SKF, the Power ofKnowledge Engineering inRenewable Energy
Presented to REC Summer Event, June 26th 2014Presented by Stefan Lammens
SKF, a Truly Global Company
© SKF Group 20 June 2014Slide4
SKF – a truly global company
• Established 1907• Sales 2012 SEK 64,575 million• Employees 46,775• Production sites around 140 in 28 countries• SKF presence in over 130 countries• Distributors/dealers 15,000 locations• Global certificates ISO 14001
OHSAS 18001 certification
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Western Europe
Middle East and Africa
Eastern Europe
Asia /Pacific
North AmericaLatin America
Net sales by geographic areas 2012
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Net sales by customer segment 2012
Aerospace
Railway
Off-highway
Trucks
Two-wheelersand Electrical
Industrial,general
Cars andlight trucks
Industrial, heavyand special
Vehicle ServiceMarket
Industrialdistribution
Energy
Commercialtransport
Industrial business
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Energy• Renewable• Traditional
CommercialTransport• Aerospace• Railways• Off-highway
SpecialIndustrialMachinery• Food & Beverage• Machine tools• Marine• Healthcare• Medical• Printing• Textile
Heavy Industry• Metal-working• Mining• Pulp & Paper
General Industry• Industrial gearboxes• Fluid power• Material handling• Industrial Electrical
• Cars and light trucks• Trucks, trailers
and buses• Two wheelers• Vehicle aftermarket• Home appliances
& Portable powertools
Automotive
Industry specialist and partner to many industries
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October 30, 2007 © SKF Group Slide 8
To equip the worldwith SKF knowledge
SKF Group Vision
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What is SKF knowledge?
Renewable Energy,a Strategic Market for SKF
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Facts Renewable Business Unit 2013
Sales 2013: 7.899 Mio. SEK (ca. 895 Mio. €)Sales Renewable: 1.826 Mio. SEK (ca. 207 Mio. €)Business areas: Renewable Energy, LSB, SRBEmployees: 3.740Production sites: 10 in 6 countriesSales Units: 8
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SKF Focus on Renewable Energy
Wind turbine Wind gearbox Wind generator
Wind aftermarket
Wave Energy Tidal Energy
PV Solar ConcentratorsConcentrators CPV Solar
Other Renewables;(Hydropower, Bioenergy)
Wind EnergyWind Energy Ocean EnergyOcean Energy Solar EnergySolar Energy
SKF Renewable Energy
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SKF Renewable Business Unit - A holistic business responsibility
Marketing
Sales
DevelopmentEngineering
Manufacturing
Sourcing
HR Controlling Quality DC
Full life cycle Responsible for all functions
GlobalAll sub-segments
Major turbine & gearbox OEM market
Major t urbine OEM marketMajor gearbox OEM market
Smaller/emerging turbine OEM market
Emerging/potential turbine OEM market
Major turbine & gearbox OEM market
Major t urbine OEM marketMajor gearbox OEM market
Smaller/emerging turbine OEM market
Emerging/potential turbine OEM market
; SKF-Wind manufacturing unit*; SKF-Wind sales & engineering center
; SKF-Wind R&D and technical center
*
**
* *** *
*
*
l
* *l
l
l
l
l
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-30%
-20%
-10%
0%
10%
20%
30%
40%
50%
2013 2014 2015 2016
Bloomberg Sept 2013
MAKE Sept 2013
BTM April 2013
Average 3 analysts
State of the wind energy industryRecovering from a challenging period – a bumpy road ahead
Average price on new windturbines (€M/MW)
0.881.011.11 1.10
1.211.20
1.06 1.02 0.990.94 0.94 0.92 0.91 0.90
0.90
0.83
0.91
H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1
2008 2009 2010 2011 2012 2013 2014 2015
Previous Index (H2 2012) Current Index (H1 2013)
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Some major trends in Wind Energy market
• Reduce LCOE to reach grid parity• Strong globalization of an emerging industry, and massive
growth by leading Asian turbine manufacturers• Challenging environments; Deserts, Arctic, Offshore, Low wind• Expanding turbine sizes, MMW-class gaining importance• Direct drive turbines expansion versus gearbox-equipped• Major expansion and maturing of wind O&M• Increasingly automotive mindset on quality, delivery and cost• An industry driven (and limited) by political decisions
© SKF Group
SKF Life cycle management for improved LCOE
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CAPEX•Design for reliability•Design for performance•Design for simplifiedmaintenance
•Cost vs. value•Reduce turbine weight•Simplify productionprocess
Reduce LCOE by maintaininghigh operational reliability and
turbine availability
OPEX•Windfarm management•Extend maintenanceintervals
•Easy & quickcomponentreplacements
•Spare partsmanagement
•Condition monitoring
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Levelized Cost Of Electricity, Q2 2013 ($/MWh)
0 50 100 150 200 250 300 350 400 450 500
Coal firedNatural gas CCGT
CHPNuclear
Small hydroLarge hydro
Biomass - anaerobic digestionLandfill gas
Geothermal - flash plantBiomass - incinerationMunicipal solid waste
Wind - onshoreGeothermal - binary plant
PV - c-SiBiomass - gasification
PV - c-Si trackingPV - thin film
STEG - tower & heliostat…STEG - parabolic trough
Wind - offshoreFuel cells
STEG - parabolic trough + storageSTEG - tower & heliostat
STEG - LFRMarine - tidal
Marine - wave
Global LCOE range Regional scenarios Q1 2013 central Q2 2013 central
1059861
531
STEG is the term used by Bloomberg New Energy Finance forwhat is also referred to as Concentrated Solar Power (CSP).
© SKF Group
Downtimes of wind turbines often not only caused bylarge components
• Component quality/reliability a key driver of downtime• Rotor, Gearbox and Generator are within top 4 in terms of downtime• Large portion of downtime also caused by smaller and more frequent failure
of electrical system and electronic control• Overall increased component quality reduces downtime expectations
significantly
Source: German wind turbine park, 2008
Electrical system
Electronic control
Sensors
Hydraulic system
Yaw system
Rotor hub
Mechanical brake
Rotor blades
Gearbox
Generator
Support/Housing
Drive train
Failure frequency p.a. Downtime per failure (days)
0.96
0.72
0.40
0.35
0.48
0.76
0.45
0.40
0.73
0.71
0.44
0.42
Downtime expectation p.a. (days)
0.07
0.11
0.12
0.12
0.13
0.15
0.2
0.2
0.25
0.25
0.4
0.6
3,1
6,1
5,9
4
6
3,8
2,4
1,4
1,6
1,8
1,6
3
Maintenance Practice
“Breakdown”
Daily
100% or Call Availability
Periodic (Routine 3 to 6 months)
Predictive (CMS)
Preventive (Inspection)
“As Required” Service
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SKF active involvement in life cycle for LCOE-reduction
OPEX
CAPEX
Reduce LCOEHigh operational reliabilityand availability
© SKF Group
SKF contribution to wind turbine life cycle
Pitch bearings
Yaw bearingMainshaft housingsand locknutsCouplings
Automatic distributedlubrication system
Monitoring anddiagnosticsservices
Mechanical repairs &refurbishment
Sealing solutionsNew re-inforcedrubber seals
Bolt tensioning toolsTower alignment services
EngineeringConsultancyServices
Plain bearings
Maintenance toolsand grease
Generator bearingsDGBB quiet running/Insocoat/Hybrid
Mainshaft bearing(s)SRB/CARB/TRB/CRB/Nautilus
Gearbox bearingsTRB/CRB/SRB/CARB/DRTRB/HC-CRB family
Condition MonitoringWindCon/WebCon
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Turbine concepts & Main shaft bearing arrangements
2-point suspension 3-pointsusp.
Moment bearing(no shaft)
2 sep.housings
1 jointhousing
1 brg ingearbox separate Integrated
in gearbox
2-pointsuspension
Moment bearing(no shaft)
1 joint housing Full / semiintegrated
2-pointsuspension
Momentbearing
Commonhub No axis
Turbines with gearbox Hybrid Turbine Direct Drive
NautilusNautilus Nautilus DRTRB+CRBTRB+TRB
NautilusCRB+DRTRBTRB+TRB
CRB+DRTRBTRB+TRB
SKF have capability to supply all mainshaft bearing arrangement solutions
SRB+CARBSRB+SRB
SRBNautilus + Nautilus + Nautilus + Nautilus +
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The SKF Nautilus™ wind-mainshaft unit
Patented segmentedPEEK cage developed bySKF.
SKF Nautilus is a Robust, Stiff,and Compact solution developedspecifically for wind mainshafts
Nautilus ™ key features;• Designed for heavy, complex loads.• Only pure torque load is being
transmitted to the drivetrain.• Segmented cage for improved
performance also undermisalignment.• Extremely low friction coefficient.• Can be either oil or grease lubricated• Available for cold-climate locations
Asset Life Cycle Management:Specification to Maintain & Repair
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Specification
The world‘s need for energy and the drive for lower costs per kWh is steadily increasing. SKF has been a developing partner forwind turbine manufacturers for nearly 20 years and this experience is used when specifying requirements for turbines with highercapacity and demanding environments. The experience gained in the other phases of the life cycle management will alsoinfluence the specification, with the end user benefiting from it as well.
Specification
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Design and Develop
SKF application engineers and SKF Engineering Consultancy Service are working globally, with professional calculation anddesign programs, to translate turbine specifications and requirements into a solution.
Engineering Consultancy Service
• Advanced calculations
• Dynamic simulations
• Lubrication engineering/tribology
• Material analysis
• Design for Six Sigma
Advanced calculation toolslike SKF Bearing Beacon andFinite Element Analysis (FEM)to decrease kWh/€.
• Increase turbine reliability by validating– the bearing requirements– the operational conditions
of the bearing– the design/dimensions of
surrounding components• Optimize performance to increase
electrical and mechanical efficiency
Design and develop
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Manufacture and test
Manufacture and test
Generator
Gearbox
Main shaftMain shaft
Pitch and yaw
Main shaft incl. generator
Pitch and yaw
With factories in all major wind markets, SKF can provide solutions for pitch,main shaft, gearbox, generator as well as yaw.This includes testing components in prototypes and supplying for large scalewind turbine serial production.
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Manufacture and test – Main shaft
With factories in all major wind markets, SKF can provide solutions for pitch, main shaft, gearbox, generator as well as yaw.This includes testing components in prototypes and supplying for large scale wind turbine serial production.
• SKF Nautilus bearing solutions
• SKF spherical roller bearings
• SKF spherical roller bearing andCARB® bearing arrangements
• Lubrication systems
• Grease
• Sealing solutions
• HMS Lock nuts
• Friction Disc
• Housings
• Couplings
• Reduce the cost of energy
• Increase reliability and operational safety
• Simplify mounting, dismounting andreplacement
• Extend maintenance intervals
• Improve serviceability
• Decrease nacelle weight
Manufacture and test
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Operate and monitor
With monitoring tools and services, SKF helps wind farm operators to improve operational efficiency and reduce plannedand unplanned downtime. This can lead to higher profitability of the wind farm.
• SKF Remote Diagnostic Centres
• SKF WindCon
• SKF Thermal Imagers
• SKF Microlog data collectors
• Baker AWA-IV static motor/generator analyzer
• Baker DX static motor/generatoranalyzer
• SKF training
• Reduced risk of unplanned shutdowns• Preventing lost energy production due
to breakdowns• Predicting remaining service life per
turbine• Reduced wind turbine operating
costs and cost per kWh produced• Lower investments• Increased data integrity• Expert SKF analysis and
recommendations• Global, 24/7 access to reports and data• GL certified remote monitoring centre
Operate and monitor
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SKFThe Knowledge Engineering Company
Thank you for your attention !