David brown

Company confidential © DB Gear Systems Limited 1

David Brown Wind Energy

Servicing the Supply Chain for

Offshore Environment

Alfonso Garcia

Business Development Manager – Renewable Energy

[email protected]

28th February 2012

mailto:[email protected]


150 Years of Assurance Critical Solutions

‘To provide customised transmission solutions for

applications where customers demand absolute assurance’


Renewable Sectors Served

Wind Hydro

TidalSolar


UK• Land defence transmissions

• Naval applications

• Renewables – wind, tidal

• High speed drives – oil & gas

• Custom designed ‘low speed,

high torque’ drives

• Rail

Eastern Europe• Sales office

USA• Precision ‘double

enveloping’ worm drive

• Renewables - solar, wind

• Packaging/food & beverage

• Machine tools, medical and

high precision applications

• Mining, steel & energy

Brazil• Sales office

France• Renewables – wind, hydro

• Rubber & tyre industries

• Cement, metals & mining

• Overhaul & upgrade

South Africa• Girth gear and mill drives

• Mining

• Power generation (coal)

• Overhaul & upgrade programmes

• Heavy duty conveying systems

India• Business & design centre

• JV with Bharat Forge

Indonesia• Sales Office

Australia• Overland conveyor &

Port handling

systems

• Mining

• Renewables – wind

• Power generation

(coal)

• Sugar processing

• Service contracting

• Rail

China JV• Rail

• Renewables - wind

Dubai• Oil & gas, power, metals,

cement, port handling

• Spares manufacture

• Service, repair and

upgrade

Chile• Mining

• Service ,repair and

upgrade

A Worldwide Capability


David Brown Gear Systems Product Groups

Products & Services

Land & NavalDefence

IndustrialAftermarket

IndustrialEngineered

Product

RenewableEnergy

Solar

Mill Drives & Girth Gears

High Speed & Rail

Low Speed, High Torque

Specialist Spares

High Integrity Repair & Overhaul

Site Services

Tracked/wheeled transmission New

Build

Tracked transmission

upgrade programmes

High Integrity Naval Drives

Tidal

Wind


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

Wind Energy – Activities & Progress


Wind Research & Development

• Existing technology – Total Life Cost

• Condition Monitoring

• Wave Energy

Feasibility analysis for geared solutions.

• Gearbox Bearing Technology

• Permanent Magnet / Hybrid Technology


• 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

Offshore Wind – A New Challenge

Company confidential © DB Gear Systems Limited 9 9

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

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 Turbinetechnicians basically perform simple visual inspections every sixmonths. Lack of GBXs specialists on site.

• There are sporadic GBX assistances on site, performed by GBXmanufacturers, when it is specifically required by WTG manufacturersor wind farm owners.

• When a GBX is damaged, it must be replaced completely in most of thetimes.

• Condition Monitoring Systems are rarely installed and, in those caseswhere it is, there is not a proper data analysis performed by operatorsat the remote control centre. Lack of knowledge.

• GBX manufactures are reluctant to share data about performance andfailure analysis.

• Reactive response way of working with WTG OEMs and final users.

Imperative for change


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.


Technical differentiation for assurance

Planet gear &

flexpin assembly

1st stage carrier & fixed

pin assembly

Individual planet gears

& flexpin assemblies

MANTAINABILITY DIFERENTATION

Example of Wind Gearbox that can be completely disassembled from downwind end

2nd stage carrier & fixed

pin assembly

Discrete,

integrated rotor

bearings1st stage

annulus

2nd stage

annulus

2nd stage

sun pinion

shaft

1st stage sun

pinion shaft

All removable

components

<10T


• 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.

Tidal Energy


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)


Thank you for your

time and kind

attention