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GE Infrastructure – Energy Wind Energy 101 Introduction to wind turbine technology Cy Harbourt

GE Infrastructure – Energy Wind Energy 101 Introduction to wind turbine technology Cy Harbourt GE Energy March 24, 2011 Virginia Mountain Section IEEE. 1.

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GE Infrastructure – Energy Wind Energy 101 Introduction to wind turbine technology Cy Harbourt

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  1. GE Infrastructure – Energy • Wind Energy 101 • Introduction to • wind turbine technology • Cy Harbourt • GE Energy • March 24, 2011 • Virginia Mountain Section IEEE 1

  2. 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

  3. 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

  4. Introduction 05 November 2010 Rev 2 4 16 December 2010 Rev 3 – Aaron Barr

  5. 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. – Abraham Lincoln - 1860 March 17, 2011 Rev 4 – CD Harbourt

  6. “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 out before we tackle that.”~Thomas Edison - 1931 March 17, 2011 Rev 4 – CD Harbourt 6

  7. Global Research Center Munich, Germany Energy Learning Center Niskayuna, NY Global Research Center Niskayuna, NY Global Research Center Shanghai, China Global Renewables Headquarters Schenectady, NY Powerful Heritage… Innovative Solutions Europe Renewables Headquarters Salzbergen, Germany Energy Engineering Greenville, SC JF Welch Technology Center Bangalore, India GE Wind Manufacturing Greenville, SC Pensacola, FL Tehachapi, CA Power Conversion Center of Excellence Salem, VA Global team with diverse expertise 7

  8. GE Energy….The largest renewables business on Earth Wind Solar • Leading N. American wind turbine supplier • 6x unit growth since ‘02 • 16,000+ 1.5MW installed globally • Residential, commercial and utility applications • Largest commercial solar project in Asia • PrimeStar Solar thin film technology investment Biogas • Power range: 0.25 MW-4 MW • Fuel flexibility: Natural gas or a variety of renewable or alternative gases • 10 manufacturing/assembly sites • 4,000 global employees • Installed base: 24+GW • Projects in 40+ countries • 10,000 sub-supplier jobs created March 17, 2011 Rev 4 – CD Harbourt 8

  9. Wind Turbine Components GE 1.5 MW 1200-1700 Households Worsham Field Rotor 35 metric tons 77 meters diameter Nacelle 52 metric tons Tower 120+ metric tons 60 to 100 meters Car (for scale) 9

  10. Small vs. Big wind energy • 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 1500kw • Two Related technologies • Different applications and economics 10kw You Source: NREL 10

  11. Wind Turbine Growth: Size, Power and Cost CoE From ~60 cents/kWh down to 5-6 cents/kWh for the period 1981 1985 1990 1996 1999 2001 2005 2010+ Rotor Dia. (m) 10 17 27 40 50 71 88 125+ KW 25 100 225 550 750 1,500 2,500 7,500+ Increased size, improved performance and technology innovation Wind energy now cost competitive with conventional fuels

  12. Wind Energy First Principles 05 November 2010 Rev 2 12

  13. Wind Turbine Principles Converting one form of energy to another KineticEnergy Mechanical Energy Electrical Energy Overall: 42 – 50% Efficient Today… Theoretical Maximum is 59.3% (no losses) 13

  14. Wind Turbine Energy Capture • Rotor power • Ideal (Betz limit) • (wind velocity slows by 2/3) V2 V1 Cp vs. PU Exit Velocity Source: “Wind turbines: Fundamentals, Technologies, Application and Economics”, Erich Hau, ISBN: 3540570640; (April 30, 2000) 14

  15. Wind Variation • Unsteady dynamics • Turbulence • Shear • Density changes • Design challenges • Across diameter • 15% average difference • 30% Instant difference • Loads analysis critical to maintaining 20-year life Source: “Wind turbines: Fundamentals, Technologies, Application and Economics”, Erich Hau, ISBN: 3540570640; (April 30, 2000) 15

  16. 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!!! DRAG LIFT Source: NREL 16 16

  17. Wind Turbine Design Concepts Horizontal axis Horizontal axis Vertical axis 3-bladed 2-bladed ( HAWT ) ( VAWT ) 17

  18. Why 3 Blades? 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. = Vtip /V1 • 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 18

  19. Aerodynamic Lift U – Windspeed, m/s R – 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 Rotor Plane 0-Pitch Line Chord Line Flow Direction  Drag U Thrust Wind Torque Lift R  Trade-off Cost: Thrust loads = Material, weight Benefit: Torque Loads = Power Thrust:Torque ~ 10:1   19

  20. Power Curve Terminology Power output vs. wind speed at hub height – 10min average wind speeds Example: official power curve for 1.5s 56 MPH! 20

  21. Wind turbines Component view 21

  22. Nacelle & Hub components 6-ft Hokie Bird is registered trademark of Virginia Tech GE 1.5 wind turbine 52 metric ton nacelle 35 metric ton rotor ‘Top box’: low voltage, control… Wind Sensors High-speed coupling Mechanical brake Gearbox Generator Pitch drive Pitch bearing Bed Frame Hub Yaw drives Yaw bearing Rotor main shaft Main bearing 22

  23. Wind turbine assembly 23

  24. Wind turbine installation 24

  25. Blades – Product Differentiators Blade Cross-section Shell Shear Webs • Blades critical to performance: • Energy capture … revenue • Aerodynamic loads… cost • Design optimization: • Materials • Airfoil geometry • Loads • Noise • Efficiency • Cost • Logistics Trailing Edge Leading Edge Spar Cap Blade Fatigue testing Source: National Renewable Energy Lab 25

  26. Hub & Pitch system Hub Assembly Source: GE energy – 2007 Sandia reliability conference • Pitch system… critical to safety • Pitch blades out of the wind • Maintain rated power • Shut turbine down Source: GE energy – 2007 Sandia reliability conference 26

  27. Gearbox and mechanical drivetrain Root cause analysis process MW-scale Gearbox Planetary stage Parallel stages Torque arms Source: GE energy – 2007 Sandia reliability conference • Drivetrain… critical to reliability Design optimizations: • Reliability… 20 year life • Torque capability • Maintainability • Size, weight, Cost • Global source-ability Output – 1600RPM Input - ~15RPM Source: GE transportation 27

  28. Wind Turbine generator types 1) Fixed Speed System – no converter 2) Doubly-Fed High speed Generator Pros: Low cost, simplicity Cons: Poor performance Poor grid integration Pros: Excellent compromise of cost & grid C) Direct-drive generator – no gearbox 3) High speed synchronous generator Pros: Elimination of gearbox – reliability Cons: Large generator – high cost Pros: Grid integration, controllability Cons: Higher power electronics cost Generator choice is critical to operational flexibility & grid integration 28

  29. Tower and Power Electronics Source: GE energy – 2007 Sandia reliability conference • Power conversion… critical to flexibility • Grid integration and compliance • Variable speed capability • Designed & manufactured at GE in Salem, VA Source; GE Energy View of 2.5MW tower base 29

  30. Wind Energy Market 30

  31. 2009 31

  32. 2030 Power Required Doubles ! 32

  33. Environmental Challenges • Increasing atmospheric CO2 is warming the planet • Power generation is leading cause of CO2 emissions Pasterze Glacier, Austria 2004 1875 Carbon constraints increase demand for renewable energy 33

  34. US Power Generation Mix • Half the US power is coal-fired • 2009 new installs : 39% wind, 9% coal Source: Energy Information Administration Non Renewable Renewable 34

  35. Wind Resource – U.S.A. Wind Speed (m/s @ 50m) > 8 7- 8 6-7 4-6 < 4 (10 m/s = 22.4 mph) US percent of electricity consumption from wind: ~1% Midwestern United States is ‘Saudi Arabia of Wind’ 35

  36. Wind Resource - Europe > 8 7- 8 6-7 4-6 < 4 Wind Speed (m/s @ 50m) (10 m/s = 22.4 mph) 36

  37. 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] 37

  38. Top Windpower US States Top 10 producers Capacity • Texas, Iowa and California generate ~½ of total • Dakotas could power the entire US Source: AWEA Production Source: AWEA Source: AWEA http://www.awea.org/ 38

  39. Wind Industry Growth - USA 2009 Installs Source: AWEA 2005: 5 turbine manufacturer active in US 2009: 10+….Competition is growing, GE remains in good position 39

  40. Wind Energy Grid Challenges 05 November 2010 Rev 2 40

  41. EON - LVRT spec Utility Scale Wind Generation …5-10% Penetration Easily Managed • Utility Windfarms • 100-500 MW Farms Being Developed • Grid Codes Rapidly Evolving 150 MW Trent Mesa, TX • 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 Danish Transmission Grid w/ Interconnects & Offshore Sites • Managing a Variable Resource • 1 to 48 Hour Wind Forecasting • Coordinated Economic Dispatch of Hydro, GT, .… Wind Site Forecasting

  42. EON - LVRT spec Zero Power Voltage Control Active Anti-islanding, Torsional, others Reserve Functions LVRT with controlled current injection Zero VRT – no trip (e.g. Western Australia) Fancy Voltage Control (WindVAR) Frequency Response Anti-islanding Voltage control (old DVAR) LVRT – no trip (e.g. Taiban, E-ON) Curtailment O/U Voltage Overcurrent O/U Frequency None PF control None Volt/VAR Control Active Power Control LVRT Protection Grid Requirements Evolution Performance Requirements Basic Advanced Application Characteristics Single WTGs Large Farms Multiple Farms Low Penetration High Penetration

  43. Grid Integration …Critical for Large Scale Wind • 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 LVRT Full Power Tests Global Transient Voltage Requirements

  44. Voltage Power 600 seconds Ancillary Services & Wind Variability Operational/Cost Regime Technology Advancements multiday forecasting –participation in SMD Spinning Reserve (Day Ahead Scheduling) Load Following (5 Minute Dispatch) Short-term forecasting and wind farm active power management <- Faster Time Scale Slower -> Frequency & Tie-line Regulation (Seconds) WTG level active and reactive power controls

  45. Clean volts on host utility grid Colorado Green 162 MW ~ 1500 mi Windfarm Electrics – Real & Reactive Power Control Taiban Mesa 204 MW Taiban Plateau 204 MW

  46. Wind Turbine Transient Response • GE Wind farms are more stable that conventional synchronous generators. Voltage recovery of the wind farm is better Synchronous Generator swings dramatically??? Time (seconds)

  47. Wind Forecasting • Eltra, 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) AWSTruewind forecast using a combination of local statistical models, and 3D meso-scale climatology • 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

  48. Wind Energy Offshore 05 November 2010 Rev 2 48

  49. Offshore Wind … GW Scale Renewable • 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 Offshore Construction, 7.2 GW RFP’s in UK GE 7x 3.6 MW – Arklow Banks, Irish Sea 20 GW Potential off NE Coast, Capacity Factors to 50%

  50. Offshore Wind Potential • 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 23 GW 9.6 GW UK Sweden 8600 600 2700 200 Denmark Canada 400 150 700 Ireland Germany 900 8600 750 USA 8300 Belgium 600 300 300 Active Develop Netherlands Concept / Early Stage Source: Emerging Energy Research / GE Wind

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