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Competitive wind turbine drive trains    through representative testing    Dr. Stefan Lammens, Vice President – Chief Sale...
Combination of ZF and Hansen                                                                                              ...
The Business Unit Wind Power Technology is                     part of the Industrial Technology Division of ZF    ZF Frie...
Key Figures                         2011 Group    The ZF Group – An Overview                                   2011    201...
Wind Market Segments                            Global Annual Market Installations (in GW)60 GW                           ...
CoE Reductions Critical to Competitiveness    Wind competitive with fossil fuels                                 Cost of E...
Impact of gearboxes on CoE    Offshore Wind Cost Drivers                         Offshore CAPEX structure                 ...
Our mission       We reduce the kWh cost of renewable energy We develop competitive products with      proven reliability...
Trends in drive train technology    Diversity in solutions on the market Search for the lowest CoE yields various        ...
Representative testing Representative testing is key to proof reliability of our competitive designsLogistic complexity a...
Representative testing                             It is possible to                             transform wind           ...
Hansen Transmissions International                  Evolution of wind turbines and testing procedures                     ...
Design verification proving reliability                                          Technology/                              ...
Component and Sub-assembly Verification ZF WP’s dynamic bearing  system test rig      testing real size bearings      i...
Gearbox Verification                                 Motor       GB1     GB2 Generator                    ZF WP’s 13.2 MW ...
Next steps in representative testing From gearbox verification to complete drive train / wind turbine testingNeed for mor...
Additional leverage to reduce CoE Minimise OPEX and optimise availability in our service offering                         ...
Additional leverage to reduce CoE Minimise OPEX and optimise availability in our service offeringO&M business is evolving...
Conclusions ZF contributes to further proof competitive wind energy technology Wind energy has grown significantly during...
Thank you very much for your attention!                                                        © ZF Friedrichshafen AG, 20...
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2012 09-27 opening-owi-lab-zf

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Official Opening of the Offshore Wind Infrastructure Application Lab (OWI-Lab).
Competitive wind turbine drive trains through representative testing
Dr. Stefan Lammens, Vice-President - Chief Sales & Marketing Officer at ZF Wind Power Antwerp nv

Publié dans : Technologie
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2012 09-27 opening-owi-lab-zf

  1. 1. Competitive wind turbine drive trains through representative testing Dr. Stefan Lammens, Vice President – Chief Sales & Marketing Officer Wind Power Technology A brand of ZF © ZF Friedrichshafen AG, 20121 Presentation Title, Date OWI-Lab, 27/09/2012 A brand of ZF
  2. 2. Combination of ZF and Hansen + Customers Products 2 MW 1,5 MW to 6,15 MW Regions Gainesville, USA Gainesville, USA Lommel, Belgium Production Lommel, Belgium Locations © ZF Friedrichshafen AG, 2012 Coimbatore, India Tianjin, China Coimbatore, India Tianjin, China Source: ZF; Hansen Transmission Annual Report 2011, 31.03.11 and Annual Report 2010, 31.03.102 OWI-Lab, 27/09/2012 A brand of ZF
  3. 3. The Business Unit Wind Power Technology is part of the Industrial Technology Division of ZF ZF Friedrichshafen AG Shareholders: 93.8 % Zeppelin Foundation and 6.2 % Dr. Jürgen and Irmgard Ulderup Foundation Division Division Division Division Joint Venture Steering Systems 4) Powertrain Chassis Commercial Vehicle Industrial Technology Technology Technology Technology 50 % CEO, Market Transmissions Chassis Systems Truck & Van Construction Passenger Car Driveline Technology Machinery Systems Steering Systems Finance, Axle Drives Chassis Components Bus Driveline Agricultural Commercial Vehicle Controlling, Powertrain Modules Technology Machinery Systems Steering Systems IT, Process Management Rubber & Plastics CV Axle Systems Material Handling Passenger Car Human Resources Steering Columns Suspension Systems Technology CV Chassis Modules Test Systems Global Aftermarket CV Damper Materials Management Technology Special Driveline Technology CV Powertrain Modules Electronic Systems Operations and Technology Marine Propulsion Systems Compliance 1) Aviation Technology Die Casting Technology2) Wind Power Technology © ZF Friedrichshafen AG, 2012 ZF Services 3) Board of Management Organizational unit 1) linked to CEO 4) ZF Lenksysteme GmbH is a joint venture between 2) linked to Materials Management domain ZF Friedrichshafen AG and Robert Bosch GmbH. Integration of Hansen Partial activities 3) linked to Market domain Transmissions in wind power3 OWI-Lab, 27/09/2012 A brand of ZF
  4. 4. Key Figures 2011 Group The ZF Group – An Overview 2011 2011/2010 Sales € 15,509 million 20 % Employees (end of year) 71,488 11 % Capital expenditure € 1,058 million 82 % R&D expenditure € 754 million 17 % 121 production companies in 27 countries 8 main development locations in 4 countries © ZF Friedrichshafen AG, 2012 34 service companies and more than 650 service partners4 OWI-Lab, 27/09/2012 A brand of ZF
  5. 5. Wind Market Segments Global Annual Market Installations (in GW)60 GW Onshore Offshore 6.3 5.650 GW 4.9 2.0 3.9 0.8 2.940 GW 1.5 0.630 GW 0.2 49.7 52.8 45.8 43.4 46.020 GW 0.2 37.9 40.5 41.1 37.6 28.210 GW 19.8 0 GW 2007 2008 2009 2010 2011 2012e 2013e 2014e 2015e 2016e 2017e Offshore wind power technology is still in the emerging stage and larger, more efficient turbines along with optimization of the nascent supply chain have large potential for reducing Cost of Energy (CoE) Reducing CoE of offshore wind will help wind to become a base-load production for the grid in mid- © ZF Friedrichshafen AG, 2012 long term Flemish stakeholders take a pioneering role in offshore innovations and developments Source: ZF WPT Market Intelligence5 OWI-Lab, 27/09/2012 A brand of ZF
  6. 6. CoE Reductions Critical to Competitiveness Wind competitive with fossil fuels Cost of Energy (EUR/MWh)  Cost of Energy (CoE) is defined as:  Onshore  A reduction of 10% in onshore wind CoE will make it directly competitive with natural gas at today’s lower energy prices  Offshore  As wind farms are installed at sites further from shore and in deeper water, the industry will have to work hard to decrease current levels of CAPEX per megawatt installed © ZF Friedrichshafen AG, 2012 Note: NG prices = USD 4.00-6.75/MMBTU, Coal = USD 1.60- 1.70.MMBTU, onshore wind capacity factor = 30%, no CO2 costs for fossil technology, EUR = 1.45 USD. Source, MAKE, Lazard, others Source: MAKE Consulting, ZF WPT Market Intelligence6 OWI-Lab, 27/09/2012 A brand of ZF
  7. 7. Impact of gearboxes on CoE Offshore Wind Cost Drivers Offshore CAPEX structure Others Preparational Management Insurance 1% Work 2% 2% 1% Contingencies 3% Electrical Grid 6% CAPEX impact of a gearbox is limited within a Substation Foundations typical offshore project, however, turbine 6% 26% suppliers are continually looking for ways to reduce component weight and material usage Installations Vessels 18% Not the offshore environment is changing wind Other Turbine turbine gearbox specifications, but the Components challenges in O&M are emphasizing the 31% importance of reliability, with a direct impact on OPEX and AEP © ZF Friedrichshafen AG, 2012 Gearbox 4% Source: MAKE Consulting, ZF WPT Market Intelligence7 OWI-Lab, 27/09/2012 A brand of ZF
  8. 8. Our mission We reduce the kWh cost of renewable energy We develop competitive products with proven reliability  to lower costs of unplanned OPEX  to guarantee AEP by increased availability © ZF Friedrichshafen AG, 20128 OWI-Lab, 27/09/2012 A brand of ZF
  9. 9. Trends in drive train technology Diversity in solutions on the market Search for the lowest CoE yields various  Mechanical power transfer: industrial solutions for the drive train,  gearbox being a trade-off between all design drivers:  hydraulic converter  reliability  Electrical generator  weight and cost  gear driven or direct drive ?  efficiency  high speed, medium speed, low speed ?  serviceability  traditional or permanent magnet generator ?  grid compatibility  Power conversion / transfer  low, medium, high voltage ?  AC or DC ? © ZF Friedrichshafen AG, 2012 All published solutions claim to be winners, but few are proven by test and experience9 OWI-Lab, 27/09/2012 A brand of ZF
  10. 10. Representative testing Representative testing is key to proof reliability of our competitive designsLogistic complexity and uncontrolled What ? environment of a wind turbine makes it a tough ‘test lab’Short time-to-market requirements in new developments put time pressure on field validation campaign Start the turbine !Representative (lab) testing capabilities are a long-term key © ZF Friedrichshafen AG, 2012 differentiator of ZF WP10 OWI-Lab, 27/09/2012 A brand of ZF
  11. 11. Representative testing It is possible to transform wind turbine behaviour into test rig conditions… © ZF Friedrichshafen AG, 201211 OWI-Lab, 27/09/2012 A brand of ZF
  12. 12. Hansen Transmissions International Evolution of wind turbines and testing procedures ZF WP Capability ZF WP DORoTe Dynamic Testing @ ZF WP 13.2 MW Test Bench Industry Standard Overload Prototype Testing100% Serial testing, first at partial, later at full load1970 1980 1990 2000 2010 2020 © ZF Friedrichshafen AG, 2012 ZF WP is continuously improving its testing procedures by implementing ZF WP specific dynamic testing methods* Indicative Numbers & years12 OWI-Lab, 27/09/2012 A brand of ZF
  13. 13. Design verification proving reliability Technology/ Materials Verification Reliable Designs Component and State-of-the-art Sub-assembly Design Tools Verification Gearbox Verification Field © ZF Friedrichshafen AG, 2012 Verification13 OWI-Lab, 27/09/2012 A brand of ZF
  14. 14. Component and Sub-assembly Verification ZF WP’s dynamic bearing system test rig  testing real size bearings  in their actual arrangement as built in the gearbox  under representative wind turbine loading and operational conditions © ZF Friedrichshafen AG, 2012 This pro-active testing method contributes largely to the design of robust bearing arrangements for new reliable gearboxes14 OWI-Lab, 27/09/2012 A brand of ZF
  15. 15. Gearbox Verification Motor GB1 GB2 Generator ZF WP’s 13.2 MW / 16.8 MW Dynamic Test Rig - 13.2 MW rated power - 1500 RPM nom speed - 1000 tons of steel - 16.8 MW peak power - 2600 RPM max speed - 1000 tons of concrete © ZF Friedrichshafen AG, 2012 - Investment - 80 kNm at motors - 35m x 10m > 10 M EUR - 100% Availability (24/7)15 OWI-Lab, 27/09/2012 A brand of ZF
  16. 16. Next steps in representative testing From gearbox verification to complete drive train / wind turbine testingNeed for more large scale test infrastructure and prototype field testingResearch topics • make tests even more representative by correlation between field and test rig conditions • increase acceleration factor for life testing on test rigsNew conditions require dedicated testing • cold / hot climate OWI climate chamber • offshore e.g. corrosion testing © ZF Friedrichshafen AG, 2012 • grid codes e.g. grid compatibility testing16 OWI-Lab, 27/09/2012 A brand of ZF
  17. 17. Additional leverage to reduce CoE Minimise OPEX and optimise availability in our service offering © ZF Friedrichshafen AG, 201217 OWI-Lab, 27/09/2012 A brand of ZF
  18. 18. Additional leverage to reduce CoE Minimise OPEX and optimise availability in our service offeringO&M business is evolving rapidlyZF has a global footprint for offering service solutions for wind turbine gearboxes Our unique gearbox know-how and large installed gearbox base will enable intelligent preventive maintenance Research challenge: innovation in performance and condition monitoring  create wind turbine data sets (SCADA, CMS, …)  develop intelligent processing algorithms © ZF Friedrichshafen AG, 2012  merge measurements and algorithms into added value for O&M18 OWI-Lab, 27/09/2012 A brand of ZF
  19. 19. Conclusions ZF contributes to further proof competitive wind energy technology Wind energy has grown significantly during last decades Further CoE reduction will support wind to gain share in future energy mix, where offshore wind is still emerging Proven reliability contributes to lower OPEX and higher AEP • Representative testing is key • ZF WP emphasizes this with large test capabilities • Next steps to focus on further improvement and expansion of test infrastructure Additional leverage to reduce CoE by using intelligent preventive maintenance as part of our service solution More and larger scale testing is better affordable in public test infrastructure (e.g. OWI), where governmental support increases regional competitiveness and contributes globally to stimulate renewable energy © ZF Friedrichshafen AG, 201219 OWI-Lab, 27/09/2012 A brand of ZF
  20. 20. Thank you very much for your attention! © ZF Friedrichshafen AG, 201220 Presentation Title, Date OWI-Lab, 27/09/2012 A brand of ZF

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