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BREMEN
1st September, 2016
ION AROCENA DE LA RÚA
Nabrawind Project ManagerANTONIO UGARTE
CENER Wind Energy Directorwww.nabrawind.com
www.cener.com
Advanced Validation Strategy for Nabrawind Self Erected Tower
NABRAWINDAdvanced Wind Technologies
1 Introduction
Drastic Cost Reduction
Modularity Proven Technologies
Modular Blade Joint
Self Erected Tower
Nabrawind Introduction
1 Introduction
Cost Increase€HH140=1.6·€HH100
Most Expensive Component HH>120
LogisticsRoads / Bridges Limiting Concepts
Assembly CranesLack of AvailabilityLarge Mobilization and Rental Costs
Installation RateNew Concepts Delaying Wind Farm Installation Rates
WTG IntegrationControl Challenges in Soft-Soft TowersSoft-Stiff Unfeasible for XXL Steel Towers
XXL Tower Challenges
2 XXL Tower Alternatives Evaluation
TubularSteel
SegmentedSteel
PrecastConcrete or
HybridLattice Nabrawind
SET
Tower Cost
Logistics
Assembly & Erection
Modal Coupling
Operation Proven Life
Good Poor
Nabrawind SET
3 Nabrawind Self Erected TowerAdvanced Lattice Structure
Client WTG
Client WTG
Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly
3 Nabrawind Self Erected TowerAdvanced Lattice Structure
80 100 120 140 160 180
Tota
l Cos
t [k€
]
Hub Height [m]
Tower + Installation Cost
Steel Tubular
Hybrid Tubular
NBW -30%+40m
3 Nabrawind Self Erected TowerAdvanced Lattice Structure
Self ErectionNo Large Cranes
Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly
3 Nabrawind Self Erected TowerAdvanced Lattice Structure
Self ErectionNo Large Cranes
Fast Assembly2-Days WTG Erection (Wind >15m/s)Prefab Foundation (T<0ºC)
0 5 10 15
SET160m
Concrete140m
Steel100m
Steel60m
Installation Days
Crane Inst
WTG Inst.
Crane Des
WTG Installation Sequence (no Foundation)
0 10 20 30 40 50 60
SET160m
Concrete140m
Steel100m
Steel60m
Installation Days
FoundationFound. CuringCrane InstWTG Inst.Crane Des
WTG Installation Sequence
Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly
3 Nabrawind Self Erected TowerAdvanced Lattice Structure
Self ErectionNo Large Cranes
Fast Assembly2-Days WTG ErectionPrefab Foundation
Easy WTG IntegrationSoft-Stiff Tower H>180No Functional Affection
Freq
uenc
y [H
z]
Rotor speed [rpm]
1P
3P
6P
1st Bending
2nd Bending
1st Torsion
⍉130 HH160 Campbell Diagram
Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly
3 Nabrawind Self Erected TowerAdvanced Lattice Structure
Simple Logistics and OperationPackable in Standard 40ft ContainersMaintenance Free Structure and Connections
Self ErectionNo Large Cranes
Fast Assembly2-Days WTG ErectionPrefab Foundation
Easy WTG IntegrationSoft-Stiff Tower H>180No Functional Affection
Ultra Low CostFoundation / Tower ComponentsLogistics / Assembly
TubularSteel
SegmentedSteel
PrecastConcrete or
HybridLattice Nabrawind
SET
Tower Cost
Logistics
Assembly & Erection
Modal Coupling
Operation Proven Life
Nabrawind Self Erected TowerTower Alternatives Comparison3
4 CENER Introduction21 M€ In 2016 the annual budget is
20,5€ million. 70% self-financing
190 190 employees
100 M€ Total investments (2002-2016): ~ 101€ million
NUMBERS:• Wind Power• Photovoltaic• Solar thermal• Biomas• Grid integration• Bioclimatic architecture
AREAS
5 Advanced Tower Validation WTG Blades vs Towers Validation Strategy Comparison
FullScaleTests
SubcomponentTests
Coupon Tests
WTG Blades
Component Verification √
Design Details
Validation√
Material Allowables Definition
√
5 Advanced Tower Validation WTG Blades vs Towers Validation Strategy Comparison
FullScaleTests
SubcomponentTests
Coupon Tests
WTG Blades
WTGTowers SET
Component Verification √ X √
Design Details
Validation√ ∼ √
Material Allowables Definition
√ ∼ √
6 Fatigue Full Scale Tower TestTest Objectives
Tower & Foundation Accelerated Proven Life
0
5
10
15
20
25
0 5 10 15 20
Ope
rativ
e Pr
oven
Life
[yea
rs]
Time [years]
Accelerated Test
Operational Proven Life Acceleration
Conventional Operation
6 Fatigue Full Scale Tower TestTest Setup
Hot SpotsLattice Members
Foundation SettlementBolt Preload Control
Tower Head MassTower Head Exciter
Strain GaugesLVDTLVDT
Bolt Load Sensors
6 Fatigue Full Scale Tower TestTest Design
Tow
er H
eigh
[m]
Bending Moment Ranges [kNm]
20y Design Loads20y Eq. Test LoadsFinal Test Loads
γt
Full Scale Test Load Distribution
Tower DesignFatigue Loads20/25 years
Test EquivalentLoads
>20/25 years
Test Loads
Damage-Equivalent Ranges Analysis
IEC61400-23 based Test Factor (γt):- Conseq. Failure- Tower Variation- Fatigue Formulation
7 XXL Tower Alternatives EvaluationAfter SET Full-Scale Test
TubularSteel
SegmentedSteel
PrecastConcrete or
HybridLattice Nabrawind
SET
Tower Cost
Logistics
Assembly & Erection
Modal Coupling
Operation Proven Life
Tower Tests
8 Nabrawind Self Erected Tower ProjectProject Summary
Design Certificate
2015 2016
Company / Project Funding
SET TechnologyDevelopment
HH160 Tower Detailed Design
2017 2018
HH160 Tower Prototype Manuf. & Erection
Tower Certificate
TowerPreserials
8 Nabrawind Self Erected Tower ProjectProject Summary
Thanks for your Attention
www.nabrawind.com
www.cener.com