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www.ricardo.com
© Ricardo plc 2012
Ricardo plc
Presentation to UKTI - Offshore Wind & Marine Energy Workshop
“Introduction to Ricardo Design and Innovation Capabilities”
28th February 2012
© Ricardo plc 2012 2
Company
Established in 1915 and independent
£196.5 million revenue (FY 10/11), up 21%
£162.8 million revenue (FY 09/10)
More than 1.600 employees with more than 1.300
technically qualified and engineering staff
Global presence in 16 locations
Positioning
Global Presence
Ricardo Overview Ricardo delivers world class strategy, engineering and technology programmes to the global
automotive, transportation, defence and energy industries
Ricardo supports
the full Clean
Energy systems
product lifecycle
© Ricardo plc 2012 3
Three dimensional Ricardo Core Business Model Market Sectors provide domain expertise and ensure relevance, Product Groups provide deep
content technology and delivery from world class global engineering teams based around the globe
© Ricardo plc 2012 4
CHP
Engineering
Ricardo provides technical and strategic support to project delivery
across all major Clean Energy technical sectors
RICARDO
Solar Energy
Systems
Wind Energy
Systems
Marine Energy
Engineering
Energy Storage
Fuel Cell
Engineering
Strategic
Consulting
22© Ricardo plc 2008RD.08/12354.1
China (6GW)
*India
(8GW)
*
Japan
*Taiwan*
South
Korea*
ASIA (1
6GW)
Due to the difference in market penetration, it is important to
manufacturers to be first movers with large projects there
Long-term these markets will
eventually pick up
Upward pressure on WTG and
O&M service prices due to
demand-supply mismatch.
Sweden is considered to be
investment grade country with
double digit growth driven by
political will
SKAB can profit from supplier’s
experience curve effects having
installed WTG in similar
topographies
Time
Ins
tall
ed
ca
pa
cit
y v
s.
Tec
hn
ica
l w
ind
po
ten
tial
Embryonic Mature
SKAB’s
implications
Market
situation
Wind market categorisation, 2007
*Egypt
Marocco*Iran*
AFRICA & MIDDLE EAST
(0,5GW)
Italy
*
Germany
(22GW)*
Denmark
(3GW)*
Spain
(15GW)*
* France*
UK (2GW)*
Netherlands*
Sweden
(0,7GW)
Greece*Rest of Europe*
Portugal*
Ireland*
Austria*
Norway*Belgium*
Poland*
EUROPE
(57GW)
Source: Ricardo Research, F&S 2007, GWEC 2008
USA
(16GW)*Canada
(2GW)*
NORTH AMERICA
(18GW)
Growing
Due to experience, the service
market is more competitive (OEM
service provider, ISPs, in-house
service departments)
Some mature markets already
display scarcity of good wind sites
Competition is heating up for
available manufacturer capacity
Shortfall of supply for essential
components, technology issues
Market characterized by high
growth rates, coming from a
low basis
BEFORE FINANCIAL
CRISIS IMPACT
Wind Power references
28© Ricardo plc 2008RD.08/12354.1
845
849
1146
912 1300
1200
30
5
30
7
27
5
50
0
80
0
1025
982
2729
80 1088
1100
1100
1121
1210
1217
1250
1262
1289
1300
1302 1573 1800
2000
DE
N
ME
X
GR
E
NE
D
US
A
JP
N
NO
R
ES
P
UK
GE
R
PO
R
CH
CA
N
ITA
IRE
Regional price differences can be significant mainly due to different
cost for total project development and technical solutions
100 100 100
30 30
55
Regional price differences [€/kW] Comments
BEFORE FINANCIAL
CRISIS IMPACT
Turbine versus project and TCO costs
Source: Ricardo estimation
Turbine system costs generally include nacelle, tower,
rotor blades, internal electrical system, transport and
erection (100%)
Project costs generally include costs for the turbine
system plus land & land development, foundation &
civil works, electrical connection, control systems,
consultancy and finance (+ appr. 30%)
Total costs of ownership (TCO) include project costs
plus operations and maintenance over the lifecycle
time (+ appr. 55%)
% of turbine
system costs
Turbine
system
(ex. Works)
Project
costs
Total cost
of ownership
(TCO)
100%
~130%
~185%
O&M
Project
development
Turbine
system
€/kW
Source: IEA, 2006 & 2007
Project costs or add. project costs
Turbine system
The average total cost per kW of installed wind power
capacity differs between countries up to 100% due to
significant cost differences for project development
and application of different technologies
The cost per installed wind power typically varies from
around 1000 €/kW (DEN) to 2000 €/kW (IRE) and
averages at 1300 €/kW
Turbine system costs varies between 850 €/kW (DEN
& USA) and 1300 €/kW (ITA) and averages at 1000
€/kW
Few numbers have been reported for Sweden
Wind Power references
© Ricardo plc 2012 5
Commercially - Ricardo’s Market strength can help clients develop
export products and overseas customer links and facilities
Ricardo can help customers by:
Promoting overseas links to key business
contacts for export sales
Assistance in developing links in other markets,
e.g. new European Offshore Wind markets
Technical centre support and assistance to set-
up facilities and provide interim office space
Supply chain development and management
Support to gain public sector funding
Links to testing facilities and management
Support to obtain certification (GL, DNV, TUV)
required for bank financing / warranties
Ricardo are already doing this for major
wind turbine manufacturers
© Ricardo plc 2012 6
Technically - Ricardo’s strength in engineering and innovation can
help customers develop advanced products for the global market
Ricardo can help companies by:
Helping manufacturers develop their “own
designs” rather than rely on licencing
Design technology advantages (performance,
mass reduction and reliability) into new and
next-generation products
Driving down the Cost of Energy through
reliability, performance and life-cycle
engineering and innovation improvements
Analysing “through-life” performance and
identifying improvement areas
Ricardo are already doing this for major
wind and marine energy manufacturers
and drivetrain suppliers in many regions Jon Wheals 2010
Accumulators
Four 2.5MW Generators
1:20 Compound
Epicyclic
Variable Ratio Stage
“Torque Only” coupling
10MW Variable Ratio Driveline
1:125 +/- 5%
Jon Wheals 2010
Accumulators
Four 2.5MW Generators
1:20 Compound
Epicyclic
Variable Ratio Stage
“Torque Only” coupling
10MW Variable Ratio Driveline
1:125 +/- 5%
Jon Wheals 2010
Accumulators
Four 2.5MW Generators
1:20 Compound
Epicyclic
Variable Ratio Stage
“Torque Only” coupling
10MW Variable Ratio Driveline
1:125 +/- 5%
3.5MW 3-stage epicyclic gearbox (lower
mass, higher reliability)
10MW variable ratio split-path drivetrain
(lower mass, higher reliability)
© Ricardo plc 2012 7
Ricardo drivetrain development process and Ricardo software, can
include client participation, software licencing and training.
• Generate time
series/LDD for client
turbine design
• Verification of
client supplied time
series/LDD data
© Ricardo plc 2012 8
Drivetrain Design Approach
Design Optimisation Examples
Design
Space
Topology
Optimisation
Detail
Design
Ricardo has extensive experience of structural design
optimisation applied across many disciplines:
Wind Turbine Gearbox Housing
– 33% improvement in weight for a given stiffness
– Improvement used to achieve greater stiffness -
Housing deflection reduced by 42% with only 7%
increase in component mass
– Factors of safety against extreme loading
maintained
– Complete turnkey task achieved including, design
analysis, models, drawings and reports in 7 weeks
Carrier intelligent design
– Topology optimisation combined with design for
manufacture and assembly gives Ricardo more
novel solutions with significantly reduced weight
– Example of a cast iron design with an original
design weighing 2350kg. This was redesigned with
a 3% reduction in torsional stiffness and weight
reduced to 1600kg – a saving of 750kg or 32%.
Design Optimisation Process
© Ricardo plc 2012 9
Ricardo can apply leading edge Design for Manufacture processes to reduce both production and
warranty cost
Design for Manufacture and Assembly (DFMA)
– Alternative process selection
– Process complexity reduction
– Product simplification and design for serviceability
– Part count/cost reduction
– Assembly/Service complexity reduction
– Virtual build in 3D CAD to optimise design for assembly
Benefits of application in Design Phase:
– Reduced risk of manufacturing/assembly issues
– Improved confidence in ‘right first time’ design
– Improved serviceability/in nacelle maintenance
– Reduced warranty
Drivetrain / Power Take-Off Design Approach
Design for Manufacture, Assembly and Maintenance/Service
Design for Maintenance/Service
– Reliability prediction to identify key features for maintenance
e.g. Access to planet gears and flex pins for ease of replacement
– Consideration of nacelle handling facilities and space
– Consideration of design features and tools to support the ‘in nacelle’
environment
© Ricardo plc 2012 10
RSC procurement support of 120 wind turbines with a total invest of
mio€ ~310 for WTG + O&M saved the client more than mio€ 60
Approach
Ricardo managed the whole procurement process
Ricardo Six-step Approach to Procurement applied
– Detailed supplier market analysis
– Evaluation of technology along product life cycle
Definition of the client requirements
– Make or buy analysis along value-chain
– Technical and commercial requirements
Definition of RfQ, negotiation strategy, supplier
nomination, negotiations, factory inspections
Ricardo led supplier negotiations/selection
Situation and objective
Utility client with ambitious plans in wind energy and
secured finance backing from own balance sheet
Determined to utilise the financial downturn for
procurement of large number of wind turbines
Client has little experience in procurement of wind
turbines and the quality track records and cost levels
for larger turbines (2-3 MW)
Objective of the project was to procure 118 onshore
wind turbines rapidly at the right cost and with lowest
operational life cycle risk
Good transparency of the supplier market with
strengths and weaknesses by key player & market
Simple RFQ with functional specifications: 16
suppliers invited, 13 offers received from well
balanced mix of tenderers (low cost & high value;
direct drive & conventional; US, European & Asian)
Four selection gates with 30%+ secured price
reductions for WTG and O&M before 2nd gate
Duration of the total 3-phase project: ~12 months
Total savings from 1st offer to final contract: mio€ 60+
Results and benefits
Procurement scope
– Turbines,
O&M, Project
development
– Turbine size?
– Technology?
Business case
Financing (EU
subsidies?)
Project & milestone
planning
Clarification of
readiness for project
implementation
– Permissions
– Location
selection
– Grid
connectivity
Supplier market
structure analysis
– Developers
– Manufacturer
– 1./2.-tier
suppliers
Supplier analysis:
Strengths, weak-
nesses, opportuni-ties
& threats of each
supplier (SWOT)
Price analysis (price
benchmark-ing for
wind farms)
Cost analysis
– breakdown on
compon.
– Total cost of
ownership
Develop procure-
ment strategy
Detailed analysis of
demand side
– Technical spec.
– Commercial
spec.
Create long list of pot.
suppliers
Decide on selection
criteria
Prepare request for
quotes (RFQ)
Ensure compliance
with legal
requirements
Send out RFQs
Draft frame contract
Collect quotes
Analyse offers
– Price
– Quality
Integrate offers into
databases
Generate short list
Schedule first round
of negotiations with
short listed
candidates
Develop negotiation
strategy (e.g. cadence
strategy)
1st round of
negotiations
Assessment
2nd round of neg.
On site excursion of
supplier facilities
Decision about
preferred supplier(s)
3rd and final
negotiation with
preferred supplier(s)
– Price & payment
– Delivery
schedule
– Frame contract
– O&M
– Service parts
Project implementation
management
– Project office
– Issue manage-
ment
– etc.
Interface management
– Investor
– Grid operator
– Contractors
– Authorities
– etc.
Project & supplier
performance tracking
Supplier management
Budget/cost controlling
Activities
Six Step Approach to Procurement
Supplier
Market
Analysis
Baseline
Definition
Preparation
of
RFQ
Analysis of
Quotes
Negotiation
s
Implemen-
tation
Clear project scope
Infrastructural &
commercial
prerequisites clarified
Supplier market
transparency
Basic price- and cost
transparency
Proc. Strategy
Selection criteria
Supplier long list
RFQ finalised
Short list of suppliers
Negotiation schedule
Preferred supplier
selected
Frame contract signed
Successful,
in-time project
implementation Results
Generator Gearbox
Control system Converter
Case Study C
S: 164
© Ricardo plc 2012 11
Case Study – 1.5MW WT drivetrain upgrade
Ricardo role
Ricardo undertook design review of the overall
drivetrain architecture and completed a concept
design for a new layout
Ricardo completed detailed re-design and analysis
of the main frame, main shaft and bearing systems
Ricardo liaised with the suppliers and teams
responsible for hub, pitch system, loads and control,
gearbox and generator to ensure a well-integrated
overall drivetrain solution
Situation and objective
Long-established WT manufacturer
Existing MW scale turbine already in production
Potential for uprate identified by manufacturer
Larger rotor and improved pitch control also to be
implemented as part of overall upgrade for:
– Improved load control
– Higher power production capability
New drivetrain layout delivered with optimised
structure and weight
Turbine uprate is being enabled within the weight
target required, to enable the uprated design to be
installed with the same equipment as the original
design
Results and benefits
© Ricardo plc 2012 12
Case Study – Concept and Detailed Design of 1MW Tidal Turbine
Ricardo role
Detailed CFD analysis for commercial demonstrator
including flow assessment of blades and Venturi and
linked to generator model for load/speed balance
Major loading input and boundary conditions
predicted to simulate components operating within
complete turbine system
FE Analysis of steel and composite structure
including lifting frames for moving 1MW tidal turbine
components during manufacture
Situation and objective
Device development plan required for scale-up and
full size commercial demonstrator
Design support for concept layout, configuration and
design of 1MW turbine
Detailed flow assessment of complete turbine unit
with individual models for blade design to optimise
hydrodynamic development and durability
Complete turbine model to assess manufacturing
process (12 major lift operations planned) and sea
base structural loading and deformation
Concept optimisation of blade number, blockage and
profile to achieve target performance
Identified concerns over Venturi and improved
design implemented for commercial demonstrator
Ricardo developed concept for hybrid blade design
allowing manufacturing flexibility whilst retaining the
blade structural benefits of composite materials
Fatigue life prediction for frame using Ricardo
FEARCE software – showed base structure
performance acceptable for deployment
Results and benefits
© Ricardo plc 2012 13
Case Study – 15MW Wind Turbine Drivetrain Test-rig Development
Ricardo role
Ricardo undertook concept design of gearbox for the
testrig including application of advanced simulation
tools to ensure robust design of core rig component
Ricardo supported definition of rig performance
envelope to maximise potential applications within
development cycle
Ricardo defined the requirements for the installation,
commissioning and operation of the test-rig with the
prototype hardware installed
Situation and objective
Design and development drivetrain testrig with
partners for testing offshore WTG drivetrain under
highly dynamic operating conditions
Development of operational and test strategy for
incorporation of advanced test facilities in the WTG
development cycle
Current status is definitive design phase of rig
completed ready to progress to detailed design and
procurement of long lead hardware
Ricardo provided support for engineering wind
industry requirements and test and development
application into the design of the testrig ensuring the
rig would be able to meet current and future
requirements and represent value in the engineering
process
Combined approach with Ricardo integrated into
programme provided key application and operational
experience
Results and benefits
© Ricardo plc 2012 14
Schematic of detailed CoE Model developed by Ricardo to guide &
prioritise turbine design innovation activities
Power Curve
Wind Weibull
Distribution
Annual energy
production
Capacity
factor
Total
Downtime
Availability
Scale and
form factors
Power
Coefficient:
components
efficiencies
Scheduled
O&M Unscheduled
O&M
Initial Capital
Costs
Machine rating
Rotor Radius
Hub height Failure rates
Downtimes Labour,
equipment needs
Occurrences
Consumables
needs
Total O&M
Costs
Annual
Levelized
Total costs
Levelized Cost
of Energy
Economic
lifetime
Interest rate
Rotor
Drive train,
Nacelle
Electrical system
Control system
+ monitoring
Tower
Balance of
station
15.5
12.5
8.8
12.5
2
3.5
7
4.5
10
0.5
4.5
2.5
3
1.5
13
-15
-10.5
-7.5
-15.5
-2
-4
-4.5
-7
-6
-1
-3
-3
-2
-0.5
-7.5
-20 -15 -10 -5 0 5 10 15 20
Converter
Generator
Rest of the Power Module…
Pitch system
Blades
Rest of the Rotor Module…
Control system
Rest of the Control Module…
Yaw System
Rest of the Nacelle
Gearbox
Tower
Rest of the Structural Module…
Other & Unknown
Downtime Failure rates
0
200000
400000
600000
800000
1000000
1200000
1400000
1600000
5000000 7000000 9000000 11000000 13000000 15000000
ICC
/a +
O&
M/a
€
Annual Energy production (kWh/yr)
13 c€/kWh
8 c€/kWh
7 c€/kWh
6 c€/kWh
5 c€/kWh
4 c€/kWh
3 c€/kWh
COE Offshore
Improved COE
Wind distributions
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
0 5 10 15 20 25 30
%
Wind speed
Wind Weibull distribution %
0
100
200
300
400
500
600
700
800
900
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Hour
s / yr
Wind speed
Wind Weibull distribution in hrs
0
0.5
1
1.5
2
2.5
3
3.5
0 5 10 15 20 25 30
Powe
r MW
Wind speed
WT Power curve
0
200
400
600
800
1000
1200
1400
1600
1800
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Ene
rgy
MW
h/y
r
wind speed m/s
Energy MWh/yr
© Ricardo plc 2012 15
Drivetrain innovation is a key focus area, but today drivetrain
architectures vary widely, with different advantages & challenges.
Source: Ricardo Analysis; Aerodyn IQPC 2010 Paper; BHO 2011 DWOW Paper
E.g. Hybrid
and Torque
Converters
E.g. Fully
Geared and
Gearless
© Ricardo plc 2012 16
Variable ratio and hybrid
drivetrain solutions Torque de-coupling
Load sharing and
bearing innovation
Torque truncation
Advanced condition
monitoring systems
with prediction of
remaining useful life
Advanced lubrication
systems
CoE factor
Influence of Drivetrain Technology
Onshore Offshore
Installed cost High Med High
Design life High High
O&M costs High V High
Turbine
availability
Med High V High
Power curve Med Med
Ricardo believes Wind Energy sector can benefit from innovative
“modular solutions” applicable to wide range of wind drivetrains
© Ricardo plc 2012 17
MultiLife History - Development Chronology, Support, Events, IPR
2012 2011 2010 2009 2008 2013 2014
Patent 1 Patent 2 Patent 3
NWIP Project
Gen1
Gen3 Design and Prototype
Turbine 1
Y/N ?
SOP
Rig Test MultiLife Indexing Device (Gen3)
© Ricardo plc 2012 18
In summary, Ricardo is ideally placed to address the Clean Energy
technology and market objectives over the short and long-term
Ricardo has a tremendous track record of delivering innovation
and product development from successful projects across a
the Automotive, Defence and Clean Energy sectors.
Customers can benefit from our ability to support the complete
product development process and operational life-cycle:
RICARDO
Detailed understanding of the market challenges, policy
drivers and opportunities focussed on customer requirements
Engineering and innovation to drive down the Cost of Energy
through reliability, performance and life-cycle improvements
Fast identification of engineering solutions, including “blue-
skies” thinking where necessary
Acceleration of technology development, cost reduction and
delivery programmes of new and next-generation products
Support to improve production processes, including design for
manufacture, assembly and quality control
“Through-life” performance improvement, analysis and testing,
including full test programme and rig design
Ricardo supports
the full clean
energy systems
product lifecycle
© Ricardo plc 2012 19
Contact Details
Paul Jordan Market Sector Director - Clean Energy & Power Generation
Mobile: +44 (0)7801 973 049
Phone: +44 (0)1926 477 676
Fax: +44 (0)1926 319 300
www.ricardo.com
Ricardo UK Ltd
Southam Road, Radford Semele
Leamington Spa
Warwickshire CV31 1FQ, UK