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BONUS-600 kW TECHNICAL DESCRIPTION Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions Repowering Solutions [RE]built [RE]built wind turbine

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BONUS-600 kW

TECHNICALDESCRIPTION

RepoweringSolutions Repowering

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[RE]built

[RE]built wind turbine

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BONUS 600KWWhere performancemeets economy

The BONUS 600kW is one of the industry’s mostreliable turbines in the kW range – a high-performingand versatile turbine suitable for high and mediumwind sites.With more than 2,700 of these turbines erectedaround the globe, the BONUS 600kW is a tried-and-tested piece of technology – rigorously proven in thefield, robustly constructed and with an enviable track-record.Investors can be confident its easily transportabledesign features make it an ideal choice for remoteareas or sites with challenging access.

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The BONUS-600 KW [RE]built turbine is the classicalworkhorse for utility-scale wind turbine projects. It is theresult of BONUS/SIEMENS experience from more than25 years of leading-edge design and construction ofwind turbines and represents the best of the qualitiesfor which we are known throughout the wind industry.It is an efficient and reliable machine combining a solidand conservative design approach with high-performance technical features, such as the FullConverter system with variable speed concept and theLM Blade technology.

The BONUS 600KW [RE]built wind turbine is suited fortough and demanding applications onshore, particularlyfor high wind speed sites.

All components are removed for cleaning andinspection.Any component not meeting OEM manufacturerspeci?cations is repaired or replaced.The nacelle frame is inspected for cracks and overallstructural integrity. Any deficiencies are repaired andtested.The machine base and frame are stripped of allpaint, cleaned of dirt and lubricant, and repainted.All critical rotating components (cylinders, rollers,etc.) are inspected for run-out. Any component notmeeting OEM manufacturer specifications arerepaired or replaced.

[RE]built PROCESS

� All bearings (roller or plain) are repaired or replacedwith new.All belting is repaired or replaced with new.All rubber hydraulic lines are repaired or replacedwith new.

All polymer couplings are repaired or replacedwith new.All hardware is repaired or replaced with new.All gear boxes are cleaned, inspected, and newseals installed. Gears are inspected and repairedor replaced if needed.All generators are cleaned, inspected, and 100%rewound.Brake calipers are rebuilt, including new brakerotor and brake pads.Bull (Yaw) gear is repaired or replaced with newhaving a wider face than the OEM gearing.Pinion gear is repaired or replaced with newhaving a wider face than the OEM gearing.All Oil on wear blocks are replaced with new.All blades are inspected for defects, includingwear, cracks, and blemishes. De?ciencies arerepaired and the surface pro?les returned to OEMmanufacturer speci?cations.All blades are protected with a new covering ofgel coat.All blades are weighed, balanced, and matched.Blade over-speed mechanisms are inspected. Anycomponent not meeting OEM manufacturerspeci?cations are repaired or replaced.All electrical wiring and components are new andupgraded above and beyond originalmanufacturer specifications.The main control system is repaired or replacedfor new.Wind vane and anemometer are repaired orreplaced with new.ABB full power converter

[RE]builton experience

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Rotor

Blades

The BONUS-600 kW rotor is athree blade self-supportingconstruction, mounted upwind of thetower. The power limitation is by stallregulation.

The blades are made of fibreglassreinforced polyester and are suppliedby LM Hub The hub is cast in nodularcast iron and is mounted on the mainshaft with a large Main shaft andmain bearing The main shaft is forgedin alloy steel. It is centre-bored for thetransfer of Gearbox The gearbox is acustom-built three-stage industrialdesign. The first, high torque CouplingThe coupling between the gearboxand the generator is a universalcoupling with Generator Thegenerator is a fully enclosed double-winding asynchronous generator. TheGlasfiber A/S of Denmark. The bladetip can be turned 85 degrees relativeto the main blade, thereby acting asan aerodynamic brake. The blade tipshaft material is carbon fibre and allother load supporting parts aremanufactured in highgrade stainlesssteel. The blade tip is actuatedhydraulically from the hub, andhydraulic pressure is required to keepthe tip in the operating position. Abuilt-in spring turns the tip to thebrake position and during rotation thecentrifugal force acts in the samedirection. Any release of the hydraulicpressure, either intentionally by thecontrol system or unintentionally byfailure of the hydraulic system, willcause the tips to deploy and theturbine to shut down.

[RE]built

The blocking of one tip will notprevent the two remaining tips fromfunctioning, and the turbine canalways shut down with only two tipsdeployed.

The hub is cast in nodular cast ironand is mounted on the main shaftwith a large flange.

The main shaft is forged in alloy steel.It is centre-bored for the transfer ofhydraulic pressure to the blade tipbrakes. The main bearing absorbs therotor thrust and reaction forces fromgravity and bending moments. It is aspherical roller bearing, fitted in acustom-built bearing housing. Thebearing is grease lubricated and it isprotected with labyrinth sealsrequiring no maintenance.

The gearbox is a custom-built three-stage industrial design. The first, hightorque stage is a planetary design,providing a compact high-performance construction. Theintermediary and high speed stagesare helical, providing the lowestpossible noise level. The gearbox issplash lubricated and is cooled with aseparate oil cooler. It is shaft-mountedwith a shrink disk connection. Thegearbox is supported on the nacellewith flexible rubber bushings whichserve to reduce structural noisetransfer. Temperature sensors arefitted to the high speed shaft bearingand in the oil sump to shut down theturbine in the event of insufficientlubrication.

Hub

Main shaft and main bearing

Gearbox

Coupling

Generator

Easy to transport and install:

The coupling between the gearboxand the generator is a universalcoupling with two flexible elements.The coupling has good damping andshock-absorbing properties. It cantolerate moderate misalignments.

The generator is a fully enclosedasynchronous generator. The rotordesign and the stator windingsare specially designed for highefficiency at partial loads. Thegenerator is protected withthermal switches and analoguetemperature measurement. Thegenerator is fitted with a separatethermostat-controlled ventilationarrangement. By having a veryefficient surface cooling thegenerator can be operated attemperatures well below thenormal level of the standardinsulation class, thereby providingthe best possible lifetime of thewinding insulation.

Thanks to our advanced designtechniques, the

can be dispatched to almostany location around the world – andall components comply with local andinternational limits for standardtransportation. The nacelle requires noon-site assembly, further loweringyour costs.

BONUS-600 kW[RE]built

Technicaldescription

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Disc brake

Nacelle bedplate

Yaw system

The mechanical brake is fitted to thegearbox high speed shaft. It is failsafeand has a spring-loaded hydrauliccaliper. The brake application systemhas two stages, one for normal shut-downs and the other for emergencyshut-down in case of malfunctioningair brakes.

The nacelle bedplate is a massivesteel construction without weldings. Itis cut out of a 120 mm steel plate.The top side has machined surfacesfor the bearing and the gearboxsupports, and the bottom side hassimilar surfaces for the yaw bearing.

The yaw bearing is an externallygeared ring with a friction bearing.The yawing motion is driven by twoelectric planetary gear motors. Theyaw brake is passive, based on thefriction of the yaw bearing. It keepsthe yaw system rigid under mostloading conditions. In case of highlyeccentric peak loads the yaw brakewill slide and the yaw motors willfollow the motion passively, therebyunloading the system.

Controller

A standard industrial computer is thebasis of the turbine controller. Thecontroller is self-diagnosing andincludes a keyboard and display foreasy status readout and adjustment ofsettings.

Power conversion

Tower

The FullConverter power conversionsystem allows generator operation atvariable speed, frequency and voltagewhile supplying power at constantfrequency and voltage to the MVtransformer. The power conversionsystem is a modular arrangement foreasy maintenance.

The turbineis mounted on a tapered tubular steeltower. The tower can be fitted with apersonnel hoist as an option.

BONUS 600 kW [RE]built

The wind turbine operatesautomatically, self-starting when thewind reaches an average speed ofabout 3–5 m/s. During operationbelow rated power, the pitch angleand rotor speed are continuouslyadjusted to maximize theaerodynamic efficiency. Rated poweris reached at a wind speed of about13–14 m/s, and at higher wind speedsthe output is regulated at rated power.If the average wind speed exceedsthe maximum operational limit of 25m/s, the turbine is shut down byfeathering of the blades. When thewind drops back below the restartspeed, the safety systems resetautomatically

Operation

Remote control

Turbine Condition Monitoring

Grid compliance

The turbineis equipped with the unique WebWPSSCADA system. This system offersremote control and a variety of statusviews and useful reports from astandard Internet web browser.The status views present electricaland mechanical data, operation andfault status, meteorological data andgrid station data.

In addition to the SCADA system, theturbine is equipped with a web-basedTurbine Condition Monitoring (TCM)system. The TCM system carries outprecise condition diagnostics on mainturbine components continuously andin real time. It gives early warning ofpossible component failures bycontinuous comparison of currentvibration spectra with previouslyestablished reference spectra. TheTCM system has various alarm levels,from informative through alertinglevel to turbine shutdown.

The supportsgrid requirements in a wide range ofmarkets and territories. Advancedcontrol of reactive power capabilitystabilises the frequency and voltageof the grid.

BONUS 600 kW [RE]built

BONUS 600 kW [RE]built

PeakPerformancefor medium andhigh wind sites

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Reliable, competitiveand compliantRe-built the future of wind

Cheaper to transport, quicker to install

Lowering maintenance costs for greaterprofitability

The light weight of the BONUS-600 kWminimises construction and transportationcosts.The BONUS-600 kW features a compact styleof blade transportation which allows the safetransportation of three blades at one timeusing existing trucks and cranes. This makesinstallation quicker and minimisestransportation costs.

Maintenance and repairs can now beperformed faster and cheaper up-tower, andwith greater technical ease, thanks to ourupdated ergonomic nacelle design withincreased access and working environment.

With a ABB full scale converter, thecomplies with even the

most challenging grid requirements of themodern energy market.

[Re]builtBONUS-600 kW

Low Balance of Plant (BOP)

Easy-access serviceability

Installation and transportation costs Just likeis designed to be

transported easily (by rail, truck or barge) tovirtually any site around the world. In termsof weight, height and width, all of itscomponents comply with local andinternational limits for standardtransportation.Specifically, not one of its componentsweighs more than 40 tonnes. Yourfoundation costs are also lowered with the

due to its improvedload control. The innovative power systemprovides excellent grid support and is highlyadaptable for future technical requirements.It also enables substations to be simpler andtherefore more cost-effective.

The nacelle isergonomically. This extra space also makes iteasier for maintenance crews to gain access– reducing the time and cost spent onservicing and therefore maximising uptime.The automatic lubrication of the yawsystem, main bearing and generator deliversthe triple benefit of increased reliability,reduced maintenance time and less frequentservicing. Combined, these factors save you

BONUS-600 KW [RE]built

BONUS-600 KW [RE]built

BONUS-600 KW [RE]built

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The technologyyou need– wherever you need it

Grid requeriments

The [Re]built BONUS-600 kW turbines aredesigned for optimum compliance with gridstandards worldwide. The Full PowerConverter of ABB advanced grid compliancesystem provides active and reactive powerregulation, fast response to changes infrequency and fault ride-through capabilitiesto support grid levels and stability in theevent of grid fluctuations.

Investing in a [Re]built BONUS-600 kWmeans investing in turbines that can adapt toeven the most challenging grid codes.

GR

IDIN

TERFA

CE

Switch gear

Bottomof the tower

Transformer

Cable in tower

Grid sidefilter

Back-to-backconverter

Stator Sidefilter

GeneratorGearbox

Excellent grid support

Full Converter

A brand new ABB full converter transformsthe energy output to DC and inverts again toAC allowing the generator to produceelectricity at all the range of Capacitors andreactors provide reactive energy transferingall active power to the grid.LCL filters control the THD injection in the gridkeeping low additions and being compliant inall grid codes.Robust control can keep the turbineconnected during a low voltage helping thegrid stability.

Advantages of Full Converter

1. Reactive compensation from 0.8Cap to 0.8ind2. LCL filter for Harmonics limiting THD emissionsinto the grid3. Low Voltage Ride Through capabilities.4. Dynamic power factor control and voltagecontrol5. Primary response in frequency control6. Crow bar optional for safety breaking

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The experience to secureyour wind energy investment

Optimiseenergyproduction

– Designed for highproductivity

– Excellent grid support

Reduceenergycosts

– Low Balance of Plant(BOP), installation andtransportation costs

– Designed for serviceability

– Innovative ABB full PowerConverter uses the wind’sown energy

Secureyourinvestment

– Proven technology– Reliable and robustproduct

275.000 €2 year guarantee

EXWORK terms of sale

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Sageguardingyourinvestment,powering your profits

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Rotor

Blades

Aerodynamic brakes (Blade tip brakes)

Load-supporting parts in the nacelle

Transmission system Coupling,

Type 3-bladed, horizontal axisPosition UpwindDiameter 43 / 44 mSwept area 1520 m²Synchronous rotor speed 27 / 18 rpm.Power regulation Stall regulationRotor tilt 4 degrees

Type Self-supportingBlade length 19 mTip chord 0.40 mRoot chord 1.65 mAerodynamic profile FFA3 - NACA 632xxConing 0 degreesMaterial Glass fibreSurface gloss Semi-mat, gloss 5-15 /

ISO 2813Surface colour Light grey, Jotun 8091Blade designation LM 19-1Blade manufacturer LM Glasfiber A/S

Type Turning blade tipsActivation Passive, with release of

hydraulic pressure

Hub Nodular cast-ironMain bearing Spherical roller bearingTransmission shaft Alloy steelNacelle bedplate Steel

hub/main shaft FlangeCoupling, main shaft/gearbox Shrink discGearbox type Three stage

planetary/helicalGearbox ratio 1 : 55Gearbox lubrication Splash lubricationOil volume 60 lGearbox cooling Separate coolerGearbox designation PEAC 4280Gearbox manufacturer Flender AGCoupling gear/generator Double flexible coupling

Brake (mechanical brake)

Type Fail-safe, brake discPosition On the gearbox high-speed

shaftNo. of calipers 1

Generator

Nacelle cover

Tower

Operating data

Type AsynchronousNominal power 600 / 120 kWSynchronous speed 1500 / 1000 o/minVoltage 690 VFrequency 50 Hz / 60HzProtection IP 54Cooling Thermostatically controlled

fanIsolation class FGenerator designation M2BG 400 XL 4/6 B3Generator manufacturer ABB Motor A/S

Type Totally enclosedMaterial Steel

Yaw system

Type ActiveYaw bearing Externally geared slew-ringYaw drive Twin electric gear motors

with combined gear/planet-gear.Yaw brake Passive friction brake

Type Conical tubular towerHub height 40m / 45m / 50m / 55m

58m / 60mCorrosion protection PaintingSurface gloss of the painted tower Semi-mat, gloss 15 - 35

ISO 2813Colour of painted tower Light grey, Hempel 55210-01050

Cut-in wind speed 3 m/sNominal power at approx 15 m/sCut-out wind speed 25 m/sMax. 2 s. wind gust 55 m/s

BONUS-600 KW [RE]builtsome impressive data

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Estimated CAPEXBonus 600kW + Full Converter

TOTAL 553.000

BONUS-600 KW + Full Converter 275.000

Foundations (420m3) 60.000

Erection & commissioning 75.000

Transport 95.000

Elec. Connection (1km+CB) 40.000

Insurance 8.000

Assumptions

Electrical connection 1km underground cable at 11kV+Circuit BreakerFoundation 420m3No mayor civil works on roads requiredCranes available national for erection

BONUS-600 KW [RE]builtsome impressive data

Advantages

Generator and Full Converter ABB

Robustness and Simplicity of moving parts

Up to 3WTGs connected to 11kV, 13kV or 20kV with no majorissues

LCL filter for THD

Power Factor 0,8 cap to 0,8 ind at full Active Power

Low Voltage Ride Through compliant

Grid Code Compliant with hignest standards

Cost turnkey 1,05 m EUR/MW

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BONUS-600 KW [RE]builtsome impressive data

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

1 5 9 13 17 21 25

Power Curve

Bonus MK IV + Full Converter ABB ACS800-77 Bonus MK IV

PO

WE

R (

MW

)

0

500

1000

1500

2000

2500

3000

5 6 7 8 9

Average Wind Speed at hub height (m/s)

MWh After Full Converter MWh Before Full Converter

Annual E

nerg

y P

roduction (

MW

h)

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Published by and copyright © 2012:REPOWERING SOLUTIONSEnergy SectorRonda de Atocha, 3728012 Madrid, SPAINwww.repoweringsolutions.com

For more information, please contactour Customer Support Center.(Charges depending on provider)E-mail: [email protected] Energy Division

All rights reserved.

The information in this document containsgeneral descriptions of the technical optionsavailable, which may not apply in all cases.The required technical options should thereforebe specified in the contract.

www.repoweringsolutions.com