2012 09-27 opening-owi-lab-zf
DESCRIPTION
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 nvTRANSCRIPT
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1 OWI-Lab, 27/09/2012 A brand of ZFPresentation Title, Date
Dr. Stefan Lammens, Vice President – Chief Sales & Marketing Officer Wind Power Technology
Competitive wind turbine drive trains
through representative testing
A brand of ZF
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2 OWI-Lab, 27/09/2012 A brand of ZF
1,5 MW to 6,15 MW
Customers
Production
Locations
Regions
+
Gainesville, USA
Products
2 MW
Source: ZF; Hansen Transmission Annual Report 2011, 31.03.11 and Annual Report 2010, 31.03.10
Lommel, Belgium
Coimbatore, India Tianjin, China
Gainesville, USA Lommel, Belgium
Coimbatore, India Tianjin, China
Combination of ZF and Hansen
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3 OWI-Lab, 27/09/2012 A brand of ZF
The Business Unit Wind Power Technology is
part of the Industrial Technology Division of ZF
4) ZF Lenksysteme GmbH is a joint venture between
ZF Friedrichshafen AG and Robert Bosch GmbH.
Die Casting Technology2)
CEO, Market
Finance,
Controlling,
IT, Process Management
Human Resources
Materials Management
Operations and
Technology
ZF Services 3)
Compliance 1)
ZF Friedrichshafen AG Shareholders: 93.8 % Zeppelin Foundation and 6.2 % Dr. Jürgen and Irmgard Ulderup Foundation
Board of Management Organizational unit
Powertrain Technology
Transmissions
Axle Drives
Powertrain Modules
ChassisTechnology
Chassis Systems
Chassis Components
Rubber & Plastics
Suspension Technology
Commercial VehicleTechnology
Truck & Van Driveline Technology
Bus Driveline Technology
CV Axle Systems
CV Chassis Modules
CV Damper Technology
CV Powertrain Modules
IndustrialTechnology
Construction Machinery Systems
Agricultural Machinery Systems
Material Handling Systems
Test Systems
Special Driveline Technology
Electronic Systems
Marine Propulsion Systems
Aviation Technology
Wind Power Technology
Steering Systems 4)
50 %
Passenger Car Steering Systems
Commercial Vehicle Steering Systems
Passenger Car Steering Columns
Global Aftermarket
Joint VentureDivision Division Division Division
1) linked to CEO
2) linked to Materials Management domain
3) linked to Market domainIntegration of Hansen
TransmissionsPartial activities
in wind power
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4 OWI-Lab, 27/09/2012 A brand of ZF
Key Figures2011 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
34 service companies and more than 650 service partners
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5 OWI-Lab, 27/09/2012 A brand of ZF
Source: ZF WPT Market Intelligence
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-long term
Flemish stakeholders take a pioneering role in offshore innovations and developments
Wind Market Segments
19.828.2
37.6 37.9 40.545.8
41.1 43.4 46.049.7 52.8
0.2
0.2
0.6 1.50.8
2.02.9
3.94.9
5.66.3
0 GW
10 GW
20 GW
30 GW
40 GW
50 GW
60 GW
2007 2008 2009 2010 2011 2012e 2013e 2014e 2015e 2016e 2017e
Global Annual Market Installations (in GW)
Onshore Offshore
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CoE Reductions Critical to Competitiveness
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
Wind competitive with fossil fuels Cost of Energy (EUR/MWh)
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 Intelligence
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Impact of gearboxes on CoE
Offshore Wind Cost Drivers Offshore CAPEX structure
Foundations26%
Other Turbine Components
31%
Gearbox4%
Installations Vessels18%
Substation6%
Electrical Grid6%
Contingencies3%
Management2%
Insurance2%
Others1%
Preparational Work
1%
CAPEX impact of a gearbox is limited within a typical offshore project, however, turbine suppliers are continually looking for ways to reduce component weight and material usage
Not the offshore environment is changing wind turbine gearbox specifications, but the challenges in O&M are emphasizing the importance of reliability, with a direct impact on OPEX and AEP
Source: MAKE Consulting, ZF WPT Market Intelligence
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Our mission
We develop competitive products with proven reliability
to lower costs of unplanned OPEX
to guarantee AEP by increased availability
We reduce the kWh cost of renewable energy
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9 OWI-Lab, 27/09/2012 A brand of ZF
Trends in drive train technology
Diversity in solutions on the market
Search for the lowest CoE yields various industrial solutions for the drive train, being a trade-off between all design drivers:
reliability
weight and cost
efficiency
serviceability
grid compatibility
Mechanical power transfer:
gearbox
hydraulic converter
Electrical generator
gear driven or direct drive ?
high speed, medium speed, low speed ?
traditional or permanent magnet generator ?
Power conversion / transfer
low, medium, high voltage ?
AC or DC ?
All published solutions claim to be winners,
but few are proven by test and experience
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Representative testing is key to proof reliability of our competitive designs
Logistic complexity and uncontrolled 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
Representative (lab) testing capabilities are a long-term key differentiator of ZF WP
What ?
Start the turbine !
Representative testing
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Representative testing
It is possible to
transform wind
turbine behaviour
into test rig
conditions…
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100% Serial testing, first at partial, later at full load
Evolution of wind turbines and testing procedures
ZF WP DORoTe
Dynamic Testing @
ZF WP 13.2 MW Test Bench
* Indicative Numbers & years
Industry Standard
ZF WP Capability
Overload Prototype Testing
ZF WP is continuously improving its testing procedures by implementing ZF WP
specific dynamic testing methods
Hansen Transmissions International
1970 1980 1990 2000 2010 2020
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13 OWI-Lab, 27/09/2012 A brand of ZF
Design verification proving reliability
Sta
te-o
f-the
-art
De
sig
n T
oo
ls
Field
Verification
Gearbox
Verification
Component and
Sub-assembly
Verification
Technology/
Materials
Verification
Re
liab
le D
es
ign
s
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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
This pro-active testing method contributes largely to the design of robust
bearing arrangements for new reliable gearboxes
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Gearbox Verification
ZF WP’s 13.2 MW / 16.8 MW Dynamic Test Rig
- 13.2 MW rated power
- 16.8 MW peak power
- Investment
> 10 M EUR
- 1500 RPM nom speed
- 2600 RPM max speed
- 80 kNm at motors
- 1000 tons of steel
- 1000 tons of concrete
- 35m x 10m
- 100% Availability (24/7)
Motor GeneratorGB1 GB2
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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
• grid codes e.g. grid compatibility testing
Next steps in representative testing
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Additional leverage to reduce CoE
Minimise OPEX and optimise availability in our service offering
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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
merge measurements and algorithms into added value for O&M
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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
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20 OWI-Lab, 27/09/2012 A brand of ZFPresentation Title, Date
Thank you very much for your attention!