Commitment to Wind Energy Manufacturing - Tecnalia ... · loads of the wind to be used directly on the structure defined in the MSC ADAMS environment. AeroDyn has been evaluated and

TECNALIA’s

Commitment to

Wind Energy

Manufacturing

www.tecnalia.com

TECNALIA / INSPIRING BUSINESS 2 │ TECNALIA’s COMMITMENT TO

WIND ENERGY MANUFACTURING

TECNALIA’s COMMITMENT TO


│ 3 TECNALIA / INSPIRING BUSINESS

The wind energy sector has globally proven to be a dynamic sector, in spite of the economic and financial downturn that has dominated the markets in recent years. Manufacturers of wind turbines for the wind energy sector rely on suppliers with direct technologies and there is an extremely dynamic associated industrial tissue, in which Spain plays a major role worldwide.

The increase in the power of wind turbines, improving technological characteristics, integration and operation of electrical and mechanical turbine components, is a key issue for the competitiveness of the sector in general and for the deployment of off-shore wind power in particular. The increase in unit capacity adds to the cost and efficiency problem that the sector currently faces by increasing the size and complexity of the components of the wind turbine, its transportation, operation and maintenance.

TECNALIA’s Commitment to Wind Energy: Cost-Saving Energy

TECNALIA is firmly committed to working together with the wind energy sector in general, and the manufacturers of wind turbines in particular, to solve the main challenge faced by the sector today, namely cost savings and efficiency; and we jointly focus our R&D efforts and technological services in this direction.

4 │ TECNALIA’s COMMITMENT TO


TECNALIA’s Commitment to Wind Energy: Cost-Saving Energy

TECNALIA’s offer for the wind energy sector includes R&D developments and services for:

The manufacture of structural and mechanical components, with particular attention to the production of new materials.

Generators and electrical components: power electronics and electric machines.

Condition control and monitoring: Condition and structural health monitoring, corrosion remote monitoring and control and communications optimisation.

We also want to share our own technological

developments with companies for the

creation of profitable and sustainable business

opportunities, growing as new knowledge assets,

technology-based companies or as new

business lines



│ 5

The increased size of wind turbines highlights needs, such as the lightening of materials and components or the introduction of structural improvements to the nacelle or tower. TECNALIA's technological offer for the wind energy sector arises from its experience in the optimisation of manufacturing processes and robotics, as well as the advanced treatment of materials and coatings that it has developed in key sectors, such as automation and aeronautics. TECNALIA has been transferring this know-how to the wind energy sector for years, with the aim of fostering a key

requirement: cost savings.



Mechanical and Structural Components

COMPOSITES FOR BLADES

Control of moulding, curing and infusion processes.

Out-of-autoclave/liquid moulding process optimisation and simulation.

Efficient heating tooling based on self- heated mould and membranes.

New thermoplastic materials for blade design and manufacturing (liquid moulding processes).

Carbon material on leading edges with anti-freeze and electrical dissipation effects.

METALLIC COMPONENTS AND NEW ALLOYS

Use of light alloys instead of standard alloys in turbine components (pitch drive, frames…) to increase turbine efficiency.

Advanced manufacturing processes for metallic components (casting, forging,…) to reduce component costs.

Mechanical engineering and simulation using CAE techniques (simulations based on Finite Element Analysis).

Component re-engineering based on redistribution/mass reduction and improved mechanical properties.

Process monitoring solutions for the machining of large-sized gear-box and its components in order to take actions online and reduce scrap and defective parts.

MANUFACTURE OPTIMISATION

Robotic-based approaches for high demanding continuous processes (increased accuracy, stiffness, repetitiveness): Robots-as-Machine Tools New robot models. External devices (vision, IPS) to improve

accuracy External devices and control strategies

to damp vibrations Replacing the robot controller for CNC

New calibration techniques, position, stiffness and dynamic calibration.

Electromechanical design of smart and flexible tooling for large-parts.

Design of the proper tools and selection of the manufacturing processes taking into account the flexibility and efficiency of the manufacturing production.

Active and flexible clamping solutions for large-parts.

MANUFACTURING

Continuous monitoring in curing control, infusion filling simulation, the use of flow sensors, less adhesive bonds…. offer companies savings of up to 50% in time and up to 30% in energy consumption. The application of re-engineering processes and redesign of the turbine's key components (pitch, drive, frames, etc.) have led to savings of around 11% in this type of components.






TECNALIA / INSPIRING BUSINESS






COMPOSITES FOR BLADES

Control of moulding, curing and infusion processes.

Out-of-autoclave/liquid moulding process optimisation and simulation.

Efficient heating tooling based on self- heated mould and membranes.

New thermoplastic materials for blade design and manufacturing (liquid moulding processes).

Carbon material on leading edges with anti-freeze and electrical dissipation effects.

METALLIC COMPONENTS AND NEW ALLOYS

Use of light alloys instead of standard alloys in turbine components (pitch drive, frames…) to increase turbine efficiency.

Advanced manufacturing processes for metallic components (casting, forging,…) to reduce component costs.

Mechanical engineering and simulation using CAE techniques (simulations based on Finite Element Analysis).

Component re-engineering based on redistribution/mass reduction and improved mechanical properties.

Process monitoring solutions for the machining of large-sized gear-box and its components in order to take actions online and reduce scrap and defective parts.

MANUFACTURE OPTIMISATION

Robotic-based approaches for high demanding continuous processes (increased accuracy, stiffness, repetitiveness): Robots-as-Machine Tools New robot models. External devices (vision, IPS) to improve

accuracy External devices and control strategies

to damp vibrations Replacing the robot controller for CNC

New calibration techniques, position, stiffness and dynamic calibration.

Electromechanical design of smart and flexible tooling for large-parts.

Design of the proper tools and selection of the manufacturing processes taking into account the flexibility and efficiency of the manufacturing production.

Active and flexible clamping solutions for large-parts.

MANUFACTURING

Continuous monitoring in curing control, infusion filling simulation, the use of flow sensors, less adhesive bonds…. offer companies savings of up to 50% in time and up to 30% in energy consumption. The application of re-engineering processes and redesign of the turbine's key components (pitch, drive, frames, etc.) have led to savings of around 11% in this type of components.





NEW CURE MONITORING SOFTWARE

This application has customisable alarms on the key points of the cure production process. The software optimises the production process, reducing cycle times, cost and energy consumption and identifying unexpected events, such as early gelation. It also contributes to decreasing VOC through resin state control, improving knowledge of production process parameters in general.

CONTINUOUS FIBRE THERMOPLASTIC COMPOSITE MANUFACTURING THROUGH IN-SITU POLYMERISATION

Low-cost and fast manufacturing process for pieces of polyamide composites with fibreglass, carbon fibre or aramid fibres that turns the traditional anionic polymerization of caprolactam into a mass production continuous process . It permits to obtain big size products, products with complex geometry and structural parts.

FRAME WEIGHT REDUCTION AND PROPERTIES IMPROVEMENT AT EXTREME CONDITIONS (PROTOTYPE GEOMETRY SUPPLIED BY GAMESA) Re-engineering of an existing frame obtaining a relevant weight reduction (~11%). This reduction was partly due to the reduction in mass (3%) and mainly due to the improvement of the material coming from static load calculations (8%) .

NEW MANUFACTURING TECHNOLOGIES FOR THE PRODUCTION OF COST-EFFECTIVE NANOCOMPOUNDS Advanced methods for the distribution and dispersion of nanocompounds in aluminium and magnesium alloys and new manufacturing casting processes for new components (automotive, wind power and construction) with high performance, reducing weight, energy, costs and increasing flexibility.

MANUFACTURING


WIND ENERGY MANUFACTURING TECNALIA / INSPIRING BUSINESS

SIMULATION OF THE PERFORMANCE STRESS (TORSION DEFORMATION) OF THE BLADE ROTOR IN ACCORDANCE WITH WIND SPEED

DRILLING END-EFFECTOR FOR CFRP COMPONENTS Automatic Tool Change Retractable dust extraction

system compatible with ATC Retractable anvil support Quick change system

MUPROD. Quality Control System that will drastically change the current concept of End Of Line quality control, going beyond currently established methodologies such as Six-sigma and SPC. It will prevent the generation of defects within the process at single stage and the propagation of defects between processes at multi-stage system level. This Quality Control System will be proactive, offering different solution strategies to avoid End of Line defects.

CableBOT. Parallel Cable Robotics for Improving Maintenance and Logistics of Large-Scale Products New generation of modular and reconfigurable robotic devices that are capable to perform many different steps in the life-cycle stages of large-scale structures. CableBOT is designed for large-workspace movements of products, having a huge positive impact in logistics, transport, and warehousing.




Mechanical and Structural Components MANUFACTURING

Simulations of a real turbine using the software tool, AeroDyn. AeroDyn allows the wind loads of the wind to be used directly on the structure defined in the MSC ADAMS environment. AeroDyn has been evaluated and certified by the Germanischer Lloyd WindEnergie GmbH.

ADVANCED, INNOVATIVE SURFACE TREATMENTS AND COATINGS Reduction of life cycle cost of wind power generation

Coating and surface modification processes for wind energy industry; coatings for improved surface properties, such as anti-ice, self-cleaning, UV light resistance, resistance to erosion or fatigue…

Evaluation of the performance of materials under “laboratory” and “industrial” conditions.

Material selection and application of heat treatments and surface treatments or coatings for specific purposes.

Tribology of offshore energy conversion technologies: Analysis & testing, assessment.

Material characterisation in mechanical tests, chemical analysis, materialography, corrosion analysis, prediction and assessment

Special tests: components and assembly, extensometry, residual stresses, metallographic replication.

Paints and paint characterisation. Wear and friction characterisation. Surface properties (roughness, coating

adherence, wettability, hardness, …). Assessment and diagnosis: causes of non-

compliance, review and definition of specifications.

Improved correlation between lab corrosion test and real conditions & early detection of corrosion degradation for reducing corrosion damage and maintenance costs in wind energy. The Tecnalia corrosion laboratory is fully equipped in order to perform material (i.e.: metallic and polymeric) ageing for degradation study. Besides the traditional salt spray chambers and immersion baths, climatic chambers (-70 to 180 ºC, 0 to 100% HR), humidity chambers, UV/Condensation chambers, and an erosion cabinet are also available.

Extensive range of testing facilities and accreditations under ISO 17025 concerning UNE-EN, ASTM, ISO, NACE and DIN standards and internal procedures. Monitoring and conformity assessment campaigns to support gearbox validation during the design processes.

Advice on Material Selection and Manufacturing Processes (welding processes).

Validation of prototypes: quality control of manufacturing processes such as rolled, forged or cast products, thermal treatments, coating, welding and others and assessment of accelerated testing response.

Failure Analyses, in-service performance and residual life.

MATERIAL CHARACTERISATION AND FAILURE ANALYSIS

Advanced treatment of wind turbine materials and coating of components allows for the smart solution of problems, such as freezing, effects of UV rays, fatigue, erosion or corrosion, which add to the cost of the operation and maintenance of the farms particularly when the machines are large and exposed to adverse conditions, like many of those in the off-shore sector.



Mechanical and Structural Components MATERIALS

CORROSION PROTECTIVE COATINGS ON GALVANISED STEEL

Sol-Gel (SG) corrosion protective coatings on Galvanised Steel to face specific problems affecting the metal finishing sector, increasing their competitiveness through the introduction in the market of new, task-specific value-added surface-finishing solutions with state-of-the-art attributes.

NOVEL PLASMA NITRIDING/NITROCARBURISING PROCESS FOR IMPROVING THE PROPERTIES OF STEELS AND SPECIAL ALLOYS Cost-effective solutions for improving wear resistance, friction performance, corrosion resistance and fatigue characteristics. New environmentally friendly thermo-chemical treatment process based on plasma diffusion treatment that produces the formation of a nitride or a carbonitride layer as a result of a reaction between the plasma and the surface of the metal. A new method of plasma nitriding, known as Active Screen Plasma Nitriding (ASPN), has been developed for these purposes.

Material characterisation of hubs and frames made of nodular cast iron: tensile and impact tests, hardness measurements and metallographic analysis. Bolts, screws and studs characterisation and nonconformity test as per the EN ISO 898-1 standard.

TOOTH BREAKAGE IN INTERMEDIATE SHAFT

Base Material: Shaft material corresponding to an EN 10084 18crNiMo7-6 designation, the quality of which corresponded to an ISO 6336-5MQ designation. Cause of failure: Tooth breakage derived from a fatigue mechanism under standard working conditions, and fatigue mechanism is triggered by the presence of a large alumina inclusions pool which is not permitted for a MQ ISO 6336-5 MQ designation.




Mechanical and Structural Components MATERIALS

GENERATOR DESIGNS

Permanent Magnet (PM) and Direct Drive (DD)

Synchronous reluctance generators with external rotor

Superconducting generator turbines for wind energy

2D and 3D finite-element computer simulations

Wind turbine mechanisms, electrical substations, energy conversion and evacuation means, and so on, have to be modified to make them more cost-effective and better adapted to the new emerging opportunities for wind energy. New solutions will provide increased power scalability, weight reduction and more reliability with the systems involved.

POWER ELECTRONICS

Multilevel converters. Development of control algorithms for:

• Grid side converter • Generator side converter • VSC-HVDC converters (MMC)

Development of solutions for connecting wind turbines directly to DC collector systems.

Integration of offshore wind energy in AC and DC grids (load flow simulations, stability and faults analysis…).

Availability of a 1.5MVA/3.3kV infrastructure to test wind converters by the end of 2014.

CONTROL HARDWARE

Experience in developing products based on Control HW and SW: power control, predictive maintenance…

Development of complex architectures of embedded systems: DSPs and microcontrollers, FPGAs design.

Signal conversion and adaptation HW. Support to HW manufacturing.

ELECTRICAL LABORATORY

Power, HV & LV Laboratories, with more than 20 years of experience, under ENAC/ILAC Accreditation. Mobile laboratories including a Resonant Test Unit rated 260 kV, 80A. Failure analysis of electrical components and equipment. Laboratory tests for conformity assessment of electrical products and equipment (transformers, MV & LV switchgear, boards…). On-site tests on substations (power transformers) and evacuation lines (HV cables).



Generators and Electrical Components HIGH POWER ELECTRONIC AND ELECTRIC MACHINES

SUPERTURBINES Reliable, light and powerful offshore compact electric generator based on superconducting technology. 10 MW, ~8.1 rpm and ~11.8 MNm. Direct Drive: no gearbox MgB2 Superconducting field coils Cryogen-free solution (low maintenance) Modular Cryostat Weight below 200 t. More than 30% weight and size

reduction in comparison to conventional generators. No scaling problems

Hot iron poles Air-gap windings in the stator No rare earth materials

MODULAR CONTROL SYSTEM Flexible and powerful architecture to control power electronics. CPU based on the 400MHz floating DSP ADSP21369

(Analog Devices), 400MHz communication micro AT91SAM9G20 (Atmel-ARM9) and Spartan-6 FPGA XC6SLX25 (Xilinx). Ethernet coms.

Analogue measurement: remote and simultaneous acquisition by distributed nodes. Up to 5x16 voltages/current signals and 5x16 temperatures can be digitalized. Adjustable gain. Sampling frequency 10ksps.

Digital PWM boards: Up to 4x16 Fibre optic PWM signals.

General purpose IO boards. Rack 19”.

THOR: MEDIUM-VOLTAGE MULTILEVEL CONVERTER THOR is a medium-voltage Neutral-Point-Clamped converter with a modular design. Each individual converter module has a nominal power of 1.5 MVA. Up to 4 modules can be connected in parallel to achieve a nominal power of 6 MVA. Possibility of reaching up to: 3.3kV, 75 Hz and 10th harmonic. THOR has been designed promoting flexibility, thus facilitating the use of this drive in multiple applications, such as cooling water, grid emulator, current source, FACTS, active filter, and medium voltage drive.




Generators and Electrical Components HIGH POWER ELECTRONIC AND ELECTRIC MACHINES

CONDITION AND STRUCTURAL HEALTH MONITORING

Ad-hoc instrumentation technologies for specific CMS and SHM >solutions: Development of sensors and devices for

corrosion monitoring, Fibre optics for blades Fibre optics integration for load

measurement. Ultrasound and vibration monitoring. Real-time signal processing and advanced

PLC/SCADA data analysis for early failure mode detection and degradation estimation.

On-board systems for data acquisition Development of artificial intelligence-based

software tools for decision-making support.

CORROSION REMOTE MONITORING

Real-time corrosion monitoring (at fully remote systems). Information about: Environmental corrosivity Structure integrity Passive corrosion system (coating)

using

Sensor techniques Remote monitoring Modelling and life time prediction

CONTROL AND COMMUNICATIONS OPTIMISATION

High performance at low cost in the communication between the wind farm and the substation’s fibre ring.

Optimising main and redundant communication systems among the network elements (plants, substations and delegations).

Resilient and robust architectures in electrical and wind farms domains in terms of security

Ultrasonic sensor development for structural health

Spectroscopy for corrosion monitoring

Experience in IEC-61400/25 Protocol Stack application to standardise the control and communication of wind farms

Our smart instrumentation technologies and our prediction systems enable the life extension of the wind turbines and the wind farms in general, contributing to more profitable operation of the farms in the long term. Our robust and resilient architectures reduce maintenance costs and increase safety in communication between different elements of the network. Our corrosion monitoring systems at marine parks represent cost savings of around 20%.



Condition Control and Monitoring

NEM SOLUTIONS’ AURA DIAGNOSTIC: DIAGNOSIS AND PROGNOSIS OF FAILURE MODES BASED ON SCADA DATA Development of algorithms with NEM Solutions for the breakdown of symptoms and failure mode prognosis based on SCADA, Osisofts’ PI data and CMMS information. Mathematical models and non-parametric algorithms were used for performance identification in different subsystems and components, such as gearbox, hydraulic group or pitch control. The system automatically generates multi-dimensional power curves, estimated degradations deviations.

SMP CONDITION MONITORING SYSTEM. PREDICTIVE MAINTENANCE SYSTEM FOR WIND TURBINES It involves equipment for acquisition and digitalisation of signals retrieved from 12 IEPE accelerometers, as well as the required processing (filtering, FFT, trend algorithms). Equipment accuracy will be as low as ±1mVolt, corresponding to 0.1 m/s2 acceleration value. CPU based on a DSP, micro and FPGA communication. Ethernet and RS232 communications. The system includes detection algorithms based on vibration analysis, and information extraction , visualisation and analysis tools (GIRE-PRED).

CORROSION MONITORING SYSTEM Complete remote controlled corrosion monitoring prototype based on two techniques : i) electrical resistance (ER) of metallic sensors in order to establish the variation of the corrosion speed with the time, and ii) based on the measurement of electrochemical impedance spectroscopy (EIS) on coupons in order to measure the degradation status of the anti-corrosion coating). The system uses a Modbus TCP communication protocol with a control system using a SCADA simulation based on Mango. The system is built with the objective of being autonomous and robust.




Condition Control and Monitoring

Energía y Medio Ambiente

AGUA Igone Ugalde

Business Development Manager_Wind Sector

[email protected]

TECNALIA

Parque Tecnológico de Bizkaia

C/Geldo, Edificio 700

E-48160, Derio (Spain)

T 902 760 000

T +34 946 430 850 (International Calls)

www.tecnalia.com

Documents

Commitment to Wind Energy Manufacturing - Tecnalia ... · loads of the wind to be used directly on the structure defined in the MSC ADAMS environment. AeroDyn has been evaluated and