didect ddive wind tudbines

Direct Drive Wind Turbines
LEITWIND AT A GLANCE
2
INVENTING
“THE”
WIND TURBINE.
Investing in wind power
is environmentally conscious,
sustainable and trendy.
With LEITWIND turbines,
it is also highly profitable.
Turn this page and find out why.
3
LEITWIND AT A GLANCE
Leitwind:
The Drive
of Direct Drive.
LEITWIND is a leading manufacturer of gearless wind turbines. It belongs to the international group
HTI which has ropeway construction among its core competences, producing the renowned
brands LEITNER ropeways and Poma. Transferring the direct drive technology from ropeways to
wind turbine construction was a logical step in terms of synergy. It led to breakthroughs in wind
turbine reliability and profitability – with strong impact on the market: Since their introduction in 2003,
around 200 LEITWIND wind turbines have been installed in three continents.
4
The Success of Synergy
The LEITWIND success story starts with
ropeways, a core competence of LEITWIND´s
parent enterprise, HTI with production sites
in Italy, Austria, France, Slovakia, Sweden,
the USA, Canada, India and China. The
group originally evolved from a ropeway
constructing company which has, for
decades, brought leading-edge technology
into spectacular mountain terrain.
With a staff of more than 3.000 employees
and operating in more than 90 international
sales and service centers, the HTI group
offers a broad range of high technology
products. The portfolio contains leading
brands like LEITNER ropeways and Poma
for rope-hauled passenger transportation
systems for the mountain and urban
environments, Agudio for material ropeway
systems, Prinoth for snow groomers and
tracked utility vehicles and DemacLenko for
snowmaking systems.
safety and reliability in most extreme
conditions. LEITWIND incorporated this
direct drive into a wind turbine with a
synchronous generator and permanent
magnets. The result was the ultimate wind
turbine that maximizes performance at all
operating levels.
The first LEITWIND turbine prototype was
installed in 2003. The results of the subsequent
test runs were literally electrifying: the direct
drive proved to be superior from simplified
assembly and maintenance to operational
reliability and profitability.
LEITWIND started serial production in 2007.
Simplicity, combined with quality, has since
convinced customers on three continents.
Backed by intra-group synergies, LEITWIND
can now offer not only turbines, but also
complete wind farm construction as well
as operation, maintenance and service
packages.
One interesting feature in ropeways is their
electric direct drive: Its simple, rugged
construction has proven its outstanding
Literally going where others cannot go,
LEITWIND has, in five short years, successfully
installed around 200 units worldwide.
5
PARTNERSHIP
The Energy
of Partnership.
Truly perfect solutions cannot be bought off the shelf. Tailoring an installation to the requirements
of climate, terrain and energy demand takes dedicated, experienced specialists. Accordingly,
LEITWIND offers customers not only leading edge technology, but also a productive project
partnership which fulfills all individual customer needs. Our goal is the perfectly efficient, reliable
and profitable solution for you - from the first stages of planning over the whole lifecycle of an
installation. If you plan an investment in a sustainable future, LEITWIND is your partner for success.
6
Planning Partnership
Economical feasibility is a result of professional
planning: To ensure the maximum return
on your investment, an installation must
be tailored to the financing, siting and grid
requirements of your project. To ensure
success, team up with LEITWIND from the
earliest project stage, the siting: A wind
data analysis compiled by the LEITWIND
expert team optimizes turbine positioning.
Calculating the annual energy output helps to
choose the perfect turbine for the selected
site. Site visits provide necessary information
like accessibility for construction and
maintenance. Entering all this into the
equation of a wind farm ensures maximum
cost efficiency over the whole project lifecycle.
Project Partnership
Developing a wind farm is a complex process.
It involves stakeholders with sometimes
contradictory needs: Investors and insurance
companies, financing partners and, last not
least, local, regional and national authorities.
LEITWIND supports you with data, technical
advice and practical assistance throughout
the whole project from the first contact down
to the completion of the project.
Tailor-made Partnership
Going where many competitors say
“impossible”, LEITWIND is your partner
of choice for challenging projects in
extreme environments: The technological
advantages of LEITWIND wind turbines allow
for installations in mountainous areas and
remote sites. In such projects, LEITWIND
customers profit from the know-how and
competence gathered by the group during
decades of ropeway construction in difficult
alpine terrain. With spectacular projects like
the “Eye of the Wind” in Vancouver, Canada,
LEITWIND has pioneered wind energy not
only in the technological, but also in the
aesthetic dimension.
Wind Turbines
from 1.0 to 3.0 MW
Research
and
Development
Project
Partnership
Leitwind
Customer
Care
Direct Drive
Technology
Production
and
Procurement
Leitwind
Park Manager
Grid
Integration
Construction
and
Commissioning
7
TECHNOLOGY
Direct Drive
Technology:
Electrifying
Advantages.
LEITWIND direct drive turbines work without gearboxes. The advantages are electrifying:
Reducing the number of rotating parts minimizes wear and tear, and increases efficiency as it
reduces friction also in low wind speeds. Furthermore, the direct drive technology allows for a
modular design concept which speeds up construction, lowers transportation and installation
costs, and provides safe and easy access to the components for maintenance. The result is
outstanding reliability and energy yield, leading to an optimal profitability.
8
Modular construction for outstanding yield at moderate costs
LEITWIND wind turbine design is based on a
modular concept that lowers transportation
and installation costs. It also enables the
installation of wind turbines even in sites with
difficult access. The generator is part of the
load-bearing structure, which contributes
to an economical weight management.
The design also renders costly external
structures like transformer stations obsolete
by integrating all power electronics and the
transformer into the tower base.
1
2
3
4
5
1
Rotor blade
2
hub
4
MACHINE CARRIER
3
SYNCHRONOUS GENERATOR
5
TOWER
Designed to minimize maintenance costs
The innovative machine carrier gives safe
and easy access to all serviceable parts. The
modular design allows speedy replacement
of generator parts without having to
dismantle the whole generator and without
having to involve crane operations. Fewer
moving parts and lower rotation speeds
reduce wear.
The sum of all advantages
All these features add up to an extremely
reliable and therefore profitable turbine as
it minimizes maintenance activities and
maximizes the energy yield.
9
TECHNOLOGY
Electrifying Simplicity: The Anatomy of LEITWIND Turbines
Patented direct drive - the game-changer:
Direct connection between hub and
generator eliminates the gearbox, a weak
point in traditional wind power turbines.
Fewer parts rotating at lower rpm´s:
Reducing the number of rotating parts
raises the reliability and lowers maintenance
activities. Even more important in this
respect: In LEITWIND wind turbines, all parts
rotate quite slowly. Traditional generators
take only a few months to go through the
number of rotations which a LEITWIND
generator will perform in a 20 year lifecycle!
Less friction for more efficiency: Fewer
rotating parts mean less friction and more
efficiency. This makes LEITWIND wind
turbines suitable even in low-density wind
power areas.
1
2
5
3
4
6
10
1
ROTOR BLADE
4
SYNCHRONOUS GENERATOR
2
hub
5
MACHINE CARRIER
3
pitch system
6
YAW SYSTEM
Pitch and yaw control for maximum performance
The LEITWIND control system automatically
monitors performance and uses variable
rpm´s and harmonious pitch control to
optimize production in the partial and full
load ranges.
The mechanical brake of the yaw system
consists of a hydraulic driven part and an
electric driven brake in every single yaw
motor. The electric driven brakes open only
during yaw maneuvers. The hydraulic driven
part consists of a main control component
and seven brakes. During the yaw maneuver
the brake torque is reduced to 25% of
nominal torque, otherwise 100% are applied.
Innovative generator for optimized energy yield
The multi-pole synchronous generator with
permanent magnets makes the most out of
the wind: The whole induction performance
is available as energy yield. The use of
permanent magnets further improves the
yield by eliminating the need for electrical
excitation of the generator coils. This gives
LEITWIND generators huge advantages,
especially in the partial load range.
11
PRODUCT RANGE, PRODUCTION AND QUALITY
Perfect
solutions for
every project:
The LEITWIND
product range.
With nominal capacities ranging from 1.0 MW to 3.0 MW and a choice of rotor diameters and
generators, there is no project demand LEITWIND cannot cover. Please consult the LEITWIND
sales and project engineering team when choosing the perfect turbine for the climate, wind and
terrain conditions of your particular project.
12
Perfect turbines for every environment: The LEITWIND product range
Pick the ideal combination of generator size
and rotor diameter to suit your project´s
local wind conditions and energy demand.
Wind speed (m/s)
5,5
Rated
power (kW)
Diameter
LTW70
2.000
70
LTW77
1.000
77
LTW77
1.500
77
LTW80
1.500
80
LTW80
1.800
80
LTW86
1.500
86
LTW101
3.000
101
LTW104
2.000
104
LTW104
2.500
104
6
6,5
IEC IIIA
The LEITWIND project engineering team
provides you with solid data to base your
decision on.
7
7,5
8
8,5
9
IEC IIA
9,5
10
IEC IA
Designed to maximize efficiency
Direct drive technology
•reduces the number of rotating parts
•reduces mechanical and electrical losses
•reduces downtime and maintenance activities
•increases availability and productivity
Synchronous generator with permanent magnets
•simplifies installation
•cuts installation costs and assembly time
•reduces wear and tear by slower rotation
Modular design
•minimizes transportation and installation costs
•makes maintenance easier and safer
•the double electric circuit boosts reliability
13
PRODUCT RANGE, PRODUCTION AND QUALITY
14
Electrifying Quality: LEITWIND production
LEITWIND takes great pride in the
outstanding quality and reliability of its
products. This, together with our ambition
to meet all individual customer demands,
dictates a strong vertical integration of the
LEITWIND production chain. By controlling
the whole production process LEITWIND
ensures the top quality which has made
our products synonymous for safety and
reliability. We achieve this vertical integration
by using the synergies within the group:
They provide us with valuable know-how,
production plants, machinery and highly
professional and experienced work force.
Running a very flexible global supply chain,
LEITWIND produces in three locations:
Sterzing, Italy
The offices in Sterzing, Italy, house the
Research and Development, procurement,
sales, project management, product care,
and customer service departments.
Telfs, Austria
The Telfs production plant produces
mainly tower head components, such as
generators, hubs and main frames. To meet
the growing demand, production capacity
was recently doubled, while also creating
the facilities for the production of the next
generation 3.0 MW-generators. Also based
in Telfs is the LEITWIND test center.
Chennai, India
Our Chennai facility is a joint venture between
LEITWIND and Shriram EPC. This brand
new plant with a staff of over 400 employees
covers our Asian markets with a capacity of
up to 250 units per year and includes our
proprietary in-house rotor blade production.
To Be the Best, Work With the Best: LEITWIND Procurement
The LEITWIND procurement is not just about
nuts and bolts. It deals with hi-tech products
like large size double-tapered bearings,
composite blades and latest pitch control
technology. LEITWIND suppliers are chosen
in extensive audits to verify their experience
in our markets, their ability to meet our
demands and their quality management, with
particular attention to the standards defined
by ISO 9001, ISO 14001 and OHSAS 18001.
15
PRODUCT RANGE, PRODUCTION AND QUALITY
16
Electrifying Innovations: LEITWIND Research and Development
Has LEITWIND revolutionized wind generator
construction? Yes. Does the story stop
here? Definitely no: Always striving to make
a good thing even better, LEITWIND runs a
sizeable R&D department. Here, we develop
convincing answers to questions like:
“Which are the market demands the next
turbine generation has to cover?”, “Can we
think of ways to make wind turbines even
cheaper to buy and easier to install, connect,
service and maintain – in other words even
more profitable?”, “How do we make wind
turbines feasible for hostile environments like
deserts and low temperature sites?”
Leitwind R&D is in charge of
• improvement of existing products,
• field testing to gather performance data,
• design and prototyping of new wind
turbines and subsystems,
• structural blade design,
• development of converters and pitch systems,
• validation and certification of products
and processes according to specifications
and norms,
• quality tests from assembly line to turnkey
status, and
• IPR (intellectual property rights) management.
LEITWIND Product Care: Certified Quality and Safety
Cooperating closely with the production
department and our external suppliers, the
LEITWIND Product Care department is in
charge of quality management, technical
support, product safety and the industrialization
of prototypes. All LEITWIND products
are designed according to international
standards and certified by TÜV Süd.
The LEITWIND quality management in
development, production, sales and after
sales service fulfils the requirements of the
ISO 9001: 2008 standard. Technical due
diligences are conducted, among others,
by GL Garrad Hassan and Fichtner, both
independent international consulting
companies on renewable energies.
“The LTW77 model is a variable speed, pitch controlled gearless wind turbine with permanent
magnet generator. The model has the advantage of superior technology and simple
design with fewer numbers of components. The power electronics is state of the art and
is compatible with the modern grid codes. [...] Most of the components and maintenance
intensive elements are accessible internally. Modular design will result in lower transport and
installation costs and easier maintenance and due to the modular structure, generator is easy
to manufacture. GL is of the opinion that Leitwind has addressed the issue of assembly
and disassembly with the modular design and this should improve the machine availability.”
“LTW77 has an advantage that the well established manufacturers do not have models with
such technical features. […] The most noticeable advantage of the LTW77 is its simple and
modular design which is expected to reduce the downtime as generator can be repaired insitu.
The special construction of the generator allows the machine to produce 87,5% of its rated
capacity even if there are problems in one of the 8 parallel circuits. […] Leitwind technology
has an advantage of having a synchronous generator which is known to be grid friendly.”
Extract from the technical due diligence
on the LTW77 (September 2010)
17
CONSTRUCTION
New Energy:
The Birth
of a LEITWIND
Turbine.
Once the foundation has been built laid according to the specifications provided by LEITWIND
engineering, installing a new LEITWIND turbine is a breeze - even in terrain where most of
our competitors would say “Impossible!” With their simplified modular construction, LEITWIND
turbines are designed for exceptionally easy installation even in complicated sites. Follow the
birth of a LEITWIND turbine step by step.
18
Professional Project Implementation
The LEITWIND project management team
is your partner in planning and coordinating
all transport, installation and commissioning
activities. It provides you with expert advice
and sometimes surprising creativity in the
customization of transport and installation
solutions. The more so because LEITWIND
project managers draw from the vast
experience of the company group, a leader
in ropeway construction and a pioneer of
transportation and construction in remote,
nearly inaccessible mountainous terrain.
Getting there
The LEITWIND logistics experts and our
external partners excel in getting big, heavy
and delicate tower heads, tower sections
and rotor blades on site, safely and yet in
time, be it via four-lane motorways, rocky
mountain roads, material ropeways or even
helicopter transport.
Up at Sunrise – Installed Before Sundown
Provided the weather does not act up, a
LEITWIND wind turbine can be installed in
one short day, from the first tower section
to the last rotor blade: Modular construction
makes installation a real breeze.
Getting it going
The timely commissioning of LEITWIND
turbines is guaranteed by our project
management team. The commissioning
process involves a pre-test phase including
adjustments necessary for the permanent
smooth operation of the wind generator,
followed by inspection and commissioning,
detailed documentation and customer
manuals and training for maintenance
engineers and technicians.
19
Grid integration and LEITWIND Park Manager
GETTING it
connected.
Turning unpredictable winds into a reliable energy source is not necessarily a headache. Rely
on LEITWIND´s brain power for perfectly grid code compatible wind power. Rely on LEITWIND
turbines for operation characteristics similar to conventional power plants. And rely on the
LEITWIND Park Manager for smooth permanent energy production under 24/7 remote
supervision by a dedicated expert team.
20
Special frequency converter for perfect grid compatibility
The combination of synchronous generators
with IGBT technology in frequency converters
produces excellent grid compatibility.
LEITWIND frequency converter technology
can be flexibly parameterized to a huge
range of connection requirements to meet
the grid codes of most any operator.
The grid side of the LEITWIND frequency
converter handles a wide reactive power
range and can support even weak and
unstable grids. With the full power yield fed
through the LEITWIND frequency converter,
the generator can be taken off the grid
completely if the need arises.
Active and reactive power control and an
ability to smoothly compensate sudden
voltage drops give LEITWIND turbines grid
connection characteristics comparable to
conventional power plants.
PSM
Permanent
magnet
synchronous
generator
Power
converter
LV- main switch
Power
transformer
SM
3
0-690V
0-15Hz
controller
690V
50Hz
MV- main switch
The double electric circuit is an important
detail of the modular LEITWIND turbine
design: It offers a safe fallback, enabling the
system to continue operation in the unlikely
case of component failure, adding once
more to the superior reliability of LEITWIND
turbines.
The behavior characteristics during grid
disturbances achieved by the LEITWIND
converter technology allow wind farms to
be connected according to regional grid
compliance standards.
21
Grid integration and LEITWIND Park Manager
A smooth ride. Even when things get rough
To meet the demands on the grid connection
characteristics of modern wind power
plants, LEITWIND turbines offer so called
conventional power plant characteristics
like low voltage ride through abilities, a wide
reactive power setting range for voltage
control and automatic output reduction in
cases of grid frequency peaks.
Active/reactive power
State-of-the art frequency converter
technology gives LEITWIND turbines a wide
reactive power setting range. The whole
setting range is available over the whole
power curve.
Active power management
An oversupply of power in a grid can produce
frequency deviations. LEITWIND turbines
automatically detect an overfrequency in
the grid and react by reducing their power
output to counteract the frequency rise.
Active power
-Qmax
Available active power
+Qmax Reactive power
Low voltage ride through
To support grid stability in short voltage
drops, LEITWIND turbines are able to
ride through low voltage events without
disconnecting from the grid. The red line
in the graph represents the characteristic
Grid frequency
f0
f1
minimum below which the turbine will
automatically disconnect from the grid.
The characteristic parameters will be set
according to the relevant grid code.
Grid voltage in % of Un
Un
Grid code compliance
• Active power control
• Reactive power control
• LVRT low voltage ride through
0
22
tmax
Time
fmax
• HVRT high voltage ride through
Leitwind Park Manager
Central
DB
Wind Collector
(VPN Client)
VPN Server
PLC
DB
CMS
(VPN Client)
Panel PC
Technician
(VPN Client)
Internet
Park Manager
WTG1
Park
Controller
WTG2
WTG3
WTGx
Grid Operator (Electrical Part)
Measurement Device
VPN Client
Point of Common Coupling
Fibre Optic Cable (Redundant ring topology)
Copper Cable
The LEITWIND Park Manager provides
an interface according to the norm IEC
61400-25 which defines the standards for
monitoring and control of wind power plants.
Listed below you find all logical node classes
defined by IEC 61400-25 and implemented
in Park Manager.
• Control and steering of the wind farm
• Real time data monitoring of wind parks
or single turbines
• Reporting
• Leitwind SCADA system:
- remote wind farm control and monitoring
- adaptable to customer specific
applications
- a key element of the Leitwind service
and maintenance program.
23
LEITWIND CUSTOMER CARE
You are NEVER
alone WITH
LEITWIND
Customer care.
LEITWIND understands customer relations as a partnership in creating a sustainable future.
We do everything possible to ensure the success, safety and profitability of every LEITWIND
project. Your successful project is our successful project.
24
lcc: leitwind customer care
To ensure safety, we follow standards which
the group has developed in the safety-critical
field of ropeway construction and other
passenger transportation. To ensure success
and profitability, we accompany our
customers from the first stages of the siting
process throughout the whole lifecycle of the
installation.
LCC, the LEITWIND Customer Care package
according to IEC 61400/26 standards, offers
a full maintenance contract for safe, efficient
wind power production including guaranteed
availability. No customer ever ordered a
LEITWIND turbine without choosing it,
because the advantages are obvious. With
the LCC package LEITWIND guarantees
superior operational reliability at flexible,
transparent costs: LCC fees are charged
per produced kilowatt hours. This gives
the customer predictable and transparent
maintenance costs and reduces costs in
years with unfavorable wind conditions. LCC
covers all eventualities of normal wind energy
production, leaving only force majeure events
to be covered by a separate insurance policy.
The LCC package covers:
• Connection to the LEITWIND 24/7
Operation&Monitoring Center. This is a
state-of-the-art facility which provides a
continuous monitoring of all LEITWIND
turbines. Remote sensors transfer
performance data to the Monitoring
Center where trends in the turbine´s
behavior are compiled and analyzed.
In case of abnormalities, the LEITWIND
service specialists receive an automatic
alert including all necessary information
regarding the event. The analysis of
the data leads to a recommendation
for the customer and enables the
LEITWIND service and support teams
to optimize scheduled maintenance
work. In case of a failure, the LEITWIND
Operation&Monitoring Center can even
restart the wind turbine via remote control.
• Scheduled service twice yearly
• Unscheduled service and repair including
all spare parts and expendables
• Speed and quality: The LCC service
staff keeps close contact to the wind
park operators and can react quickly in
case of emergencies. All members of the
service staff have permanent access to
the LEITWIND Park Manager system and
to SCADA.
25
www.leitwind.com
italy
LEITWIND AG / SPA
Brennerstraße 34 / Via Brennero, 34
39049 Sterzing / Vipiteno (BZ) - ITALY
Ph: +39 0472 722 111
Fax: +39 0472 722 586
E-mail: [email protected]
austria
LEITWIND GmbH
Perlhofgasse 2B
2372 Gießhübl bei Wien - AUSTRIA
Ph: +43 (0)2236 866 270-0
Fax: +43 (0)2236 893 713 55
E-mail: [email protected]
india
Leitner Shriram ManufacTuring Ltd
D-17, Sipcot Industrial Complex,
Gummidipoondi - 601 201, Thiruvallur Dist.
Tamil Nadu - India
Ph: +91 (0) 44 2792 6000
Fax: +91 (0) 44 2792 4944
E-mail: [email protected]
USA
LEITWIND NORTH AMERICA
Leitner - POMA of america Inc.
2746, Seeber Drive - Bldg A
Grand Junction - Colorado, 81506 - USA
Ph: +1 970 241 4442
Fax: +1 970 241 3023
E-mail: [email protected]
© Text and graphics: 2012 LEITWIND AG / SPA. All rights reserved.
A special thanks to Georg Tappeiner, the photographer of the majority of pictures shown in this Company Profile.
Art direction by PG&W.
EN