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Suzlon Energy Ltd.
1 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Suzlon Energy Ltd.
2 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Agenda • Suzlon Technology
• Suzlon product evolution towards S128
• Critical drive train design features
4-point rotor suspension
Main bearing O-layout
Casted main shaft
Drive train assembly
High Speed + DFIG vs. Medium Speed + Full converter
• Q & A
Suzlon Energy Ltd.
3 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Suzlon Technology
Suzlon Energy Ltd.
4 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Suzlon Technology Locations & Skills
Germany Hamburg - Management - Development & Integration - Certification
Rostock - Development & Integration - Design & Product Engineering - Innovation & Strategic Research
The Netherlands
Hengelo - Blade Design and Integration
India Pune - Design & Product Engineering - Turbine Testing & Measurement - Technical Field Support
Vadodara - Blade Testing Center
Denmark Aarhus Vejle
- SCADA - Blade Science Center
Over 400 Technology Professionals in Germany, Netherlands, India & Denmark
Hamburg
Ham
burg
R
ost
ock
H
enge
lo
Pune
A
arhu
s
Suzlon - Technology
Suzlon Energy Ltd.
5 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Seamless collaboration of teams is key to the success
SG1 SG2 SG3 SG4 SG5 SG6 SG7 SG8 SG9 SG10
B-Components and detailed parts
System and Main components
WTG Development &
Integration
Platforms
Design and Product Engineering Test,
Verification &
Integrity Technical Fleet Services
Technical Advisory
Innovation & Strategic Research
Technical Guidance & Support
Coordination & Control
Suzlon – Development process
Suzlon Energy Ltd.
6 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
45% of installations outside India are in USA
Suzlon - 15 GW of installations worldwide
Suzlon Energy Ltd.
7 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
S52 - S82 S88 S9X S97 – 120 S111 S128 DFIG S128 MS
MW Rating 0.6 – 1.5
MW 2.1 MW 2.1 MW 2.1 MW 2.1 MW 2.6 MW 3.0
Hub Height Available
75m 80-100m 80/90m 120m 90-140m 90/140m 90/120m
Wind Class IEC II A /
IIIA IEC II A IEC II A IEC III A IEC III A IEC III A IEC II A
Global Installation
7.1 GW 5.7 GW 1.9 GW 600 MW >500 MW
Sold Proto
assembly In design
Rotor Diameter 52-82 m
Hub Height 75 m
Rotor Diameter 88 m
Hub Height 90 m
Rotor Diameter 95 / 97 m
Hub Height 90 m
Rotor Diameter 97 m
Hub Height 120 m
Rotor Diameter 128 m
Hub Height 90 - 140m
Rotor Diameter 111 m
Hub Height 120 m
20 Years of “Hard Work & Innovation”
Technology Evolution - 600 kW to 3.0 MW
Suzlon Energy Ltd.
8 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Critical drive train design features
Suzlon Energy Ltd.
9 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
New platform in development – 30%+ more yield
3 models optimized for its target market sharing a common concept & blade
Low wind Site specific & class III turbine Class II
Attribute India site spec. 60Hz Version for USA All Geographies
S128-2.6 S128-2.6 S128-3.0
Rotor (m) 128 128 128
Rating (MW) 2.6 2.6 3.0
Noise <105dBA* <105dBA*
Wind conditions
Class S India spec. Vavg=7.25m/s, Vref=37.5m/s
max.1.16kg/m³
Full Class IIIA Full Class IIA
Gear Box (GB ) 3 Stage 2 stage
Blade SB63 – hybrid carbon/glass fibre blade
Generator 50 Hz, 6 pole, DFIG 60Hz, 6 pole, DFIG Medium Speed, full
conversion
S128 Platform: Configuration overview
Suzlon Energy Ltd.
10 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Medium Speed Concept 3.0MW
2 Stages Gear box (same base design like 3 stage)
Medium Speed Generator Electrically Excited Synchronous Generator (EESG)
Or (fully interchangeable) Permanent Magnet Generator (PMG)
Full Scale Converter
Small support girder for cabinets
High Speed Concept 2.6MW
3 Stages Gear box
DFIG Generator
Coupling between the generator and gear box
Partial converter
Large Girder for full generator support
S128 Medium Speed vs. High Speed
4 point suspension with casted shaft
Low RPM concept
Suzlon Energy Ltd.
11 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
1st MB 2nd MB Coupling Shrink D GB GEN coupling GB Mounts Rotor Shaft
S128 2.6 vs. S111 drive train
Suzlon Energy Ltd.
12 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
S111 - 3 Point Suspension
S111
Not Overdetermined system:
Bearing points coupling does not matter
bending moment and vertical forces
transferred to gear box
Suzlon Energy Ltd.
13 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
S128 2.6 - 4 Point Suspension
S128 2.6
Overdetermined system:
Bearing points coupled by main frame
elasticity
Reduced bending moment and vertical
forces on gear box
Suzlon Energy Ltd.
14 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
S128 3.0 – 4+1 Point Suspension
1
2
3
4 MB1
MB2
GBM1
GBM2
WS 5
Fx
Overdetermined system:
Bearing points coupled by main frame elasticity
Reduced bending moment and vertical forces on gear box
Additional Weight Support (WS) in comparison to S128 2.6
Suzlon Energy Ltd.
15 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
S128 – 2 Main Bearings
4-point rotor suspension system uses two
single row tapered roller bearings in O-arrangement
Suzlon Energy Ltd.
16 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Main bearing mounting – 4 point susp.
Mounting step
- Step 1: - Rotate frame 180° that yaw flange is on top - To be settled on a support rack and transported
to assembly plant for mounting
- Step 2: - Mounting of the outer main bearing rings in
horizontal position.
Suzlon Energy Ltd.
17 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Main bearing mounting – 4 point susp.
Mounting step
- Step 3: - Jig on the rear of the main frame - Approximate height of main frame on rack ~6.5 m - Step 4 - Assembling in vertical position - Rotating shaft on table
Suzlon Energy Ltd.
18 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Components:
• 3 phase 3 winding system
• Machine side converter – diode
operation
• 3 independent stages PMSG
~900V AC
~1200V DC
690V AC OUTPUT TO TRAFO
Advantages:
• 3 MVA STATCOM capabilities
• 3 independent ACB protection
• Active and reactive power control
• Increased availability and redundancy
• No spend on extra park equipment
S128 3.0 full scale converter topology
Suzlon Energy Ltd.
19 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
The SUZLON Software portfolio covers:
• SC Trinity
• Reporting
• Online monitoring
• 24/7 monitoring
• Configuration management
• Enterprise customer interfaces (Hist. data & Online) etc.
• SC-Commander
• SC-Power Plant Controller
SUZLON SC Trinity SCADA
SUZLON has a centralized SCADA Server platform
Suzlon Energy Ltd.
20 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
• Designed and manufactured by Suzlon
• New generation profiles from Risø Technical University of Denmark, rigorously tested in the wind tunnel facility in France
• Long slender blade design with a pre-bent
• Improved Lift to Drag ratio & lighter weight
• Use of Carbon Girder & High Tensile Glass
• Performance enhanced with vortex generators
• Superior leading edge protection coating for longer maintenance cycles and less wear & tear
Thick Airfoils towards the root for high structural strength
Thin Airfoils along the tip for high lift/drag ratio
SB63 Rotor Blades: Key Features
Designed and manufactured by Suzlon using latest profiles and materials
Suzlon Energy Ltd.
21 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
First key components for India version are already built
Type certificate targeted for beginning 2018
S128 2.6MW in manufacturing
Hub pattern
Casted main shaft
Blade main mould
converter
Suzlon Energy Ltd.
22 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Benefits of design advances
129m carbon girder rotor Higher AEP : 15109 MWh/a
Full power converter Global grid compatibility and FRT capabilities
Integrated Medium Speed drive train Reduced life cycle cost (low OMS cost)
4-point rotor suspension Higher availability (no bending on GB)
Towers hub heights up to 140m more site viable
SC Trinity SCADA and Visualization Higher availability (more effective OMS)
Low rotor RPM Standard Sound power level below 105dB(A)
Suzlon Energy Ltd.
23 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
Suzlon wind farm in Paracuru, Brazil
Thank you
Suzlon Energy Ltd.
24 S128 – Mexico WindPower 2017
© 2017 by Suzlon Energy Limited. All rights reserv ed
The information contained in this presentation is the property of Suzlon Energy GmbH and Suzlon Energy Limited India. This presentation and extracts thereof may only be duplicated or forwarded to third parties following explicit written approval by Suzlon Energy GmbH and Suzlon Energy Limited India. All product names used in this documentation are trademarks or otherwise protected by law, even if not specifically indicated. © 2017 by Suzlon Energy Limited All rights reserved.