march 24 2011 rev 4 – cd harbourt ge infrastructure – energy wind energy 101 introduction to...

March 24 2011Rev 4 – CD Harbourt

GE Infrastructure – Energy

Wind Energy 101Introduction to wind turbine technology

Cy Harbourt

GE Energy

March 24, 2011

Virginia Mountain Section IEEE

1


•This presentation was originally authored by Aaron Barr from GE Energy in Greenville, SC and was presented at the December meeting of the ASME in Greenville.

•Thanks to Aaron for making it available to us


Agenda

• Introduction – GE and Wind energy

•Wind Energy first principles

•Wind energy market

•Wind Turbines – component view

•GE Wind Energy opportunities

•Q & A session

3

Introduction

05 November 2010Rev 2

416 December 2010Rev 3 – Aaron Barr


Early wind energy engineer…

Of all the forces of nature, I should think the wind contains the largest amount of motive power.

All the power exerted by all the men, beasts, running-water, and steam, shall not equal the one hundredth part of what is exerted by the blowing of the wind.

Quite possibly one of the greatest discoveries, will be the taming and harnessing of it.

5March 17, 2011Rev 4 – CD Harbourt

– Abraham Lincoln - 1860– Abraham Lincoln - 1860


“I'd put my money on the sun and solar energy. What a source of power! I hope we don't have to wait ‘til oil and coal run outbefore we tackle that.”

~Thomas Edison - 1931



Europe Renewables HeadquartersSalzbergen, Germany

Energy Learning CenterNiskayuna, NY

Global Research CenterMunich, Germany

JF Welch Technology CenterBangalore, India

Global Research CenterShanghai, China

Global Research CenterNiskayuna, NY

Global Renewables HeadquartersSchenectady, NY

GE Wind ManufacturingGreenville, SCPensacola, FLTehachapi, CA

Powerful Heritage… Innovative Solutions

Energy EngineeringGreenville, SC

Global team with diverse expertise

7

Power Conversion Center of ExcellenceSalem, VA


Wind

• Leading N. American

wind turbine supplier

• 6x unit growth since ‘02

•16,000+ 1.5MW installed globallyBiogas

• Power range: 0.25 MW-4 MW

• Fuel flexibility: Natural gas or a variety of renewable or alternative gases

Solar

• Residential, commercial and utility applications

• Largest commercial solar project in Asia

• PrimeStar Solar thin film technology investment

• 10 manufacturing/assembly sites• 4,000 global employees• Installed base: 24+GW• Projects in 40+ countries•10,000 sub-supplier jobs created

GE Energy….The largest renewables business on Earth



Wind Turbine Components

Rotor35 metric tons77 meters diameter

Nacelle52 metric tons

Tower120+ metric tons60 to 100 metersCar (for scale)

GE 1.5 MW1200-1700 HouseholdsWorsham Field

9


Small vs. Big wind energy

Two Related technologies

Different applications and economics

10kw

You

1500kw

Utility-Scale Wind Power - 850 - 6000 kW

•Owned by utilities, multi-million $ companies

•Installed on wind farms, 10 – 600 MW

•Professional maintenance crews

•>13 mph (6 m/s) avg wind speed

Small Wind Power - 300 W - 250 kW

•Individual homes, farms, businesses, etc.

•On the “customer side” of the meter

•Or…off the grid entirely

•High reliability, low maintenance

•>9 mph (4 m/s) avg wind speed

Source: NREL

10


1981 1985 1990 1996 1999 2001Rotor Dia. (m)10 17 27 40 50 71

KW 25 100 225 550 750 1,500

200588

2,500

Increased size, improved performance and technology innovation

Wind energy now cost competitive with conventional fuels

CoE

From ~60 cents/kWh down to 5-6 cents/kWh for the period

Wind Turbine Growth: Size, Power and Cost

2010+125+

7,500+

11

Wind Energy First Principles


12


Wind Turbine PrinciplesConverting one form of energy to another

KineticEnergy

Mechanical Energy

Electrical Energy

Overall: 42 – 50% Efficient Today… Theoretical Maximum is 59.3% (no losses)

Component

Rotor Gearbox Generator Converter

Efficiency 45-52% 95-97% 97-98% 96-99%

13


Rotor power

Ideal (Betz limit)

(wind velocity slows by 2/3)

Rotor power

Ideal (Betz limit)

(wind velocity slows by 2/3)

V1

V2

area swept rotor A

density air

tcoefficien power rotor

:

312

1

p

p

C

where

CρAVP

131

2

p

VV

:where

5930C

.

Wind Turbine Energy Capture

14

Source: “Wind turbines: Fundamentals, Technologies, Application and Economics”, Erich Hau, ISBN: 3540570640; (April 30, 2000)

Cp vs. PU Exit Velocity

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 0.2 0.4 0.6 0.8 1 1.2

PU Exit Velocity

Cp

Cp vs. PU Exit VelocityCp vs. PU Exit Velocity


Source: “Wind turbines: Fundamentals, Technologies, Application and Economics”, Erich Hau, ISBN: 3540570640; (April 30, 2000)

Unsteady dynamics•Turbulence•Shear•Density changes

Design challenges•Across diameter•15% average difference•30% Instant difference

Loads analysis critical to maintaining 20-year life

Wind Variation

15


Wind energy technologies

3-blade horizontal axis turbines are optimal

Wind is….

•Really solar power!

•Uneven heating of earth

•Coreolis - earth rotation

•Moving mass

•Kinetic Energy!!!

AreaSweptA

velocity windV

density airρ

EfficiencyC

ρAV2

1CP

P

3Pw

59.3% 16/27CMax P

DRAG LIFT

Source: NREL

1616


Horizontal axis Horizontal axis Vertical axis 3-bladed 2-bladed

( HAWT )( VAWT )

Wind Turbine Design Concepts

17


0

0.1

0.2

0.3

0.4

0.5

0.6

0 5 10 15

= Tip Speed Ratio

Cp

1 Blade

2 Blades

3 Blades

4 Blades

Ideal

= Vtip / V1

Blade calculations include realistic airfoils, L/D, and tip losses. Each point along a curve represents an optimized airfoil for given tip speed ratio. Ideal curve is zero drag optimum with rotational wake.

-4 blades cost more than 3 – provide marginal performance benefit

-2 blades provides loads balancing issue - requires teetered hub/downwind rotor

-3 blades (tripod) provides solution to loads resolution

Actual Cp is constrained by Betz limit

Also: noise (tip speed), loads, blade geometry

Why 3 Blades?

18


Aerodynamic LiftU – Windspeed, m/sR – Blade radial position, m - Rotational Velocity, rad/s

Varies with windspeed - Local twist angle, deg

Varies with radius - Blade pitch angle, deg

Varies with windspeed - Angle of attack, deg

Varies with radius and wind speed

Wind

Roto

r Pla

ne

0-P

itch

Lin

eC

hord

Lin

eFl

ow D

irec

tion

Thrust

Torque

Drag

Lift

U

R

Trade-offCost: Thrust loads = Material, weight

Benefit: Torque Loads = PowerThrust:Torque ~ 10:1

19


Power Curve Terminology

Power output vs. wind speed at hub height – 10min average wind speeds Example: official power curve for 1.5s

20

56 MPH!

56 MPH!

Wind turbines

Component view

21


Nacelle & Hub components

Rotor main shaft

Pitch drive

Hub

Main bearing

‘Top box’:low voltage, control…

Generator

Bed Frame Yaw

drives

High-speed coupling

Gearbox

Wind Sensors

GE 1.5 wind turbine52 metric ton nacelle35 metric ton rotor

Pitch bearing

Mechanical brake

Yaw bearing

6-ft

Hokie Bird is registered trademark of Virginia Tech 22


Wind turbine assembly

23


Wind turbine installation

24


Blades – Product Differentiators

Blades critical to performance:Energy capture … revenueAerodynamic loads… cost

Design optimization:MaterialsAirfoil geometryLoadsNoiseEfficiencyCostLogistics

Spar CapLeading Edge

Shell

Trailing Edge

Shear Webs

Blade Cross-section

Blade Fatigue testing

25

Source: National Renewable Energy LabSource: National Renewable Energy Lab


Hub & Pitch system

Hub Assembly

Pitch system… critical to safety Pitch blades out of the windMaintain rated powerShut turbine down

Source: GE energy – 2007 Sandia reliability conferenceSource: GE energy – 2007 Sandia reliability conference


26


Gearbox and mechanical drivetrain

MW-scale Gearbox

Torque arms

Input - ~15RPM

Planetary stage

Output – 1600RPM

Parallel stages

Source: GE transportation

Drivetrain… critical to reliabilityDesign optimizations:Reliability… 20 year lifeTorque capabilityMaintainabilitySize, weight, CostGlobal source-ability


Root cause analysis processRoot cause analysis process

27


3

3GEAR BOX

WOUND ROTOR INDUCTION GENERATOR TRANSFORMER

GRID

IGBT POWER CONVERTERS

3

3

GEAR BOX

INDUCTION GENERATOR TRANSFORMER

GRID

GEAR BOX

SYNCHRONOUSGENERATOR TRANSFORMER

GRID

Rectifier

33

IGBTInverter

2) Doubly-Fed High speed Generator

1) Fixed Speed System – no converter

3) High speed synchronous generator

Wind Turbine generator types

C) Direct-drive generator – no gearbox

Pros: Low cost, simplicity

Cons: Poor performance

Poor grid integration

Pros: Low cost, simplicity

Cons: Poor performance

Poor grid integration

Pros: Grid integration, controllability

Cons: Higher power electronics cost

Pros: Grid integration, controllability

Cons: Higher power electronics cost

Pros: Excellent compromise of cost & gridPros: Excellent compromise of cost & grid

Pros: Elimination of gearbox – reliability

Cons: Large generator – high cost

Pros: Elimination of gearbox – reliability

Cons: Large generator – high cost

28

Generator choice is critical to operational flexibility & grid integration



Tower and Power Electronics

View of 2.5MW tower base

Source; GE EnergySource; GE Energy

Power conversion… critical to flexibilityGrid integration and complianceVariable speed capabilityDesigned & manufactured at GE in Salem, VA

29

Wind Energy Market

30

2009

31

2030

Power Required Doubles !32


Pasterze Glacier, Austria

Environmental Challenges

Increasing atmospheric CO2 is warming the planet

Power generation is leading cause of CO2 emissions

1875 2004

Carbon constraints increase demand for renewable energy

33


US Power Generation Mix

Half the US power is coal-fired

2009 new installs : 39% wind, 9% coal

Source: Energy Information Administration

Non Renewable

Non Renewable

RenewableRenewable

34


> 8

7- 8

6-7

4-6

< 4

Wind Speed (m/s @ 50m)

US percent of electricity consumption

from wind: ~1%

(10 m/s = 22.4 mph)

Wind Resource – U.S.A.

Midwestern United States is ‘Saudi Arabia of Wind’

35


> 8

7- 8

6-7

4-6

< 4

Wind Speed (m/s @ 50m)

Wind power penetration

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

Denmark Spain Germany Ireland Portugal Greece Netherlands EU

% o

f e

lec

tric

ity

co

ns

um

pti

on

Source: BTM Consult ApS - September 2005

Wind power penetration

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

Denmark Spain Germany Ireland Portugal Greece Netherlands EU

% o

f e

lec

tric

ity

co

ns

um

pti

on

Source: BTM Consult ApS - September 2005

(10 m/s = 22.4 mph)

Wind Resource - Europe

36


Top Wind Power countries

US and China with more than 1/3 of the World’s MW

China expected to take #1 position by 2015

Source: BTM Consult [3]

MW % world

35,195 22%

25,853 16%

25,813 16%

18,784 12%

10,827 7%

4,845 3%

4,775 3%

4,340 3%

3,474 2%

3,408 2%

22,770 14%

37


Top Windpower US States

26.8%

10.4%

7.95%

5.6%5.1%5.0%

4.4%

3.6%

3.5%

3.42%

24.1%

TexasIowaCaliforniaWashingtonMinnesotaOregonIllinoisNew YorkColoradoNorth Dakota26 Others

Texas, Iowa and California generate ~½ of total

Dakotas could power the entire US

CapacityTop 10 producers

Source: AWEA

Source: AWEA

Source: AWEA

Production

38

http://www.awea.org/http://www.awea.org/


Source: AWEA

2005: 5 turbine manufacturer active in US

2009: 10+….Competition is growing, GE remains in good position

Wind Industry Growth - USA2009 Installs2009 Installs

39

Wind Energy Grid Challenges


40


Utility Scale Wind Generation …5-10% Penetration Easily Managed

Managing a Variable Resource

•1 to 48 Hour Wind Forecasting

•Coordinated Economic Dispatch of Hydro, GT, .…

Danish Transmission Grid w/ Interconnects & Offshore Sites

Jutland - Western Denmark

3000 MW Wind Capacity Out of 6800 MW Total

•20% of Average Demand Supplied by Wind

•Max 1 Hr Penetration Is 80%, max 20% change per hour

•HVDC Link to Norway, Hydro As Virtual Storage

Wind Site Forecasting

Utility Windfarms

100-500 MW Farms Being Developed

•Grid Codes Rapidly Evolving150 MW Trent Mesa, TX

EON - LVRT spec


Application Characteristics

Single WTGs Large Farms Multiple Farms

Low Penetration High Penetration

Per

form

ance

Req

uir

emen

ts

Bas

ic

A

dvan

ced

LVRT

O/U VoltageOvercurrent

O/U Frequency

Anti-islandingAnti-islanding

PF control

Voltage control(old DVAR)

Zero Zero PowerPower

Voltage Voltage ControlControl

Fancy Voltage Control

(WindVAR)

None

Protection Volt/VAR Control

Active Power Control

None

LVRT – no trip(e.g. Taiban, E-ON)

Zero VRT – no tripZero VRT – no trip(e.g. Western (e.g. Western

Australia)Australia)

LVRT with controlled LVRT with controlled current injectioncurrent injection

Curtailment

Frequency Frequency ResponseResponse

Reserve Reserve FunctionsFunctions

Active Anti-islanding,Active Anti-islanding,Torsional, Torsional,

othersothers

Grid Requirements Evolution

EON - LVRT spec


Grid Integration …Critical for Large Scale Wind

Composite (Worst Case) Emergency Voltage

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

1.10

1.20

1.30

1.40

1.50

0.0 0.1 1.0 10.0 100.0 1000.0 10000.0

Time (seconds)

Vo

ltag

e (P

U)

Australia

EON

Denmark

France

Scotland

ScotlandEON Denmark

EONLVRT Full Power Tests

Global Transient Voltage Requirements

Rapidly Evolving Grid Codes

• Success of wind is driving sweeping changes

• New electrical control features evolving

• Ride-Thru, Real/Reactive Power control

• Wind needs to be as Grid-Friendly as Traditional Generation for 50 GW Global market

Voltage

Power


Unit Dispatch

0

100

200

300

400

500

600

700

0 2000 4000 6000 8000

Hour

MW

9500

10000

10500

0 60 120 180

MAPS Load MAPS Pgen Total MAPS Base Load

QSS Load QSS Pgen(i) QSS Pgen Total

600 seconds

Voltage Power

Spinning Reserve (Day Ahead Scheduling)

Load Following(5 Minute Dispatch)

Frequency & Tie-line Regulation (Seconds)

Ancillary Services & Wind Variability

multiday forecasting –participation in SMD

<-

Fas

ter

Tim

e S

cale

S

low

er -

>

Operational/Cost Regime

Technology Advancements

Short-term forecasting and wind farm active power management

WTG level active and reactive power controls


Taiban Mesa 204 MW

~ 1500 mi

Colorado Green 162 MW

Windfarm Electrics –Real & Reactive Power Control

Clean volts on

host utility grid

Taiban Plateau 204 MW


GE Wind farms are more stable that conventional synchronous generators.

Voltage recovery of the wind farm is better

Synchronous Generator swings dramatically???

Time (seconds)

Wind Turbine Transient Response


Wind ForecastingEltra, Denmark - 2000 Study

• 1.9GW onshore farms, 16% consumption

• 3.4TWh produced, 1.3TWh miscalculated (38%)

• Climatology-based forecast, inaccuracies up to 800MW

• $12M imbalance payments (0.3c/kWh)

Current State-of-the-Art• Local statistical model + 3D climatology model - 10-15% mean abs error for day-ahead and 5-10% error for 6 hr ahead forecasts• 2005 regulations in Spain provide:

- Penalties for >20% error on 24hr production forecast- Incentives for <10% error over rolling 4hr forecast

• 2003 Cal ISO regulations – unbiased hourly, daily forecasts – settlement monthly for net deviations at average rate• Utilities need short (<6h), med (24-36h) and long term (>72h) forecasts

AWSTruewind forecast using a combination of local statistical models,

and 3D meso-scale climatology

Wind Energy Offshore


48

• US East Coast, Great Lakes, BC, UK, Germany, …

• Proximity to Population & Load Centers

• 10-20 Km Offshore, Water Depths to 10-40 M

Challenges

• Hurricane Exposure, Waves, Sea Bed Stability

• Deep Water Foundations > 40 m Can Open Vast Resource

• Tough Service Environment, Need Autonomous Operation GE 7x 3.6 MW –

Arklow Banks, Irish Sea

Offshore Construction,7.2 GW RFP’s in UK

Offshore Wind … GW Scale Renewable

20 GW Potential off NE Coast,Capacity Factors to 50%


Offshore Wind Potential

300300

150150 400400

86008600 750750

300300

900900

27002700200200

Germany

Sweden

Denmark

Ireland

Belgium

Netherlands

86008600 600600

UK 23 GW

83008300 600600

USA

700700

Canada

9.6 GW

Concept / Early Stage

Active Develop

Source: Emerging Energy Research / GE Wind

Significant Offshore Growth Potential . . . Drivers Are:• Renewable Obligations ( UK, US) • Kyoto compliance (Germany, Ireland)

Over 30GW Of Specific Sites In Various Stages Have Been Announced


Offshore Multi-Generational Plan

Depth dependence on weight can be reduced substantially

with a floating foundation system

Now

Phase I

Jacket weight increases with depth even at

constant MW rating

Phase II

Fatigue Effect

?


Floating Wind Challenges

f2 > 1.785 Hz

0.312 < f1 < 0.383 HzExcitation from

rotor operation

Excitation from

blade passing

Current Wind Opportunity(Narrow)

Oil & Gas Opportunity(Wide)

Compliant Floating System


DOE LWST 2 Offshore Program – 5MW+

2 Blade vs 3 Blade Tradeoff

Offshore Turbine System Design• 5-7 MW turbine rating• Design for Availability, Reliability• Access & service strategies• 5-6 c/kWh target in 20 m depth

R&D Focus• Foundation technology• Turbine configuration – 2 vs. 3 blade• Drivetrain development• Rotor development to 140 m• RM&D, CBM

Medium & Deep Water Foundations

Service Technology, RM&D

Wind Turbines

Gearbox Epoxy-Glass

Composite Blades

Electrical Pitch Drives

Transformer & Electrical

Doubly-FedGenerator

Main Shaft & Bearing

Power ElectronicConverter

GE 1.5 MW• 77 M Rotor Diameter

• 50-100 M Tower

• 98% Availability

• Speed 10-20 RPM

• Variable Pitch

Wind Energy Opportunities


55


Advanced technology developmentBlade

Construction

Power Electronic

s

Wind Sensin

g

Aerodynamic

optimization

Advanced Load

Control

Advanced Material

Development

Advanced

Generators

Wind Farm Manageme

nt

Compact Drivetrain

s

Advanced Tower Design

Possibilities are endless

Engineers Needed! VT Grad

GE Electrical Engineer 56


Additional ReadingGE Wind Energy external

http://www.gepower.com/businesses/ge_wind_energy/en/index.htm

Organizations

European Wind Energy Association www.ewea.org

American Wind Energy Association www.awea.org

Danish Wind Industry Association www.windpower.org

Windpower Monthly www.wpm.co.nz

AGORES www.agores.org A Global Overview of Renewable Sources

Competition

Overall list: http://energy.sourceguides.com/businesses/byP/wRP/lwindturbine/byN/byName.shtml

Vestas, Denmark www.vestas.com

Enercon www.enercon.de

REpower, Germany www.repower.de/index.php?id=347&L=1

Suzlon ww.suzlon.com

Siemens, Danmark http://www.powergeneration.siemens.com/products-solutions-services/power-plant-soln/windpower/windturbines.htm

Nordex www.nordex.dk

Gamesa, Spain http://www.gamesa.es/index.php/en

Against windpower lobby: www.windkraftgegner.de in German with links to English sites

57


GEEnergy

Thank you … Questions?

Cy Harbourt

[email protected]

58

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