Contenu connexe Similaire à David brown (20) David brown1. David Brown Wind Energy
Servicing the Supply Chain for
Offshore Environment
28th February 2012
Alfonso Garcia
Business Development Manager – Renewable Energy
agarcia@davidbrown.com
Company confidential © DB Gear Systems Limited 1
2. 150 Years of Assurance Critical Solutions
‘To provide customised transmission solutions for
applications where customers demand absolute assurance’
Company confidential © DB Gear Systems Limited 2
4. A Worldwide Capability
UK France Eastern Europe
• Land defence transmissions • Renewables – wind, hydro • Sales office
• Naval applications • Rubber & tyre industries
• Renewables – wind, tidal • Cement, metals & mining
• High speed drives – oil & gas • Overhaul & upgrade
• Custom designed ‘low speed,
China JV
• Rail
high torque’ drives
• Renewables - wind
• Rail
USA
• Precision ‘double Indonesia
enveloping’ worm drive
• Sales Office
• Renewables - solar, wind
• Packaging/food & beverage
• Machine tools, medical and
high precision applications
• Mining, steel & energy
Chile Australia
• Mining • Overland conveyor &
• Service ,repair and Port handling
upgrade systems
• Mining
• Renewables – wind
• Power generation
(coal)
Brazil • Sugar processing
• Sales office South Africa Dubai • Service contracting
• Girth gear and mill drives • Oil & gas, power, metals, • Rail
• Mining cement, port handling India
• Power generation (coal) • Spares manufacture • Business & design centre
• Overhaul & upgrade programmes • Service, repair and • JV with Bharat Forge
• Heavy duty conveying systems upgrade
Company confidential © DB Gear Systems Limited 4
5. Products & Services
David Brown Gear Systems Product Groups
Renewable Industrial Industrial Land & Naval
Energy Engineered Aftermarket Defence
Product
Wind Mill Drives & Girth Specialist Spares Tracked/wheeled
Gears transmission New
Build
Tidal High Speed & Rail High Integrity Repair Tracked transmission
& Overhaul upgrade programmes
Solar Low Speed, High Site Services High Integrity Naval
Torque Drives
Company confidential © DB Gear Systems Limited 5
6. Wind Energy – Activities & Progress
Since 2009…
• Aftermarket Services – Globally
European repair contract with Vestas
25% UK market share in gearbox services
UK Wind Service & Upgrade Research Facility announced
Wind Service operating on 5 continents
• New Build Onshore – Joint Venture, China
1.5MW gearbox in production, 3MW in development
State-of-the-art manufacturing facility with 550 staff
• New Build Offshore
Selected as gearbox partner for 2 Wind Turbine OEM
Programmes for UK Round 3
Product development 7-10MW
Company confidential © DB Gear Systems Limited 6
7. Wind Research & Development
• Existing technology – Total Life Cost • Gearbox Bearing Technology
• Condition Monitoring • Permanent Magnet / Hybrid Technology
• Wave Energy
Feasibility analysis for geared solutions.
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8. Offshore Wind – A New Challenge
• New paradigm - Offshore wind is a different
challenge to onshore
– New entrants can take a leading role
• Offshore wind demands new & innovative
thinking
– Environment is harsh – safety considerations
are paramount
– Development costs are very high – a
different model for investment is required
– Operators need to know that their turbines
are reliable - exacting testing standards are
required
– Deployment is challenging – standardisation
& simplified logistics required
– Reactive offshore maintenance is expensive
& prohibitive
– Planned interventions require predictive
technology
Company confidential © DB Gear Systems Limited 8
9. Imperative for change
Existing GBX performance
• Most of the problems with the current fleet of wind turbine gearboxes
are generic in nature, meaning that the problems are not specific to
a single gear manufacturer or turbine model. Over the years, most
wind turbine gearbox designs have converged to a similar
architecture with only a few exceptions. (*)
• The majority of wind turbine gearbox failures appear to initiate in the
bearings. (*)
• Problems that manifested themselves in the earlier 500kW to
1000kW, still exist in many of the larger 1 to 2 MW gearboxes being
built today with the same architecture. (*)
• Many of the gearbox problems are the direct result of institutional
barriers that hinder communication and feedback during the design,
operation, and maintenance of turbines. Hence, a collaborative is
needed to bring together the various portions of the design process,
and to share information needed to address the problems.
(*) Musial W., and Butterfield S. “Improving Wind Turbine Gearbox Reliability “. National Renewable Energy Laboratory , 2007
Company confidential © DB Gear Systems Limited 9 9
10. Imperative for change
Existing offerings in the market
• Normally, GBXs are manufactured in different facilities and locations.
Then, they are sent Nacelle assembly plant.
• Existing fix warranty periods for WTG components (normally 2 years).
• Maintenance is currently done by WTG manufacturers. Wind Turbine
technicians basically perform simple visual inspections every six
months. Lack of GBXs specialists on site.
• There are sporadic GBX assistances on site, performed by GBX
manufacturers, when it is specifically required by WTG manufacturers
or wind farm owners.
• When a GBX is damaged, it must be replaced completely in most of the
times.
• Condition Monitoring Systems are rarely installed and, in those cases
where it is, there is not a proper data analysis performed by operators
at the remote control centre. Lack of knowledge.
• GBX manufactures are reluctant to share data about performance and
failure analysis.
• Reactive response way of working with WTG OEMs and final users.
Company confidential © DB Gear Systems Limited 10 10
11. David Brown approach to Offshore
‘Assured’ UK Gearbox Design & Supply Chain Partner to
OEM’s looking to UK Round 3 development:
• UK presence & established supply chain. David
Brown is the only British company with the know-how &
immediate capability to engineer, source, handle,
manufacture & assemble the large components and
functionally test very large MW gear units.
• Product Innovation. Modular design for reliability and in
nacelle maintenance. Gearbox flexible designs for 6 to
10MW wind turbine generators. Scope includes design,
verification, manufacture and testing
• Rapid Prototyping capability. Already prepared to meet
2012/13 Demonstrator sites.
• High degree of engineering capability. DB has a long
history in delivering mission critical solutions where the
consequences of failure are extremely high; defence,
marine, airspace and offshore oil & gas.
• Willing to invest in the necessary facilities/assets.
Company confidential © DB Gear Systems Limited 11 11
12. Technical differentiation for assurance
Discrete,
Planet gear & 2ndstage
All removable 1st
stage integrated rotor
flexpin assembly annulus components annulus bearings
<10T
2nd stage
sun pinion
shaft
1st stage sun
pinion shaft
Individual planet gears
1st stage carrier & fixed & flexpin assemblies
2nd stage carrier & fixed
pin assembly pin assembly
MANTAINABILITY DIFERENTATION
Example of Wind Gearbox that can be completely disassembled from downwind end
Company confidential © DB Gear Systems Limited 12
13. Tidal Energy
• In December 2011, the 1MW Hammerfest Strøm
HS1000 tidal turbine (1 MW) was successfully
deployed in the North Sea, signaling a major step
forward for the global marine renewable energy
industry.
• The HS1000 tidal turbine is fitted with a three
stage David Brown gearbox which was designed,
manufactured and tested at our Huddersfield
facility and delivered in April last year.
• Following successful load testing, the turbine was
installed at the European Marine Energy Centre
(EMEC) in Orkney. The HS1000 device will now
enter a test period to confirm its performance and
reliability, in preparation for larger scale production
and deployment.
Company confidential © DB Gear Systems Limited 13
14. David Brown Summary
• David Brown is rapidly establishing itself as a trusted Supply Partner
in Renewable Energy
• R&D programmes give significant innovation in products and services
• Collaborative approach ensures OEMs get a gearbox specifically
designed for multi MW wind turbine applications with lowest cost of
energy
– Reduced transmission weight and length from structurally efficient
architecture
– High reliability from reduced component count
– Innovative design for up-tower maintenance
• Global supply chain in place for multi MW gearbox components
• Facilities in the UK and China and supply chain investments make it an
ideal partner for supplying the Northern European and Asian Markets
– Wind
– Tidal
– Any other technical solution (Waves)
Company confidential © DB Gear Systems Limited 14
15. Thank you for your
time and kind
attention
Company confidential © DB Gear Systems Limited 15