesdevices justasinthe5.0MWcase,butthesedevicesareratedat10kVinthe7.5MWcase. Table518Linematrixcosting,7.5MWMVturbine
7.5-MW MV Diode-IGCT Matrix BOM Item # 1 2 3 4 5 6 7 8 9 10 Unit Cost 12,000.00 500.00 1,800.00 2,500.00 500.00 118.00 510.00 47.00 3.00 75.00 Ext Cost 12,000.00 500.00 21,600.00 2,500.00 500.00 118.00 10,200.00 1,034.00 66.00 750.00

Qty 1 1 12 1 1 1 20 22 22 10

Description Inductor, Link, 2mH, 800A Assy, Bus Fixture IGCT, 1200A, 10kV Heatsink Cooling Fan Fiber-Optic Harness Diode, Overvoltage Protection, 10kV, 200A Capacitor, 8200uF, 450V Electrolytic Resistor, Balance, 10k, 25W MOV, 1000V

Quoted Y Y Y Y Y Y Y Y Y Y

TOTAL:

49,268.00

5.4.4 Line Filter for 7.5-MW MV Turbine Thelinefilterschematicisthesameasinthe3.0MWand5.0MWcases.Costingforthe7.5 MWlinefilterisprovidedbelow. Table519Linefiltercosting,7.5MWMVturbine

7.5-MW MV Diode-IGCT Filter BOM Item # 1 2 3 4 Unit Cost 4,000.00 500.00 2,850.00 800.00 Ext Cost 4,000.00 1,500.00 2,850.00 800.00 9,150.00

Qty 1 3 1 1

Description Reactor, Line, 200uH, 750A, 3 Phase, 2400V Resistor, Stainless, 3 phase, 0.1 /Phase Capacitor, 100 kVAR, 3 Phase, 7200V Enclosure TOTAL:

Quoted Y Y Y Y

5.4.5 Converter Subpanel Costing for 7.5-MW MV Turbine Thesubpanelstructureandcostforthe7.5MWconverteristhesameasthe3.0and5.0 MWsystems.

516

 Table520Convertersubpanelcosting,7.5MWMVturbine
7.5-MW MV Diode-IGCT Subpanel BOM Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 Unit Cost 1,500.00 50.00 180.00 120.80 5.00 5.00 15.00 300.00 93.80 70.00 17.00 5.00 350.00 Ext Cost 1,500.00 50.00 180.00 241.60 15.00 15.00 30.00 300.00 93.80 70.00 68.00 1,250.00 350.00 4,163.40

Qty 1 1 1 2 3 3 2 1 1 1 4 250 1

Description Xfmr, 3 phase Isolation, 2400:240, 5kVA Fab, Panel, Power Distribution Switch, Disconnect, 80A, 600V, 2p Circuit Breaker, 30A, 600V, 3-P Fuse, 30A, 600V Fuseblock, 100A, 600V Capacitor, Electrolytic, 300uF, 250V Assy, Harness, Main Circuit Breaker, 20A, 600V Circuit Breaker, 2A, 600V SSR, 12A, 200Vdc, MOSFET OUT 350 MCM 15kV Cable Transformer, Control, 4kVA 1ph TOTAL:

Quoted Y Y Y Y Y Y Y Y Y Y Y Y Y

5.4.6 Controlled Rectifier Costing for 7.5-MW MV Turbine The7.5MWturbinecontrolledrectifierisidenticaltothe5.0MWcaseinthatitusestwo seriesSCRstoachievethenecessaryblockingvoltagemargin.Inthe7.5MWcase,however, thedevicesareratedat10kV. Table521Controlledrectifiercosting,7.5MWMVturbine
7.5-MW MV Diode-IGCT Controlled Rectifier BOM Item # 1 2 3 4 5 6 7 Unit Cost 1,087.00 1,809.00 1,604.00 356.00 12.00 5.00 118.00 Ext Cost 13,044.00 1,809.00 1,604.00 356.00 144.00 60.00 118.00 17,135.00

Qty 12 1 1 1 12 12 1

Description SCR, 800A, 10kV Bus Fixture Assy Heatsink Cooling Fan Balancing Resistor Balancing Capacitor Fiber-Optic Harness TOTAL:

Quoted Y Y Y Y Y Y Y

517

6 Comparison of COE Estimates and Conclusions

Inthissection,thecostsofthevarioussystemspresentedinthisreportarecomparedand contrastedintabularformat.Theinfluenceofthedesignsonannualenergyproduction (AEP)andCOEisalsopresentedandaseriesofstudyconclusionsispresentedbasedon thesespecificlineitems,allofwhichsummarizethestudiesfindings.

6.1 Cost Comparisons, AEP, and COE Estimates for the Study
Table5.1summarizesandcontraststhecostsoftheLVandMVdesignsdiscussedinthis reportforthe3.0MW,5.0MW,and7.5MWturbines.AlsoshowninthetableareAnnual EnergyProduction(AEP)estimatesfortheturbinesin5.8m/secand6.7m/secaveragewind speedsites.COEestimatesatthesewindspeedsarealsoprovidedforturbinesassumingthe turbinedesignfeatures,aspresentedinSection1ofthisreport.CopiesofthedetailedCOE spreadsheetsareprovidedinAppendixA. ThebaselineturbinestandardizedintheNRELCOEcalculationsisbasedon2002dollars. Forequivalentcomparisonpurposes,Table5.2containsthesamecostdataasTable5.1, adjustedto2002dollars.AllcomponentshavebeenadjustedbasedontheU.S.Department ofLaborBureauofLaborStatisticsProducerPriceIndex(PPI)forindustrialcommodities, excludingfuel,fromJanuary2002throughJanuary2005.Inaddition,certaincomponents havehighcontentsofcopperandsteel,commoditiesthathaveexperiencedsignificantly higherpriceincreasesrelativetothemoregeneralindex.Thecostsforthesematerialshave beenadjustedusingthespecificPPIdataforthosecommoditiesoverthesametimeperiod. AppendixBcontainsthesameCOEspreadsheetsprovidedinAppendixAbutexpressedin 2002dollars

61

 Table61Capitalcost,AEP,andCOEestimates(in2005dollars)
Low Voltage (575V) Generator Tower Pendant Cables (Building Wire) Tower Pendant Cables (15% Hi-Flex Wire) Converter Transformer & Switchgear TOTAL: AEP MWh @ 5.8m/s AEP MWh @ 6.7m/s COE $/kWh @ 5.8m/s COE $/kWh @ 6.7m/s COE Reduction in %@5.8m/s COE Reduction in %@6.7m/s 114,000 18,932 3,712 139,275 34,318 310,237 9522 11722 0.0496 0.0403 3 MW Medium Voltage Voltage Source Current Source (2400V) (2400V) 114,000 7,578 1,471 110,494 34,212 267,755 9522 11722 0.0490 0.0398 -1.1% -1.2% 114,000 7,578 1,471 83,660 34,212 240,921 9522 11722 0.0487 0.0396 -1.8% -1.7% Low Voltage (575V) 164,000 48,681 9,546 265,128 45,911 533,266 16736 20340 0.0600 0.0494 5 MW Medium Voltage Voltage Source Current Source (4160V) (4160V) 164,000 7,795 1,513 146,167 41,354 360,829 16736 20340 0.0587 0.0483 -2.1% -2.1% 164,000 7,795 1,513 115,240 41,354 329,902 16736 20340 0.0585 0.0482 -2.4% -2.4% Low Voltage (575V) 241,000 74,857 14,677 345,858 62,445 738,837 26360 31648 0.0591 0.0492 7.5 MW Medium Voltage Voltage Source Current Source (6900V) (6900V) 248,312 9,589 1,862 191,218 51,050 502,031 26360 31648 0.0580 0.0483 -1.8% -1.8% 248,312 9,589 1,862 136,885 51,050 447,698 26360 31648 0.0578 0.0481 -2.2% -2.2%

AEPestimatesbasedonL.J.Fingersh,NREL/NWTCWeibulBetzAEPworksheet,July2004 COEestimatesbasedonA.Laxson,NREL/NWTCCOEProjectionsheet,July2004

62

 Table62Capitalcost,AEP,andCOEestimatesagainstbaseline(in2002dollars)
1.5 MW Baseline Low Voltage 3 MW Medium Voltage Voltage Source Current Source (2400V) (2400V) 81,006 5,944 1,154 90,259 24,310 202,673 9522 11722 0.0482 0.0398 0.9% -0.7% -1.0% -2.6% -0.1% -3.3% 81,006 5,944 1,154 68,640 24,310 181,054 9522 11722 0.0480 0.0396 1.4% -0.2% 0.5% -2.8% -22.6% -26.3% Low Voltage 5 MW Medium Voltage Voltage Source Current Source (4160V) (4160V) 116,534 6,114 1,187 119,052 29,385 272,272 16736 20340 0.0581 0.0478 1.7% 1.7% -20.6% -24.2% 116,534 6,114 1,187 94,134 29,385 247,354 16736 20340 0.0579 0.0477 2.0% 2.0% -20.2% -23.8% -21.0% -26.1% Low Voltage 7.5 MW Medium Voltage Voltage Source Current Source (6900V) (6900V) 176,444 7,522 1,461 155,411 36,275 377,113 26360 31648 0.0574 0.0478 1.5% 1.5% -19.2% -24.2% 176,444 7,522 1,461 111,573 36,275 333,275 26360 31648 0.0572 0.0477 1.8% 1.8% -18.8% -23.8%

(575V) Generator Tower Pendant Cables (Building Wire) Tower Pendant Cables (15% Hi-Flex Wire) Converter Transformer & Switchgear TOTAL: AEP MWh @ 5.8m/s AEP MWh @ 6.7m/s COE $/kWh @ 5.8m/s COE $/kWh @ 6.7m/s COE Reduction vs Low Voltage COE Reduction in %@5.8m/s COE Reduction in %@6.7m/s COE Reduction vs Baseline COE Reduction in %@5.8m/s COE Reduction in %@6.7m/s 97,500 21,180 4,140 100,500 34,680 258,000 4439 5554 0.0482 0.0385 81,006 14,850 2,912 113,447 24,386 236,601 9522 11722 0.0486 0.0395

(575V) 116,534 38,185 7,488 214,920 32,623 409,750 16736 20340 0.0591 0.0486

(575V) 171,249 58,717 11,513 280,161 44,372 566,012 26360 31648 0.0583 0.0486

AEPestimatesbasedonL.J.Fingersh,NREL/NWTCWeibulBetzAEPworksheet,July2004 COEestimatesbasedonA.Laxson,NREL/NWTCCOEProjectionsheet,July2004 Costadjustmentfrom2005to2002dollarsbasedonrelevantProducerPriceIndices,U.S.DeptofLabor,BureauofLabor Statistics

63

6.2

Summary of Conclusions

Discussionisprovidedbelowonthecapitalcost,AEP,andCOEestimates. 6.2.1 Capital Cost Discussion IntheMVturbineclass,asignificantcapitalcostadvantagegoestoMVsystemswhen comparedtotraditionalLVsystems.The3.0MWturbineshowsacapitalcostreductionof 14%,whilethelargestturbine,rated7.5MW,showsthemostsubstantialcostreduction, approximately40%.TheaveragecapitalcostreductionofMV,voltagesourcesystems acrossthisclassofMWratingsis20%comparedtoLVsystems.MV,currentsource systemsshowanaverage33%capitalcostreductioncomparedtotheLVsystems.The largercostreductionsareskewedtowardlargersystems,whichisinlinewithtraditional thinking. OtherconsiderationswhenexaminingthecostreductionlevelsoftheMVequipmentclass are: o TheperceivedtechnicalriskinthedevelopmentofMVconvertersystemsisa concerntoturbinemanufacturersandoperators.Itisimportanttopointout, however,thatmanyofthehistorictechnicalproblemshavebeenovercomeinrecent yearsbytechnologicaladvances.Thisincludes,forexample,highervoltagepower semiconductors(6.6and10kV)andincreasedswitchingspeedsofthose semiconductors.TheIGCTimprovementsovertheGTOareagoodexampleofthe latter.Further,aratherrichandsuccessfulhistoryoftheseconvertersindemandside applicationsatthevoltagesandpowerlevelsdiscussedhereexistsandcanbedrawn upontoblunttheperceivedconcerns.Theseconverterssimplyhavenotbeen extendedtowindturbinesyet.Further,theIGCTreliabilityneedstobeconsidered againstthatoftheIGBTusedintheLVdesign.Anexhaustivestudyhasnotbeen performedhere;however,themonolithicnatureoftheIGCTwouldnormallygivea significantreliabilityadvantagetothatdevice.However,thegatedriveboardforthe IGCTisconsiderablymorecomplexwithmuchalargerpartcountandstandsin starkcontrasttotheverysimpleIGBTdriver.Anexampleofafirstlevelreliability comparisonisgiveninreference[2]fromSection3. o Thenewridethroughrequirementscreateanewandchallengingsetofissuesonthe convertersystems.Theclassofvoltagesourceinvertersinherentlydealswiththis requirement,andthecurrentsourceinvertercanbereadilyadaptedtoovercomeits inherentshortcomingsinthisarea.Also,verylittlehistoryexistswitheithervoltage

64

 orcurrentsourceequipmentmeetingthistypeofrequirementinthedemandside applicationmentionedabove.Moreworkisrequiredtofullyunderstandthe performanceofbothvoltagesourceandcurrentsourceconvertersduringperiodsof ridethrough. o ThependantcablelineiteminthecapitalcostsectionofTable5.1showsasubstantial reductioninpendantcablecostssimplyduetothereducedamountofcopperbeing used.WhiletheMVpendantcableisquiteabitmorecomplexinitsinsulation systemapproachthantheLVcable,thereisjustasignificantlylesseramountoftotal cableusedintheMVsystems. o ThereislittledifferenceinpadmounttransformercostwhenmovingfromLVtoMV systems.Differentcostpatternsamongvariousmanufacturerswouldbenoticeable, butinallcasestherewasnosignificantcostdifference. 6.2.2 AEP Estimates TheAEPlineitemsinTable5.1showthesameenergycaptureindependentofturbine electricalsystem.Attheratherhighlevelofanalysisusedinthisstudy,nocompelling improvementinsystemefficiencywasfoundtoexistatmediumvoltage.Theconverter efficiencywasaboutthesameinLVandMVconverters,generators,pendantcables,and transformerefficiencydatawereessentiallythesame.Smalladvantageswereoffsetby disadvantageselsewhere.Amoredetailedanalysismayrevealanadvantagetoonesystem ortheother,butifitcouldbefound,itisexpectedtobequitesmallwithnomeaningful positiveimpactonenergycapture.Thesecommentsarenottobeconfusedwithincreasing energyefficiencyonallofthedescribedsystems,whichisachievable(butatanincreased capitalcost). 6.2.3 COE Estimates AnumberofimportantpointsmustbemaderelativetotheCOElineiteminTable5.1. o MVsystemsshowareductionintheCOErangingfromabout1.2%to2.5%over comparableLVsystems.However,theabsoluteCOElineiteminthetableshouldbe viewedwithsomeuncertainty.Duringthestudyperiod(approximately9months), commoditypricesincreasedsubstantially,andcostscalingrelationshipsusedinnon electricalsystemcomponentsbecamequitevolatile.Ontheelectricalside,the componentsmostaffectedbycommoditypricesarethegenerator,pendantcables, andtransformers.Present,accuratecostingisincludedfortheselineitems,buttheir costsarehigherthanthoseusedatthebeginningofthestudybecauseofinflationary

65

 commoditypressures.Theseinflationarypressuresalsoputthebaseline1.5MW machinecapitalcostandCOEinquestionatthistimeasthismachinewasaddedto themodelsometimeago.Convertersystemcostincreaseshavebeenmostly unaffectedbycommodityprices,butwheretheyexist,theseareincludedinthe costingasshown. o TheCOEestimatesincludeinstallationlineitems,whicharedominatedby mechanicalerectionandfoundationcosts.Asmallcomponentofthislineitem involveselectricalinterconnect,however.OneexpressedconcernwithMV equipmentisthatcostsassociatedwiththeseactivitieswouldriseduetoincreased skilllevelandpersonnelwages.Thisisaverycomplexquestioninvolvingmany factors.Tolookatthisinatractableway,asimplependantcableterminationanalysis wasperformed.ThedetailsforthisanalysisareincludedinAppendixB.The comparisoninvolveslargenumberofsimple,lowcost,LVterminationsversusa smallnumberofhighercostcomplexterminations.TheanalysisintheAppendix showsthatat3.0MW,thereisnoclearadvantageintheterminationinstallation costs.At7.5MWhowever,thedifferenceincreasesquiteabit,butreallynotinaway thatwoulddriveCOE.Recallthatthewayvoltageswereselected,leadingtothe samesizeandnumberofMVcables,theterminationofMVsystemsisthesameat 3.0,5.0,and7.5MW. o Maintenancecostismoredifficulttoanalyzethaninstallationcost.Clearlythe requiredskilllevelincreasesfortheelectriciansworkingontheequipment,andan approximate10%12%wageaddergoeswithit(seeSection1).However,a reliabilityanalysis(notperformedinthisstudy)wouldlikelyrevealthatbecauseof significantlyreducedpartcountoverLVequipment,reliabilityshouldincreaseand unscheduledturbinevisitsshoulddecrease.Intheextreme,however,without reliabilityenhancement,thelaborcontentofelectricalmaintenanceinmostturbine maintenancemodelsissosmallthata10%12%increaseandevena100%increase duetotwomencrewsstillhasverylittleimpactonthemaintenancelineitemand thereforeCOE.Inotherwords,themajorityofthemaintenancecostshavenothing todowithelectricalissuesdrivenbyMVorLVoperation. o AcomparisonofMVturbinesagainstthe2002Baseline1.5MWturbineisalso providedinTable5.2.Thistableincorporatestheresultsfromthisstudywith2002 costinglevelstooffsettherecentrunupincommodityprices.Tworowsatthe bottomcomparelowvoltagetomedium,whichshowthefavorableeffectsoftheMV apparatus.Thebottomrowsareacomparisonagainstthebaselineturbine,andthese areshownunfavorablewithregardtoCOE,owingentirelytothesimplescalinglaws appliedtothesizeandcostofnonelectricalcomponents(i.e.,therotor,tower,

66

 foundationandotherstructural/mechanicalcomponents).OtherNRELstudieshave describedthis,andwhendesignsarecompletedandmovepastthesimplescaling laws,COEshavehistoricallygonedown.Thissamephenomenonisexpectedto occurhereintheeventthatathoroughdesignprocesswouldbefollowed.Afurther complicationinvolvesthedoublyfedsystemusedinthebaseline.Itwouldnotmeet thenewstringentridethroughrequirementsasdiscussedinthisstudy,makingan exactcomparisondifficult. AppendixCprovidesanapplicationspecificationdevelopedtosolicitdataandfeedback frommanufacturersandvendors.

67

Appendix A COE Details Using 2005 Dollars for Components Included within Study
Thefollowingthreetablesdetailcapitalcost,operationandmaintenancecosts,annual energyproduction,andCOEforthreeconfigurations: o LowVoltage,VoltageSource o MediumVoltage,VoltageSource o MediumVoltage,CurrentSource. InthisAppendix,componentsincludedinthisstudywerecostedin2005dollars. Costsfornonelectricalcomponentsnotdirectlysizedandcostedinthisstudywerescaled fromtheWindPACTTurbineRotorDesignStudyJune2000June2002(Malcolm,D.J.,and Hansen,A.C.NationalRenewableEnergyLaboratory,NREL/SR50032495,August2002).

A1


Turbine Rating (kW) Component TURBINE CAPITAL COST (TCC) 1500 Baseline Component Costs $1000 248 148 64 36 563 20 12 151 3 98 101 12 64 60 7 36 10 101 921 3000 Projected Component Component Normalized % Costs $1000 Improvement 727 46.9% 437 47.8% 213 65.9% 77 8.3% 1,077 -4.3% 56 41.0% 41 66.4% 357 18.3% 6 0.5% 114 -41.5% 141 -29.9% 28 15.8% 192 50.0% 57 -52.5% 14 3.7% 71 -1.1% 10 -50.0% 303 50.0% 2,117 14.9% 5000 Projected Component Component Normalized % Costs $1000 Improvement 1,484 79.9% 906 83.9% 429 100.5% 149 25.7% 2,151 14.7% 121 82.8% 102 148.4% 697 38.6% 10 0.5% 164 -49.5% 267 -20.4% 110 172.9% 434 103.5% 104 -47.9% 23 2.2% 119 -0.6% 11 -67.0% 647 92.1% 4,293 39.8% 7500 Projected Component Component Normalized % Costs $1000 Improvement 2,356 90.4% 1,440 94.9% 688 114.4% 228 28.3% 3,272 16.3% 192 93.4% 164 166.3% 1,081 43.3% 15 0.5% 241 -50.6% 348 -30.8% 174 187.8% 692 116.3% 152 -49.3% 35 3.7% 178 -0.8% 12 -76.0% 1,030 104.0% 6,670 44.8% BALANCE OF STATION COST (BOS) 162 1,472 981 690 16 31 39 5 4439 5554 11.85% 0.0482 0.0385 324 3,295 1,098 783 32 67 82 10 9522 11722 11.85% 0.0496 0.0403 2.9% 4.6% 49 51 79 51 127 33 388 58 253 136 113 224 70 854 -40.2% 148.0% -13.8% 11.4% -11.5% 7.0% 9.9% 0.0% 11.9% 11.9% 13.4% 0.0% 7.3% 5.5% 0.0% 108 1,312 255 225 432 127 2,459 540 7,292 1,458 927 54 117 142 16 16736 20340 11.85% 0.0600 0.0494 24.5% 28.2% -33.2% 671.7% -3.1% 33.1% 2.4% 16.5% 89.9% 0.0% 48.6% 48.6% 34.3% 0.0% 13.1% 9.9% 0.0% 147 2,140 377 347 643 194 3,848 810 11,328 1,510 958 80 185 222 24 26360 31648 11.85% 0.0591 0.0492 22.6% 27.8% -39.4% 739.2% -4.5% 36.8% 1.6% 18.7% 98.1% 0.0% 53.9% -69.2% -72.2% 0.0% 18.8% 14.0% 0.0%

LOW-VOLTAGE VOLTAGE-SOURCE

Rotor Blades Hub Pitch mechanism & bearings Drive train,nacelle Low speed shaft Bearings Gearbox Mech brake, HS cpling etc Generator Variable spd electronics Yaw drive & bearing Main frame Electrical connections Hydraulic system Nacelle cover Control, safety system Tower

A2

Foundations Transportation Roads, civil works Assembly & installation Elect interfc/connect Permits, engineering

Project Uncertainty

Initial Capital Cost (ICC)

Installed Cost per kW Turbine Capital per kW sans BOS

LEVELIZED REPLACEMENT COSTS (LRC) ($10.70/kW) O&M, 5.8 m/s site ($0.007/kWh) O&M, 6.7 m/s site ($0.007/kWh) Land ($3.20/kW)

NET 5.8 m/s ANNUAL ENERGY PRODUCTION MWh (AEP) Net 6.7 m/s ANNUAL ENERGY PRODUCTION Energy MWh (AEP)

Fixed Charge Rate

COE at 5.8 m/s $/kWh COE at 6.7 m/s $/kWh


Turbine Rating (kW) TURBINE CAPITAL COST (TCC) 1500 Baseline Component Costs $1000 248 148 64 36 563 20 12 151 3 98 101 12 64 60 7 36 10 101 921 3000 Projected Component Component Normalized % Costs $1000 Improvement 727 46.9% 437 47.8% 213 65.9% 77 8.3% 1,034 -8.1% 56 41.0% 41 66.4% 357 18.3% 6 0.5% 114 -41.5% 112 -44.3% 28 15.8% 192 50.0% 43 -63.9% 14 3.7% 71 -1.1% 10 -50.0% 303 50.0% 2,074 12.6% 5000 Projected Component Component Normalized % Costs $1000 Improvement 1,484 79.9% 906 83.9% 429 100.5% 149 25.7% 1,978 5.5% 121 82.8% 102 148.4% 697 38.6% 10 0.5% 164 -49.5% 148 -55.9% 110 172.9% 434 103.5% 51 -74.7% 23 2.2% 119 -0.6% 11 -67.0% 647 92.1% 4,120 34.2% 7500 Projected Component Component Normalized % Costs $1000 Improvement 2,356 90.4% 1,440 94.9% 688 114.4% 228 28.3% 3,035 7.8% 192 93.4% 164 166.3% 1,081 43.3% 15 0.5% 248 -49.1% 193 -61.6% 174 187.8% 692 116.3% 63 -79.2% 35 3.7% 178 -0.8% 12 -76.0% 1,030 104.0% 6,433 39.6% BALANCE OF STATION COST (BOS) 162 1,472 981 690 16 31 39 5 4439 5554 11.85% 0.0482 0.0385 3,252 1,084 768 32 67 82 10 9522 11722 11.85% 0.0490 0.0398 1.8% 3.5% 324 49 51 79 51 127 33 388 0.0% 10.5% 10.5% 11.3% 0.0% 7.3% 5.5% 0.0% 58 253 136 113 224 70 854 -40.2% 148.0% -13.8% 11.4% -11.7% 7.0% 9.9% 108 1,312 255 225 430 127 2,457 540 7,118 1,424 892 54 117 142 16 16736 20340 11.85% 0.0587 0.0483 21.9% 25.5% -33.2% 671.7% -3.1% 33.1% 2.0% 16.5% 89.8% 0.0% 45.1% 45.1% 29.2% 0.0% 13.1% 9.9% 0.0% 147 2,140 377 347 641 194 3,846 810 11,089 1,478 925 80 185 222 24 26360 31648 11.85% 0.0580 0.0483 20.4% 25.4% -39.4% 739.2% -4.5% 36.8% 1.3% 18.7% 98.0% 0.0% 50.7% -69.9% -73.2% 0.0% 18.8% 14.0% 0.0%

MEDIUM-VOLTAGE VOLTAGE-SOURCE

Component

Rotor Blades Hub Pitch mechanism & bearings Drive train,nacelle Low speed shaft Bearings Gearbox Mech brake, HS cpling etc Generator Variable spd electronics Yaw drive & bearing Main frame Electrical connections Hydraulic system Nacelle cover Control, safety system Tower

A3

Foundations Transportation Roads, civil works Assembly & installation Elect interfc/connect Permits, engineering

Project Uncertainty

Initial Capital Cost (ICC)

Installed Cost per kW Turbine Capital per kW sans BOS

LEVELIZED REPLACEMENT COSTS (LRC) ($10.70/kW) O&M, 5.8 m/s site ($0.007/kWh) O&M, 6.7 m/s site ($0.007/kWh) Land ($3.20/kW)

NET 5.8 m/s ANNUAL ENERGY PRODUCTION MWh (AEP) Net 6.7 m/s ANNUAL ENERGY PRODUCTION Energy MWh (AEP)

Fixed Charge Rate

COE at 5.8 m/s $/kWh COE at 6.7 m/s $/kWh


Turbine Rating (kW) Component TURBINE CAPITAL COST (TCC) 1500 Baseline Component Costs $1000 248 148 64 36 563 20 12 151 3 98 101 12 64 60 7 36 10 101 921 3000 Projected Component Component Normalized % Costs $1000 Improvement 727 46.9% 437 47.8% 213 65.9% 77 8.3% 1,007 -10.5% 56 41.0% 41 66.4% 357 18.3% 6 0.5% 114 -41.5% 85 -57.6% 28 15.8% 192 50.0% 43 -63.9% 14 3.7% 71 -1.1% 10 -50.0% 303 50.0% 2,048 11.1% 5000 Projected Component Component Normalized % Costs $1000 Improvement 1,484 79.9% 906 83.9% 429 100.5% 149 25.7% 1,948 3.8% 121 82.8% 102 148.4% 697 38.6% 10 0.5% 164 -49.5% 117 -65.1% 110 172.9% 434 103.5% 51 -74.7% 23 2.2% 119 -0.6% 11 -67.0% 647 92.1% 4,089 33.2% 7500 Projected Component Component Normalized % Costs $1000 Improvement 2,356 90.4% 1,440 94.9% 688 114.4% 228 28.3% 2,980 5.9% 192 93.4% 164 166.3% 1,081 43.3% 15 0.5% 248 -49.1% 138 -72.4% 174 187.8% 692 116.3% 63 -79.2% 35 3.7% 178 -0.8% 12 -76.0% 1,030 104.0% 6,378 38.5% BALANCE OF STATION COST (BOS) 162 1,472 981 690 16 31 39 5 4439 5554 11.85% 0.0482 0.0385 324 3,225 1,075 759 32 67 82 10 9522 11722 11.85% 0.0487 0.0396 1.1% 2.8% 49 51 79 51 127 33 388 58 253 136 113 224 70 854 -40.2% 148.0% -13.8% 11.4% -11.7% 7.0% 9.9% 0.0% 9.6% 9.6% 9.9% 0.0% 7.3% 5.5% 0.0% 108 1,312 255 225 430 127 2,457 540 7,087 1,417 885 54 117 142 16 16736 20340 11.85% 0.0585 0.0482 21.5% 25.1% -33.2% 671.7% -3.1% 33.1% 2.0% 16.5% 89.8% 0.0% 44.5% 44.5% 28.3% 0.0% 13.1% 9.9% 0.0% 147 2,140 377 347 641 194 3,846 810 11,034 1,471 918 80 185 222 24 26360 31648 11.85% 0.0578 0.0481 19.9% 24.9% -39.4% 739.2% -4.5% 36.8% 1.3% 18.7% 98.0% 0.0% 50.0% -70.0% -73.4% 0.0% 18.8% 14.0% 0.0%

MEDIUM-VOLTAGE CURRENT-SOURCE

Rotor Blades Hub Pitch mechanism & bearings Drive train,nacelle Low speed shaft Bearings Gearbox Mech brake, HS cpling etc Generator Variable spd electronics Yaw drive & bearing Main frame Electrical connections Hydraulic system Nacelle cover Control, safety system Tower

A4

Foundations Transportation Roads, civil works Assembly & installation Elect interfc/connect Permits, engineering

Project Uncertainty

Initial Capital Cost (ICC)

Installed Cost per kW Turbine Capital per kW sans BOS

LEVELIZED REPLACEMENT COSTS (LRC) ($10.70/kW) O&M, 5.8 m/s site ($0.007/kWh) O&M, 6.7 m/s site ($0.007/kWh) Land ($3.20/kW)

NET 5.8 m/s ANNUAL ENERGY PRODUCTION MWh (AEP) Net 6.7 m/s ANNUAL ENERGY PRODUCTION Energy MWh (AEP)

Fixed Charge Rate

COE at 5.8 m/s $/kWh COE at 6.7 m/s $/kWh

Appendix B COE Details Using 2002 Dollars for Components Included within Study
Thefollowingthreetablesdetailcapitalcost,operationandmaintenancecosts,annual energyproduction,andCOEforthreeconfigurations: o LowVoltage,VoltageSource o MediumVoltage,VoltageSource o MediumVoltage,CurrentSource. InthisAppendix,componentsincludedinthisstudywerecostedin2002dollars.Costsare adjustedaccordingtotherulesstatedinTable52. Costsfornonelectricalcomponentsnotdirectlysizedandcostedinthisstudywerescaled fromtheWindPACTTurbineRotorDesignStudyJune2000June2002(Malcolm,D.J.,and Hansen,A.C.NationalRenewableEnergyLaboratory,NREL/SR50032495,August2002).

B1


Turbine Rating (kW) Component TURBINE CAPITAL COST (TCC) 1500 Baseline Component Costs $1000 248 148 64 36 563 20 12 151 3 98 101 12 64 60 7 36 10 101 921 3000 Projected Component Component Normalized % Costs $1000 Improvement 727 46.9% 437 47.8% 213 65.9% 77 8.3% 1,002 -11.0% 56 41.0% 41 66.4% 357 18.3% 6 0.5% 81 -58.5% 113 -43.6% 28 15.8% 192 50.0% 42 -64.9% 14 3.7% 71 -1.1% 10 -50.0% 303 50.0% 2,042 10.8% 5000 Projected Component Component Normalized % Costs $1000 Improvement 1,484 79.9% 906 83.9% 429 100.5% 149 25.7% 2,026 8.0% 121 82.8% 102 148.4% 697 38.6% 10 0.5% 117 -64.1% 215 -35.8% 110 172.9% 434 103.5% 78 -60.9% 23 2.2% 119 -0.6% 11 -67.0% 647 92.1% 4,168 35.7% 7500 Projected Component Component Normalized % Costs $1000 Improvement 2,356 90.4% 1,440 94.9% 688 114.4% 228 28.3% 3,097 10.1% 192 93.4% 164 166.3% 1,081 43.3% 15 0.5% 171 -64.9% 280 -44.2% 174 187.8% 692 116.3% 115 -61.8% 35 3.7% 178 -0.8% 12 -76.0% 1,030 104.0% 6,495 41.0% BALANCE OF STATION COST (BOS) 162 1,472 981 690 16 31 39 5 4439 5554 11.85% 0.0482 0.0385 324 3,220 1,073 757 32 67 82 10 9522 11722 11.85% 0.0486 0.0395 1.0% 2.6% 49 51 79 51 127 33 388 58 253 136 113 224 70 854 -40.2% 148.0% -13.8% 11.4% -11.5% 7.0% 9.9% 0.0% 9.4% 9.4% 9.6% 0.0% 7.3% 5.5% 0.0% 108 1,312 255 225 432 127 2,459 540 7,167 1,433 901 54 117 142 16 16736 20340 11.85% 0.0591 0.0486 22.6% 26.3% -33.2% 671.7% -3.1% 33.1% 2.4% 16.5% 89.9% 0.0% 46.1% 46.1% 30.6% 0.0% 13.1% 9.9% 0.0% 147 2,140 377 347 643 194 3,848 810 11,153 1,487 934 80 185 222 24 26360 31648 11.85% 0.0583 0.0486 21.0% 26.1% -39.4% 739.2% -4.5% 36.8% 1.6% 18.7% 98.1% 0.0% 51.6% -69.7% -72.9% 0.0% 18.8% 14.0% 0.0%

LOW-VOLTAGE VOLTAGE-SOURCE

Rotor Blades Hub Pitch mechanism & bearings Drive train,nacelle Low speed shaft Bearings Gearbox Mech brake, HS cpling etc Generator Variable spd electronics Yaw drive & bearing Main frame Electrical connections Hydraulic system Nacelle cover Control, safety system Tower

B2

Foundations Transportation Roads, civil works Assembly & installation Elect interfc/connect Permits, engineering

Project Uncertainty

Initial Capital Cost (ICC)

Installed Cost per kW Turbine Capital per kW sans BOS

LEVELIZED REPLACEMENT COSTS (LRC) ($10.70/kW) O&M, 5.8 m/s site ($0.007/kWh) O&M, 6.7 m/s site ($0.007/kWh) Land ($3.20/kW)

NET 5.8 m/s ANNUAL ENERGY PRODUCTION MWh (AEP) Net 6.7 m/s ANNUAL ENERGY PRODUCTION Energy MWh (AEP)

Fixed Charge Rate

COE at 5.8 m/s $/kWh COE at 6.7 m/s $/kWh


Turbine Rating (kW) Component TURBINE CAPITAL COST (TCC) 1500 Baseline Component Costs $1000 248 148 64 36 563 20 12 151 3 98 101 12 64 60 7 36 10 101 921 3000 Projected Component Component Normalized % Costs $1000 Improvement 727 46.9% 437 47.8% 213 65.9% 77 8.3% 968 -14.0% 56 41.0% 41 66.4% 357 18.3% 6 0.5% 81 -58.5% 90 -55.1% 28 15.8% 192 50.0% 31 -73.8% 14 3.7% 71 -1.1% 10 -50.0% 303 50.0% 2,008 9.0% 5000 Projected Component Component Normalized % Costs $1000 Improvement 1,484 79.9% 906 83.9% 429 100.5% 149 25.7% 1,888 0.7% 121 82.8% 102 148.4% 697 38.6% 10 0.5% 117 -64.1% 119 -64.5% 110 172.9% 434 103.5% 37 -81.7% 23 2.2% 119 -0.6% 11 -67.0% 647 92.1% 4,030 31.2% 7500 Projected Component Component Normalized % Costs $1000 Improvement 2,356 90.4% 1,440 94.9% 688 114.4% 228 28.3% 2,908 3.3% 192 93.4% 164 166.3% 1,081 43.3% 15 0.5% 176 -63.8% 155 -69.1% 174 187.8% 692 116.3% 45 -84.9% 35 3.7% 178 -0.8% 12 -76.0% 1,030 104.0% 6,306 36.9% BALANCE OF STATION COST (BOS) 162 1,472 981 690 16 31 39 5 4439 5554 11.85% 0.0482 0.0385 324 3,185 1,062 745 32 67 82 10 9522 11722 11.85% 0.0482 0.0392 0.1% 1.7% 49 51 79 51 127 33 388 58 253 136 113 224 70 854 -40.2% 148.0% -13.8% 11.4% -11.7% 7.0% 9.9% 0.0% 8.2% 8.2% 7.9% 0.0% 7.3% 5.5% 0.0% 108 1,312 255 225 430 127 2,457 540 7,028 1,406 873 54 117 142 16 16736 20340 11.85% 0.0581 0.0478 20.6% 24.2% -33.2% 671.7% -3.1% 33.1% 2.0% 16.5% 89.8% 0.0% 43.3% 43.3% 26.5% 0.0% 13.1% 9.9% 0.0% 147 2,140 377 347 641 194 3,846 810 10,962 1,462 908 80 185 222 24 26360 31648 11.85% 0.0574 0.0478 19.2% 24.2% -39.4% 739.2% -4.5% 36.8% 1.3% 18.7% 98.0% 0.0% 49.0% -70.2% -73.7% 0.0% 18.8% 14.0% 0.0%

MEDIUM-VOLTAGE VOLTAGE-SOURCE

Rotor Blades Hub Pitch mechanism & bearings Drive train,nacelle Low speed shaft Bearings Gearbox Mech brake, HS cpling etc Generator Variable spd electronics Yaw drive & bearing Main frame Electrical connections Hydraulic system Nacelle cover Control, safety system Tower

B3

Foundations Transportation Roads, civil works Assembly & installation Elect interfc/connect Permits, engineering

Project Uncertainty

Initial Capital Cost (ICC)

Installed Cost per kW Turbine Capital per kW sans BOS

LEVELIZED REPLACEMENT COSTS (LRC) ($10.70/kW) O&M, 5.8 m/s site ($0.007/kWh) O&M, 6.7 m/s site ($0.007/kWh) Land ($3.20/kW)

NET 5.8 m/s ANNUAL ENERGY PRODUCTION MWh (AEP) Net 6.7 m/s ANNUAL ENERGY PRODUCTION Energy MWh (AEP)

Fixed Charge Rate

COE at 5.8 m/s $/kWh COE at 6.7 m/s $/kWh


Turbine Rating (kW) Component TURBINE CAPITAL COST (TCC) 1500 Baseline Component Costs $1000 248 148 64 36 563 20 12 151 3 98 101 12 64 60 7 36 10 101 921 3000 Projected Component Component Normalized % Costs $1000 Improvement 727 46.9% 437 47.8% 213 65.9% 77 8.3% 946 -15.9% 56 41.0% 41 66.4% 357 18.3% 6 0.5% 81 -58.5% 69 -65.9% 28 15.8% 192 50.0% 31 -73.8% 14 3.7% 71 -1.1% 10 -50.0% 303 50.0% 1,986 7.8% 5000 Projected Component Component Normalized % Costs $1000 Improvement 1,484 79.9% 906 83.9% 429 100.5% 149 25.7% 1,863 -0.7% 121 82.8% 102 148.4% 697 38.6% 10 0.5% 117 -64.1% 94 -71.9% 110 172.9% 434 103.5% 37 -81.7% 23 2.2% 119 -0.6% 11 -67.0% 647 92.1% 4,005 30.4% 7500 Projected Component Component Normalized % Costs $1000 Improvement 2,356 90.4% 1,440 94.9% 688 114.4% 228 28.3% 2,864 1.8% 192 93.4% 164 166.3% 1,081 43.3% 15 0.5% 176 -63.8% 112 -77.8% 174 187.8% 692 116.3% 45 -84.9% 35 3.7% 178 -0.8% 12 -76.0% 1,030 104.0% 6,262 35.9% BALANCE OF STATION COST (BOS) 162 1,472 981 690 16 31 39 5 4439 5554 11.85% 0.0482 0.0385 324 3,164 1,055 738 32 67 82 10 9522 11722 11.85% 0.0480 0.0390 -0.5% 1.1% 49 51 79 51 127 33 388 58 253 136 113 224 70 854 -40.2% 148.0% -13.8% 11.4% -11.7% 7.0% 9.9% 0.0% 7.5% 7.5% 6.9% 0.0% 7.3% 5.5% 0.0% 108 1,312 255 225 430 127 2,457 540 7,003 1,401 868 54 117 142 16 16736 20340 11.85% 0.0579 0.0477 20.2% 23.8% -33.2% 671.7% -3.1% 33.1% 2.0% 16.5% 89.8% 0.0% 42.7% 42.7% 25.8% 0.0% 13.1% 9.9% 0.0% 147 2,140 377 347 641 194 3,846 810 10,918 1,456 902 80 185 222 24 26360 31648 11.85% 0.0572 0.0477 18.8% 23.8% -39.4% 739.2% -4.5% 36.8% 1.3% 18.7% 98.0% 0.0% 48.4% -70.3% -73.9% 0.0% 18.8% 14.0% 0.0%

MEDIUM-VOLTAGE CURRENT-SOURCE

Rotor Blades Hub Pitch mechanism & bearings Drive train,nacelle Low speed shaft Bearings Gearbox Mech brake, HS cpling etc Generator Variable spd electronics Yaw drive & bearing Main frame Electrical connections Hydraulic system Nacelle cover Control, safety system Tower

B4

Foundations Transportation Roads, civil works Assembly & installation Elect interfc/connect Permits, engineering

Project Uncertainty

Initial Capital Cost (ICC)

Installed Cost per kW Turbine Capital per kW sans BOS

LEVELIZED REPLACEMENT COSTS (LRC) ($10.70/kW) O&M, 5.8 m/s site ($0.007/kWh) O&M, 6.7 m/s site ($0.007/kWh) Land ($3.20/kW)

NET 5.8 m/s ANNUAL ENERGY PRODUCTION MWh (AEP) Net 6.7 m/s ANNUAL ENERGY PRODUCTION Energy MWh (AEP)

Fixed Charge Rate

COE at 5.8 m/s $/kWh COE at 6.7 m/s $/kWh

Appendix C Cable Termination Study

Thefollowingtableprovidesasimpleanalysishighlightingcableterminationactivitiesfor LVandMVsystems.Theresultsofthisstudywerethenusedintheinstallationcost calculations.

C1


Low Voltage (575V) 36.00 72.00 Low Voltage (575V) 72.00 144.00 60.00 0.25 15.00 60.00 0.25 15.00 3 MW Medium Voltage Medium Voltage Voltage Source Current Source (2400V) (2400V) 9.00 9.00 18.00 18.00 5 MW Medium Voltage Medium Voltage Voltage Source Current Source (4160V) (4160V) 9.00 9.00 18.00 18.00 Low Voltage (575V) 90.00 180.00 60.00 0.25 15.00 7.5 MW Medium Voltage Medium Voltage Voltage Source Current Source (6900V) (6900V) 9.00 9.00 18.00 18.00 70.00 0.50 35.00 70.00 0.50 35.00 70.00 0.50 35.00 70.00 0.50 35.00 70.00 0.50 35.00 70.00 0.50 35.00 1080.00 630.00 630.00 2160.00 630.00 630.00 2700.00 630.00 630.00

Cable Termination & Connection:

# Cables # Terminations

LV Electrician Rate ($/hr) LV Termination Time per Lug (hrs) Labor $ / Termination

C2

MV Electrician Rate MV Termination Time per Lug Labor $ / Termination

Total Termination & Connection Cost ($)

Appendix D Application Specification

Theattachedreportprovidesanapplicationspecificationdevelopedtosolicitdataand feedbackfrommanufacturersandvendors.

D1

Medium Voltage Electrical Drive System for Variable Speed Wind Turbines Application Specification
Revision 3 April 1, 2005 Prepared by: William L. Erdman, Ph.D. Michael R. Behnke, P.E. Behnke, Erdman & Whitaker Engineering, Inc. 2303 Camino Ramon, Suite 220 San Ramon, CA 94583

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Medium Voltage Electrical Drive System Application Specification

Change Tracking Revision Date 0 9/1/04 1 11/2/04 2 3 Reasons for Changes Initial Draft North America (4.16 kV) Change power ratings to 3, 5 and 7.5 MW; add E.ON Netz requirements; add generator construction details; 11/23/04 Add voltage source inverter option 4/1/05 Revised to reflect new voltage ratings and relocation of rectifier from nacelle to down tower Paragraphs Affected 1.0, 2.0, 5.1-5.16, 3.0, 8.0, 8.8.4 5.11, 6.0, 6.5, 7.2, 7.3, 8.4, 8.4, 9.2, 10.4, 10.13

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Medium Voltage Electrical Drive System Application Specification

Table of Contents 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 Scope and Purpose. 1 Applicable Codes and Standards... 2 General System Description.. 3 General Environmental Requirements.. 4 Generator4 Rectifier......................................... 6 Intra-Tower Power Distribution.. 7 Inverter... 8 Output Power Distribution.. 11 Transformer and Switchgear.. 12 Tables Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. Table 7. Table 8. Table 9. Table 10. Table 11. Generator Power Ratings. 5 Generator Minimum Efficiency Based on 6-Pole Machine. 6 Generator EMF Constants6 Rectifier Assembly AC Current Ratings .7 DC Power Cable Construction..... 7 DC Power Distribution, Power Cable Conductor Sizes...8 Inverter Apparent Power and Current Ratings.....9 AC Power Cable Construction..... 12 AC Power Distribution, Power Cable Conductor Sizes...12 Transformer Apparent Power Ratings..... 13 AC Power Circuit Breaker Ratings.. 13

Figures Figure 1. Figure 2. Figure 3. Figure 3. Figure 4. Figure 5. Scope of Specification. 1 System Block Diagram with Current Source Inverter..... 3 System Block Diagram with Voltage Source Inverter.....3 Generator Load Profile Based on 6-Pole Machine...... 5 Minimum Inverter Efficiency.. 9 Low Voltage Ride-Through Requirement... 11

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Medium Voltage Electrical Drive System Application Specification

1.0 Scope and Purpose The purpose of this document is to define application requirements for a medium voltage drive train to be utilized for reduced COE from low wind speed multimegawatt wind turbines. These application requirements establish design criteria by which cost and performance data may be estimated. The scope of this document is limited to the electrical drive train components consisting of a single synchronous generator, a rectifier assembly, DC power distribution from the nacelle to the tower base, an inverter assembly, and AC power distribution from the inverter to a transformer/switchgear assembly located external to the turbine tower, as shown in Figure 1, below.

Figure 1. Scope of Specification The rotor, hub, gearbox, main and high speed shafts, pitch and yaw systems and tower are specifically excluded from the scope of this document. However, certain assumptions about these components are necessary in order to fully specify the electrical system. It has been assumed the generator is driven by a two-stage gearbox to provide a speed range of approximately 600 to 1440 rpm for the generator. With regard to tower height, which greatly impacts DC power cable costs, it has been assumed that the hub height is equal to the rotor diameter. Rotor diameter is scaled at a constant ratio of swept rotor area to turbine power, and turbine ratings of 3 MW, 5 MW and 7.5 MW are addressed. The specifications delineated herein are applicable to each of these ratings, except where noted. This document is specifically not intended as a procurement specification, and, thus, does not address manufacturing, quality assurance, documentation, shipping
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Medium Voltage Electrical Drive System Application Specification

and after-sales service requirements. Such requirements on the component suppliers will be addressed in procurement specifications to be developed in later phases of the LSWT program. 2.0 Applicable Codes and Standards ANSI/IEEC C37.06-2000 ANSI/IEEE C57.12.26-1992 AC High Voltage Circuit Breakers Rated on a Symmetrical Current Basis -- Preferred Ratings and Related Required Capabilities. Requirements for Pad-Mounted, CompartmentalType, Self-Cooled, Three-Phase Distribution Transformers for Use with Separable Insulated High-Voltage Connectors. Petition For Rulemaking/Request For Clarification Of FERC Order 2003-A (a.k.a. proposed Grid Code for Wind Turbines) Grid Code for High and Extra High Voltage, Version of 8/1/2003. Rotating Electrical Machines - Part 1: Rating and Performance High Voltage Alternating Current Contactors and Contactor-Based Motor Starters Degrees of Protection Provided by Enclosures (IP Code). Wind Turbine Generator Systems - Part 21: Measurement and Assessment of Power Quality Characteristics of Grid Connected Wind Turbines High Voltage Switchgear and Controlgear - Part 100: High Voltage AC Circuit Breakers Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems Test Procedures and Requirements for High Voltage Alternating Current Cable Terminations Enclosures for Electrical Equipment (1000 Volts Maximum) Medium Voltage Controllers Rated 2001 to 7200 Volts AC Motors and Generators Portable and Power Feeder Cables for Use in Mines and Similar Applications 5-46 kV Shielded Power Cable for Transmission and Distribution of Electric Energy National Electric Code High Voltage Industrial Control Equipment Medium Voltage Power Cables
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AWEA FERC Filing of 5/20/2004 E.ON Netz GmbH IEC 60034-1:2004 IEC 60470:2000 IEC 60529:2001 IEC 61400-21:2001

IEC 62271-100:2003 IEEE 519-1992 IEEE 48-1990 NEMA 250-2003 NEMA ICS3-2000 NEMA MG1-2003 NEMA WC58-1997 (ICEA S-75-381) NEMA WC74-2000 (ICEA S-93-639) NFPA 70-2002 UL 347 UL 1072

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Medium Voltage Electrical Drive System Application Specification

3.0

General System Description The medium voltage electrical drive system is depicted in block diagram form in Figures 2 and 3, below, for two different inverter topologies. For either topology, the major subsystems consist of a single synchronous generator, a rectifier assembly, DC power distribution, an inverter assembly, AC power distribution and a transformer/switchgear assembly.
Rectifier Assembly Inverter Assembly Aux. Power Panel Transformer/ Switchgear Assembly

Generator Assembly

DC Link Inductor
Gate Drive Circuitry

3-Phase Line Filter

Current Feedback Voltage Feedback

Control and Communications Board

Voltage Feedback Current Feedback

Turbine Controller

Figure 2. System Block Diagram with Current Source Inverter

Figure 3. System Block Diagram with Voltage Source Inverter The synchronous generator, which may be either permanent magnet or wound field excited, operates with approximately constant volts per hertz open circuit voltage over its entire speed range. The AC terminal voltage of the generator is then primarily influenced by this no-load speed voltage and the voltage drop across the generators synchronous reactance under load. Generator torque is controlled by regulating the rectifier output current with the inverter in response to an external torque control signal (provided by a turbine master controller, for example).
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Medium Voltage Electrical Drive System Application Specification

Power factor at the turbine output is controlled by phase displacing the current waveform generated at the inverter output terminals from the line voltage. The inverter is programmed to either dynamically perform this phase displacement in response to an external power factor or reactive power control signal or through a static power factor or reactive power setting implemented in the inverter control firmware. 4.0 General Environmental Requirements The following environmental requirements apply to each of the major subsystems of the electrical drive system: 4.1 4.2 4.3 4.4 4.5 Altitude: Sea level to 2000 meters. Humidity: Up to 100%, condensing. Operating Ambient Temperature: -30 to +45C Non-Operating Ambient Temperature: -40 to +45C Contamination: All drive system components will be subjected to windblown dust, as well as dripping rain water and gear oil.

4.6 Design Life: A drive systems components shall provide for a minimum 20year design life. 5.0 Generator 5.1 General Description: The generator shall be either a wound field excited or permanent magnet excited machine. In the event a wound field generator is selected, the generator shall be excited in such a way so as to provide a constant volts/Hz in the open circuit condition. The pole count, and therefore frequency, can vary dependent on the generator design, but it is expected that the pole count will be either four, six or eight poles. Larger pole counts on a permanent magnet machine could be accommodated by the design of the diode bridge assembly. The generator will be feeding a six pulse, three switch rectifier and the characteristic 5th, 7th, 11th, and 13th harmonics will be present in the generator current waveform. The synchronous reactance of the generator has some latitude and will be discussed later, however, it is important to note that there exist limits on the reactance. The upper reactance is limited by the ability of the generator to provide rated power into a rectifier bridge and the limit on the low end is determined by the short circuit fault torque and current necessary for survival of the gearbox under these fault conditions.
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5.2 Construction: The synchronous generator shall be rated at the IP54 level or better. This can be accomplished by means of air-to-air heat exchanger, or a water-to-air heat exchanger. The stator winding shall be of the form wound construction, using all class H materials and with a class B design temperature rise. In the event that a wound field machine is used, the rotor winding shall also use class H materials with a class B rise. 5.3 Nominal Continuous Power Output: Generator shall have a continuous output power rating at nominal speed per Table 1, below. Turbine Rating Generator Rating 3 MW 3.2 MW 5 MW 5.3 MW 7.5 MW 8.0 MW Table 1. Generator Power Ratings 5.4 Speed Range: Generator speed shall vary from a cut-in speed of 600 rpm to a nominal speed of 1200 rpm, with transient overspeed conditions to 1440 rpm, maximum based on a six-pole design. Load Profile: The generator load profile is as shown in Figure 3, below. Applied generator torque will vary in proportion to the square of the generator speed from cut-in (Tci) to 100% of rated torque. Generator torque will be reduced above rated speed to provide for constant power operation between rated speed and maximum transient overspeed.
Generator Load Profile
Torque (% of nominal)

5.5

100.0

Tci 0.0
500 600 700 800 900 1000 1100 1200 1300 1400 1500

Speed (rpm)

Figure 3. Generator Load Profile Based on 6-Pole Machine 5.6 Efficiency: Generator efficiency shall meet or exceed the efficiency specified in Table 2, below, at each load point.

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Medium Voltage Electrical Drive System Application Specification

Load Point 1 3

Speed (rpm) 600 1200

Torque (% nom.) Tci 100

Power (% nom.) TBD 100

Efficiency (%) 92% 95%

Table 2. Generator Minimum Efficiency Based on 6-Pole Machine 5.7 5.8 5.9 Number of Phases: Three. Number of Stator Windings: One. Stator Phase Connection: Wye connected.

5.10 EMF Voltage Constant: Per Table 3, below. Turbine Rating 3 MW 5 MW 7.5 MW EMF Constant (VACrms/rpm) 1.59 2.76 4.58

Table 3. Generator EMF Constants 5.12 Synchronous Reactance: 0.33 pu, +10%, -0%. 5.13 Shaft Speed Sensing: Not required for torque control. Low resolution speed sensor to be supplied by turbine manufacturer for feedback to turbine master controller. 5.14 Temperature Sensing: Each stator winding shall be equipped with a thermostatic device to indicate excess temperature. Location of the temperature sensing device shall be in the stator slot and not in the end turns. 5.15 Anti-Condensation Heating: Generator shall be equipped with space heaters to prevent condensation during idle periods. If a water-to-air heat exchanger, then water temperature can be used to keep prevent condensation. 6.0 Rectifier The rectifier assembly, collocated with the inverter assembly at the base of the turbine tower, shall conform to the following: 6.1 Type: Three-phase, six-pulse, controlled (SCR based) bridge rectifier.

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6.2 Cooling: Rectifier assembly shall be cooled by either natural or forced air convection. 6.3 6.4 6.5 Maximum Open Circuit AC Voltage: 96% of nominal AC line voltage. Minimum Full Load AC Voltage: 70% of nominal AC line voltage. Maximum Continuous AC Current: Per Table 4, below. Turbine Rating AC Current (Arms) 3 MW 1070 5 MW 1030 7.5 MW 930 Table 4. Rectifier Assembly AC Current Ratings 6.6 6.7 7.0 AC Frequency Range: 30 to 72 Hz for 6-pole machine. Losses: Rectifier SCRs shall be selected such that the rectifier assembly losses do not exceed 0.5% of the turbine output rating at full load.

Intra-Tower Power Distribution Intra-tower power cabling includes the medium voltage insulated conductors utilized to transmit power from the generator to the input terminals of the rectifier at the base of the turbine tower. A flexible pendant loop is provided between the generator and a junction box mounted on the interior surface of the tower directly below the yaw bearing. A transition to fixed wiring is made in the junction box to complete the run to the rectifier/inverter assembly. 7.1 Construction: Cable construction shall be per Table 5, below. Cable Section Type Voltage Rating Insulation Level # of Conductors Conductors Fixed Pendant UL Type MV-105 ICEA Type SHD 5/8 kV 5/8 kV 133% 100% 1 3 Copper, compact Copper, flexible rope-lay stranded stranded Conductor Shield Extruded Semiconducting tape semiconducting EPR Insulation EPR EPDM Insulation Shield Copper tape over Tinned copper braid over semiconducting EPR semiconducting tape Jacket UV-resistant, flameThermoset CPE retardant PVC Table 5. Intra-Tower Power Cable Construction
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Medium Voltage Electrical Drive System Application Specification

7.2

Conductor Size: Conductor sizes shall be per Table 6, below. # Conductors Conductor per Phase Size Fixed 1 900 MCM 3 MW Pendant 1 900 MCM Fixed 1 700 MCM 5 MW Pendant 1 700 MCM Fixed 1 900 MCM 7.5 MW Pendant 1 900 MCM Table 6. Intra-Tower Power Distribution, Power Cable Conductor Sizes Turbine Rating Cable Type

7.3 Installation: 7.3.1 Fixed Cables: Fixed cables shall run along the inside surface of the turbine tower from inverter assembly to the junction box below the yaw bearing. Cables shall be supported by insulated clamps at distances not greater than NEC Table 300.19(A). Cables shall be terminated at each end with copper compression lugs and IEEE-48 stress cones rated at 5 kV or 8 kV. Pendant Cables: Pendant cable shall pass through the yaw bearing from the tower junction box to the generator cable termination box. Cable loops shall be of sufficient length to maintain manufacturers recommended minimum bending radius for the maximum number of yaw rotations in one direction allowed by the turbine master controller. Cables shall be terminated at each end with copper compression lugs and IEEE-48 stress cones rated at 5 kV or 8 kV. Mesh-type cable grips shall be used at each termination.

7.3.2

8.0

Inverter The inverter assembly, located at the base of the tower (internal to tower assembly), controls generator torque and output power factor. The inverter shall be one of two types: 1) a pulse width modulated (PWM) current-source type utilizing symmetrical gate commutated turn-off (SGCT) thyristors, or 2) a pulse width modulated (PWM) voltage-source (three level) type utilizing high voltage insulated gate bipolar transistors (IGBT) or asymmetrical gate commutated turn-off (GCT) thyristors. 8.1 Packaging: The inverter assembly shall be housed in an electrical enclosure with a minimum NEMA-250 rating of 3R and a minimum IEC-529 IP23 degree of protection. The inverter shall be packaged to meet the construction and safety requirements of UL 347. Cooling: Forced air cooling shall be utilized.
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Medium Voltage Electrical Drive System Application Specification

8.3

AC Line Voltage and Frequency: Nominal voltage per Table 7, below, 3phase, 60 Hz nominal. Inverter shall be operable on a continuous basis with a +/- 10% tolerance on voltage and +/3 Hz tolerance on frequency. (See 8.9.3 for additional transient voltage tolerance requirements.) Continuous Apparent Power and Current Rating: Per Table 7, below. Turbine Apparent Nominal Line Current Rating Power Rating Voltage Rating 3 MW 3.5 MVA 2,400 V 840 A 5 MW 5.8 MVA 4,160 V 810 A 7.5 MW 8.8 MVA 6,900 V 740 A Table 7. Inverter Apparent Power, Voltage and Current Ratings

8.4

8.5 8.6

Power Factor: Programmable over a range of 0.95 leading to 0.95 lagging. Harmonic Distortion: Current harmonics at the primary of the transformer assembly shall comply with the requirements of IEEE Standard 519 and IEC Standard 61400-21. Efficiency: Inverter efficiency shall meet or exceed the curve of Figure 4, below.
100% 97% 94% 91% 88% 85% 82% 79% 76% 73% 70% 0 20 40 60 80 100
Pow er Output (% of Rating)

8.7

Efficiency

Figure 4. Minimum Inverter Efficiency 8.8 Protective Functions: The inverter shall include the following protection functions: 8.8.1 8.8.2 Gate Drive Fault: Inverter shall trip instantaneously upon receipt of a fault signal from the SGCT driver circuits. Overtemperature: Inverter shall monitor and provide programmable time delayed tripped on overtemperature on the thyristor/transistor heat sinks and DC and AC filter components.
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8.8.3

Overcurrent: Instantaneous short circuit detection shall be provided through the inverters AC and DC current sensors. (Note: as the inverter is a current limited device, no overload protection is required.) DC Overvoltage: Inverter shall detect DC overvoltage and include a voltage clamping circuit to limit voltage in the event of a failure in the inverter bridge assembly (current source topology, only). AC Voltage and Frequency: Inverter shall provide AC voltage and frequency protection with programmable time delays for coordination with the requirements of paragraphs 8.3 and 8.13.3.

8.8.4

8.8.5

8.9

Control: The inverter shall include the following control functionality: 8.9.1 Generator Torque Control: The inverter shall respond to a DC link current control command issued by the turbine master controller via serial communications. The ramp rate on DC link current shall be programmable.

8.9.2 VAR Control: Inverter shall be capable of operation at either constant power factor or constant reactive power, subject to the power factor and apparent power restrictions of 8.4 and 8.5. This capability shall be either locally programmable or in response to an external power factor or reactive power command from the turbine master controller. 8.9.3 Low Voltage Ride Through: In addition to the continuous overvoltage and undervoltage capability described in paragraph 8.3, the inverter shall provide ride-through capability for the wind turbine for transient low voltages that may occur as a result of symmetrical or unsymmetrical faults on the high voltage transmission network. This capability shall meet or exceed the magnitude and duration specified by Figure 5, below.

Figure 5. Low Voltage Ride-Through Requirement

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During these low voltage transient events, the inverter shall remain operational to its continuous AC current rating, as specified in paragraph 8.4, reducing generator torque (if necessary) to limit AC current. 8.10 Communications and Monitoring 8.10.1 Serial Communications: Inverter communication and control board shall included two serial communications ports, one for communication with the turbine master controller and one for local communication. Each comm port shall have capability for either twisted pair or fiber optic communication media. Capability for implementation of various industry standard protocols (e.g., Modbus, Interbus, CAN, DeviceNet) through firmware changes shall be provided. 8.10.2 Monitored Functions: The following parameters shall be available through serial communications: Desired Generator Torque Estimated Generator Speed Estimated Generator Torque DC Link Current or Voltage AC Line Currents (3) AC Line Voltage (3) 9.0 Output Power Cabling AC output power cabling consists of the insulated conductors utilized to transmit power from the AC output terminals of the inverter assembly to the power circuit breaker located in the transformer assembly. The conductors will be installed in underground duct banks which pass through the tower foundation. 9.1 Construction: Cable construction shall be per Table 8, below. Type UL Type MV-105 Voltage Rating 5/8 kV Insulation Level 133% # of Conductors 1 Conductors Copper, compact stranded Conductor Shield Extruded semiconducting EPR Insulation EPR Insulation Shield Copper tape over semiconducting EPR Jacket UV-resistant, flame-retardant PVC Table 8. AC Output Power Cable Construction
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Output Power Output Power Factor AC Line Frequency Inverter Operating State Inverter Fault Codes

Medium Voltage Electrical Drive System Application Specification

9.2

Conductor Size: Conductor size for each phase shall be per Table 9, below. Turbine # Conductors Conductor Rating per Phase Size 3 MW 1 900 MCM 5 MW 1 700 MCM 7.5 MW 1 900 MCM Table 9. AC Power Distribution, Power Cable Conductor Sizes

9.3

Installation: AC power cables shall be installed in a single rigid nonmetallic conduit encased within the turbine tower foundation. Cables shall be terminated at each end with copper compression lugs and IEEE-48 stress cones rated at 5 kV or 8 kV.

10.0 Transformer The transformer assembly provides voltage transformation from the inverter output voltage to 34.5 kV (or other wind plant collection system voltage), overcurrent and ground fault protection for the AC system and overcurrent protection and disconnection means for the transformer itself. The transformer assembly is located outside of the base of the turbine tower in a weather and tamper proof outdoor enclosure which complies with the construction requirements of ANSI/IEEE C57.12.26-1992. 10.1 10.2 Enclosure: Oil filled, self-cooled (OA), compartmental-type, with separate deadfront primary and secondary compartments. Apparent Power Rating: Per Table 10, below. Turbine Rating Apparent Power Rating 3 MW 3000 kVA 5 MW 5000 kVA 7.5 MW 7500 kVA Table 10. Transformer Apparent Power Ratings 10.3 10.4 10.6 10.7 Primary Voltage and Connection: 34.5 kV (150 kV BIL), grounded wye. Secondary Voltage and Connection: Per Table 7, above; grounded wye. Taps: Four full capacity taps at 2.5% and 5% of nominal; external gang operated no-load tap changer located in primary compartment. Impedance: 5.75%.

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10.8 10.9

Temperature Rise: 65C winding average rise. Efficiency: Core losses shall not exceed 0.2% of transformer rating. Full load copper losses shall not exceed 1.0% of transformer rating.

10.10 Coil/Core Construction: Aluminum windings with laminated silicon steel with five-legged core construction. 10.12 Primary Switchgear and Overcurrent Protection: Primary compartment shall be arranged for loop feed, with six universal bushing wells with load break inserts for use with insulated separable connectors. Internal oil immersed cartridge fuses shall be provided for primary overcurrent protection. A single 3-pole gang operated load break oil switch, operable from primary compartment, shall provide for disconnection of the primary winding without interruption of the primary loop. 10.13 Secondary Switchgear: The secondary compartment shall be equipped with a fixed vacuum circuit breaker mounted behind a deadfront panel and wired to the secondary terminals of the transformer. The circuit breaker shall be rated at 5 or 8 kV, with continuous and interrupting current ratings as specified in Table 11, below. The circuit breaker shall be equipped with an integral electronic trip unit with ground fault detection capability. Turbine Rating Continuous Current Interrupting Current 3 MW 800 A 16 kA 5 MW 1200 A 16 kA 7.5 MW 800 A 20 kA Table 11. AC Power Circuit Breaker Ratings

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REPORT DOCUMENTATION PAGE

Form Approved OMB No. 0704-0188

The public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing the burden, to Department of Defense, Executive Services and Communications Directorate (0704-0188). Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number.

PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ORGANIZATION. 1. REPORT DATE (DD-MM-YYYY) 2. REPORT TYPE

3.

DATES COVERED (From - To)

November 2005
4. TITLE AND SUBTITLE

Subcontract Report

June 15, 2004 - April 30, 2005

5a. CONTRACT NUMBER

Low Wind Speed Turbine Project Phase II: The Application of Medium-Voltage Electrical Apparatus to the Class of Variable Speed Multi-Megawatt Low Wind Speed Turbines

DE-AC36-99-GO10337
5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER

6.

AUTHOR(S)

5d. PROJECT NUMBER

W. Erdman and M. Behnke

NREL/SR-500-38686
5e. TASK NUMBER

WER6 0301
5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION REPORT NUMBER

Behnke, Erdman & Whitaker Engineering, Inc. 1293 Hyacinth Court Livermore, CA 94551-9830
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

TAM-4-33200-03
10. SPONSOR/MONITOR'S ACRONYM(S)

National Renewable Energy Laboratory 1617 Cole Blvd. Golden, CO 80401-3393

12. DISTRIBUTION AVAILABILITY STATEMENT

NREL
11. SPONSORING/MONITORING AGENCY REPORT NUMBER

NREL/SR-500-38686 National Technical Information Service U.S. Department of Commerce 5285 Port Royal Road Springfield, VA 22161
13. SUPPLEMENTARY NOTES

NREL Technical Monitor: A. Laxson

14. ABSTRACT (Maximum 200 Words)

Kilowatt ratings of modern wind turbines have progressed rapidly from 50 kW to 1,800 kW over the past 25 years, with 3.0- to 7.5-MW turbines expected in the next 5 years. The premise of this study is simple: The rapid growth of wind turbine power ratings and the corresponding growth in turbine electrical generation systems and associated controls are quickly making low-voltage (LV) electrical design approaches cost-ineffective. This report provides design detail and compares the cost of energy (COE) between commercial LV-class wind power machines and emerging medium-voltage (MV)-class multi-megawatt wind technology. The key finding is that a 2.5% reduction in the COE can be achieved by moving from LV to MV systems. This is a conservative estimate, with a 3% to 3.5% reduction believed to be attainable once purchase orders to support a 250-turbine/year production level are placed. This evaluation considers capital costs as well as installation, maintenance, and training requirements for wind turbine maintenance personnel. Subsystems investigated include the generator, pendant cables, variable-speed converter, and padmount transformer with switchgear. Both current-source and voltage-source converter/inverter MV topologies are compared against their lowvoltage, voltage-source counterparts at the 3.0-, 5.0-, and 7.5-MW levels.
15. SUBJECT TERMS

wind energy; wind turbines; low wind speed; low wind speed turbine project; variable speed; cost of energy; COE
16. SECURITY CLASSIFICATION OF:
a. REPORT b. ABSTRACT c. THIS PAGE 17. LIMITATION 18. NUMBER OF ABSTRACT OF PAGES 19a. NAME OF RESPONSIBLE PERSON

Unclassified

Unclassified

Unclassified

UL

19b. TELEPHONE NUMBER (Include area code) Standard Form 298 (Rev. 8/98)
Prescribed by ANSI Std. Z39.18

F1146-E(12/2004)