Wind Forum Korea 2011...WTC4-5 Able to offer independently hardware platform. 7 14. oktober 2011 Marketing Offshore turbine controller development • Vindeby 1991 11 0.5MWoffshoreturbines

1Marketing

POWERFUL INTELLIGENCE

kk-electronicpresentation to

Wind Forum 2011

Seoul, October 2011

Marketing2 14. oktober 2011

kk-electronic

- the world largest control systems suppler

for

ONSHORE

And

OFFSHORE


New Headquarter – Ikast-Denmark

Herning-Denmark, where it all started

• kk-electronic was founded in 1981

• Pioneers in Control systems for wind turbines

• App. 750 engaged and competent employees

• Total Sales in 2010 of US$150 Million

• Locations in Denmark, Poland and China

• One of Denmark’s largest pension funds, PKA holds

the majority ownership of kk

• Standard & Poor AAA rated in 2011.


The offshore wind farms

• 450KW:

• Vindeby: 11 units

• 2.0MW

• Middelgrunden: 20 units

• 2.3MW:

• Samsø 10 units• Rødsand: 72 units• Lillgrund: 48 units• Horns rev 2 91 units

• 3.6MW:

• Burboe Banks: 25 units• Gunfleet Sands 48 units• Rhyl Flats: 25 units• Linn & Inner Dowsing 54 units• Greater Gabbard 140 units

• 5.0MW

• Nordsea: 23 units

• Today we have made about 600 real offshore wind turbines• And got another 600 in production, or pipeline.

- biggest in the world

- With kk controlsystems indside


Offshore, how to be successful?

Agenda

• Offshore turbine controller development.

• Challenges to the future.

• How kk-electronic sees the future.

• What does it take to be successful in the Offshore business?


Offshore turbine controller development

WTC3

Controller and

WEB-WPS

monitoring

system were

developed with

the aim of

making

optimizing after

installation

possible.

1978 kk build its

first wind turbine

controllers

based on

contactors and

switch module

technology.

WTC1In 1984 we

combined our

knowledge

about wind

turbines and

electronics

and build the

first computer-

based wind

turbine

controller.

WTC2was made

with the aim

of making

service

simple.

SCADAwas

developed.

WTC4-5

Able to offer

independently

hardware

platform.



• Vindeby 1991 11 0.5 MW offshore turbines

• Nøjsomheden 1999 21 1.0 MW made as offshore

• Middelgrunden 2000 20 2.0 MW offshore turbines

• King Mountain 2001 214 1.3 MW made as offshore

• Samsø 2002 10 2.3 MW offshore turbines

• Nysted 2003 72 2.3 MW offshore turbines

Projects which have given us offshore experience



First Offshore 1991, Vindeby

Our background:• With experience from 3000

WTG installed world wide.• With a very reliable control

system. • Optimized for fast service

and low MTR.• With a remote monitoring

and control system.

• We felt very prepared for offshore.

The first offshore wind farm: 11 units of 450 kW,

Vindeby, Denmark) 1 km from shore and

4 km from harbour



Installation challenge: Vindeby• Installation took a year

- The degree of finish or maturity of both the turbine and kk control system was far too low.

- Onshore, it was no problem to have an extra service crew to fix a problem. In most cases the turbines kept running in the meantime.

- But offshore, the access to the wind turbine is• not possible or • too risky most of the time• very expensive, and very time consuming.

• This calls for the capability to: predict problems, planning, logistic, service crew management, and often at a very high level.



Operation challenge: Vindeby

• It turned out that the turbines always failed in “nice windy weather.”

• The same condition where the wind turbines is not accessible. Due to wind and waves.

• A simple failure which could be fixed in minutes could result in a 5 days stand-still, huge production losses, and loss of availability.

• After 2 years of intensive effort, and a lot of improvements, we reached the desired availability.



• From this experience, all the involved parties were motivated to learn and do better.

- The Investor and operator “E2- energy” (today known as DONG energy)

- The wind turbine manufacture

- Other suppliers

- And sub suppliers

• The aim of this cooperation was to come up with better solutions for the next offshore wind farm

• The Ideas, Suggestions, Demands ….

- were the starting point for a lot of improvement to the whole work-process at kk-electronic

• E2-energy placed a second order for Nøjsomhedens Odde,

- A project, intended to be treated as “a premiere movie-script” for the next offshore-generation for all suppliers



Next project.

• ISO 9000 Certification of all processes involved in the project

• Design, for offshore

• with design verification, and type testing

• Production for offshore,

• with customer inspection.

• 100% functional test of control system.

• 100% functional test of nacelle, hub, power-unit.

• On-shore prototype, the exact one to be copied.

• To qualify tools and materials for all work and operations

• On harbor pre-assembly for inspection an test before shipping

• Prepare everything to reduce the offshore erection time (measured in hours)

• Develop service and maintenance strategy



• Environmental control, removing salt and humidity • Heat exchangers, for all cooling • Redundancy of critical components • Extended Lightning protection, 5 clean hits a year • Lightning measurement system • Power backup of control and communication

system• Automatic reset of protection and breakers• Arc containment • Firefighting system• More sensors and feedback points• Data logging and Fastlog system • Remote software updating • And much more….

Some Offshore design elements



Projects which have given us offshore experience

• Vindeby 1991 11 0.5 MW offshore turbines

• Nøjsomheden 1999 21 1.0 MW made as offshore

• Middelgrunden 2000 20 2.0 MW offshore turbines

• King Mountain 2001 214 1.3 MW made as offshore

• Samsø 2002 10 2.3 MW offshore turbines

• Nysted 2004 72 2.3 MW offshore turbines



A lot better but only half the way

• Not all the things was implemented at the Nøjsomhedens Odde project.

• But at the first real offshore project Middelgrunden, following this development.

• We got all the wind turbines up and running during the summer.

• The budget overrun for getting the turbines up running with the desired availability was only 2 million DKK

• Our WTC2 control system did not fulfill all of the needs, and therefore we started development of WTC3 control system.

Middelgrunden:

The world’s most famous

offshore wind farm, 2000,

20 turbines of 2 MW


Challenges to the future.

• Reducing the Cost of energy, making wind

competitive.

• Reliability, making the turbines better and

better.

• Increase in turbine size, capability and

efficiency.

• Reduce the cost.

• Reduce the time to market.

• Change our mindset.


How kk-electronic sees the future.

Control system is the brain and intelligence of the turbine.



• Model-based development tool

• Low Investment

• Low O&M

• Dedicated Intelligent Controller for

WTG

• High lifetime revenue (ROI)



Model-based development tool.

• No programming skills (MATLAB-

Simulink.

• Faster development.

• Extensive library.



Low Investment.

• Less over dimensioning.

• Faster learning loops.

Additional safety margin on main components

Level of requirements based on performance



Low O&M.

• Optimal control



Low O&M.

• Predictive maintenance

Maintenance

costs

Reaction time

Reactive

Corrective

Preventive

Predictive

60 %

30 %

10 %



High lifetime revenue (ROI).

• Design for extended lifetime of wind

turbines.

• Predictive maintenance.

• Design for lower operation and

maintenance costs.

• Choose other components with wider

tolerances.

• Choose light-weight components.


What does it take to be successful in the

Offshore business?

Quality and reliability is relevant on two levels:

1. Project culture in kk in general

2. Project work within each project (project group)

Time

Rela

tive Q

uali

ty


정말정말정말정말중요하다면중요하다면중요하다면중요하다면,

kk-electronic에에에에

맡기세요맡기세요맡기세요맡기세요

오프쇼어오프쇼어오프쇼어오프쇼어제어제어제어제어시스템시스템시스템시스템분야분야분야분야세계세계세계세계 1위위위위


Thank youfor

your attention!

Please do not hesitate to

contact us for further

information

Sales Manager, AsiaJorgen Kjaersgaard

[email protected]

Documents

Wind Forum Korea 2011...WTC4-5 Able to offer independently hardware platform. 7 14. oktober 2011 Marketing Offshore turbine controller development • Vindeby 1991 11 0.5MWoffshoreturbines