Ministry of Electricity & Energy (MEE) New & Renewable Energy Authority (NREA)

Welcome
To ZAFARANA Wind Farm
Eng. Ibrahim Abdou Chief Engineer of Operation Dep. Ibrabdo_eg@yahoo.com za.ibrahim@nreaeg.com Mobil: 002 01062725923 Web Site: www.nrea.gov.eg

Ministry of Electricity & Energy (MEE) New & Renewable Energy Authority (NREA)

Contents :
1- Why Zafarana? 2- Zafarana On-land & Future Projects.

3- Availability and capacity factor in Zafarana.

4- Routine and Predictive Maintenance. 5- Dust Contamination and Blades cleaning.

6- Projects in near future.

7- Other plan for Zafarana.

Egypt enjoys excellent wind regimes, particularly in the Suez Gulf where the average wind speed reaches 10.5 m/sec.

The wind energy resource is available in large regions on the Nile banks in the Eastern and Western Deserts and parts of Sinai.

Resource Assessment
Egypt Wind Map, 1987 Wind Atlas of Gulf of Suez, 1991 - 2001 Wind Atlas of Egypt, 2005

In cooperation with USAID

In cooperation with Risoe (Denmark) & EMA

In cooperation with Risoe (Denmark) & EMA

In 2003, a detailed Wind Atlas of Suez Gulf area which includes accurate wind data over period from 1991 2001 for ( 10 ) sites was finalized by cooperation with RIS
Region
Ras Sedr Abu Aldarag

Av. Wind Speed (m/s)

7.5 8.8

Zafarana (North) Zafarana Zafarana (west)

St. Paul Ras Ghareb El Tour El Zeit Gulf (Average) Hurghada

9.5 9.0 7.5

8.4 10.0 5.6 10.5 6.7

ZAFARANA
Zafarana site location
In the south east of Cairo by 190 km

Zafarana site features:* Average wind speed ( 9.5 ) m/s * Flat area * Low turbulence * High capacity factor

Wind Rose
NREA

Zafarana wind rose

Site layout for Zafarana wind farms

Unused Area

Spain 85 MW Japan 120 MW

80 MW

German 47 MW

Substation NREA

33 MW Danish 30 MW 120 MW 30 MW

Zafarana Wind Farm 8 Projects

On Land Running and in Operation.

On Land Running and in Operation Projects

Zafarana-1 (DANIDA1) 30 MW
50 Nordex N43 Turbines.

600 KW each.
In cooperation with DANIDA.

Was handed over on Apr. 2001

Zafarana-2 (KFW1)
55 Nordex N43 Turbines. 600 KW each.

33 MW

In cooperation with KFW .

Was handed over on May. 2001

On Land Running and in Operation Projects

Zafarana-3 (DANIDA2) 30 MW
46 Vestas V47 Turbines

660 KW each
In cooperation with DANIDA

Was handed over on Nov. 2003

Zafarana-4 (KFW2,3)
71 Vestas Turbines V47

47 MW

660 KW each
In cooperation with KFW .

Was handed over on June 2004

On Land Running and in Operation Projects

Zafarana5 (SPAIN)

85 MW

100 Gamesa G52 Turbines

850 KW each In cooperation with Spain

Was handing over on Sep. 2006

On Land Running and in Operation Projects

Zafarana6 (KFW4) 80 MW
94 Gamesa G52 Turbines

850 KW each In cooperation with KFW. Was handed over

on Mar. 2008

On Land Running and in Operation Projects

Zafarana7 (Japan) 120 MW

142 Gamesa G52 Turbines

850 KW each In cooperation with JBIC

Started in Sep 2008

Under construction Projects

Zafarana8 (DANIDA4) 120 MW

142 Gamesa G52 Turbines

850 KW each In cooperation with DANIDA
Started in Feb 2010

The last project in Zafarana

Next Will be in el Zeit Gulff

Zafarana Wind Farm Last Finance year 2009-2010

Total Number of Turbines : 700 WTG

Total Instaled Capacity

Total Produced Energy

: 545 MW :1152450 MWh : 32.7 %

: 97.6 % : 8.2 m/s

Capacity Factor
Performance Availability Average Measured W.S

FUEL SAVED CO2 EMMISION

: 252357 TON : 633848 TON

High Availability in Zafarana

Zafarana Wind Farm achieved high Availability and Performance factors for the following reasons :1- High qualified Operation and maintenance staff. 2- High advanced Predictive maintenance: (Vibration, Balance, Alignment and Oil analysis) 3- Local repair for main components (generator, gearbox). 4- Spare parts stock.

ZAFARANA Wind Farm Development

ZAFARANA Wind Farm Development

ZAFARANA WIND FARM DATE 2009-2010

ZAFARANA MONTHLY PRODUCTION VS WIND SPEED
160000

10.0

8.7
140000

8.4 7.8

8.3 8.5 7.7 8.2

9.0

138501
120000

127347 123412 111151 114859

6.4 6.8 5.5

130840 115866

8.0

7.0

100000

6.0

Prod (MWh)

5.6
80000

87145 79101

5.4
5.0

4.0
60000

40000

48920

51200

52260

3.0

2.0

20000

1.0

0.0

Jun-09

Jul-09

Aug-09

Sep-09

Oct-09 Nov-09 Production

Dec-09 Jan-10 Wind Speed

Feb-10

Mar-10

Apr-10

May-10

W.S (m/s)

ZAFARANA WIND FARM DATE 2009-2010

ZAFARANA MONTHLY WIND SPEED
10. 0

9. 0

8. 0

8.7 8.4 8.3 7.7 6.8 5.6 5.5 8.2 7.8

8.5

7. 0

WIND SPEED (m/s)

6. 0

6.4
5. 0

5.4

4. 0

3. 0

2. 0

1. 0

0. 0

Jun-09

Jul-09

Aug-09

Sep-09

Oct-09

Nov-09

Dec-09

Jan-10

Feb-10

Mar-10

Apr-10

May-10

ZAFARANA WIND FARM DATE 2009-2010

ZAFARANA MONTHLY CAPACITY FACTOR
50. 0%

45. 0%

44.2% 36.2%

42.1% 38.5% 37.1% 28.8% 37.8% 36.0%

CAPACITY FACTOR C.F%

40. 0%

35. 0%

30. 0%

27.0% 19.6%

25. 0%

20. 0%

16.1%

16.7%

15. 0%

10. 0%

5. 0%

0. 0%

Jun-09

Jul-09

Aug-09

Sep-09

Oct-09

Nov-09

Dec-09

Jan-10

Feb-10

Mar-10

Apr-10

May-10

ZAFARANA WIND FARM Avilability% 2009-2010

100.0%

96.4% 95.3%

96.5%

96.0% 95.2% 94.7%

94.7%

96.4%

96.1%
95.2%

96.0%

95.0%

94.6%

90.0%

Availability%

85.0%

80.0%

75.0%
Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10

Nacelle
Blade Low speed shaft Wind van Wind anemometer

Yaw system

Nacelle housing Gearbox Disc brake Generator Hydraulic system

1- Manual Control. 2- Automatic Control.

3- Operation Status. 4- Data Collecting , Calculating, Analyzing, & storing.

5- Data & Error log.

6- Grid behavior sensors . 7- Remote Control (SCADA System Monitoring, Data managements, WTG Controlling).

Group A
Auto start

Group B
Remote Start

Group C
Manual Start

Control and monitoring system

Collecting data from the turbines to CMS through fiber optic cables

Control system for turbine

Control unit for turbine with many microprocessors

Build-up of WP3000 Controller

WP3000 Controller

Build-up of WP3000 Controller

WP3002 digital Input / Output board

Relays Power supply 24VAC Power supply 24DC (inputs) Bus cable for power supply WP3001 and digital I/O Opto couplers Ditgital Inputs surge protection Internal power conversion Connection for WP3053 display

Build-up of WP3000 Controller

WP3001 Mother Board with CPU
Power supply 24VDC analogue I/Os

Pressure input
Temp. input

Display interface Park com. interf. PC connection DSP (grid) Slave Master Grid measurem. Analogue output Counter input Internal battery

Build-up of WP3000 Controller

WP3001 Mother Board

Control and monitoring system

Operation the turbine from control room

Preventive Maintenance Corrective Maintenance Predictive Maintenance

Visual Maintenance
Mechanical Maintenance Electrical Maintenance

Electronic Maintenance

NORDEX MAINTENANCE TYPES

TYPE 2 AFTER FIREST 6 MONTHES AND, THEN ANNUALLY LUBRICATION INSPECTION CLEANING

TYPE 3 AFTER FIREST 12 MONTHES AND, THEN ANNUALLY LUBRICATION INSPECTION CLEANING RETORQUE

TYPE 4 0NCE EVERY FIVE YEARS LUBRICATION INSPECTION CLEANING RETORQUE REPLACING

VESTAS MAINTENANCE TYPES

TYPE 1 AFTER FIREST 3 MONTHES LUBRICATION INSPECTION CLEANING RETORQUE

TYPE 2 AFTER FIREST 6 MONTHES AND, THEN ANNUALLY LUBRICATION INSPECTION CLEANING

TYPE 3 0NCE EVERY YEAR LUBRICATION INSPECTION CLEANING MEASURMENTS RETORQUE

Turbine connection with Transformer In the middle of the line

To Next Turbine

690 V side

22 kV side

Ground cabinet

Transform er Under ground cable From prev.

Power Cables distributions for Z1

1 10 11 18 19 25

26

32 33

41 42

50

S.V.D
Feede Feede r1 r2 Feede r3 To Zafarana Substation

Power Management & Grid Connection.

Generation Voltage is 690 VAC. The voltage is stepped up to 22KV by local transformer

in each Turbine.
Power Factor and Grid frequency are kept synchronized with the grid by each unit.

Lines are connected to Zafarana Substation by under ground Power cables. The voltage is stepped up to 220KV in the substation which is by sequence linked through El-Sukhna Substation by overhead lines.

Zafarana Substation

Egyptian Electricity Transmission Company

Substation Capacity :- ( 7 Transformers ) 775 MVA Devided to 2 beldings

Old Zafarana S/S Capacity (5 Transformers) 525 MVA
Transformer 1 :- 75MVA ( J6,J7,J8,J9,J10) Transformer 2 :- 75MVA ( J25,J26,J27,J28,J29,J30)

Transformer 3 :- 125MVA ( J14,J15,J42,J51,J52,J36,J36,J38,J40) Transformer 4 :- 125MVA ( J55,J57,J61,J65,J69,J70, J71) Transformer 5:- 125MVA (J75,J76,J78,J84,J85,J88,J89)

New Zafarana S/S Capacity (2 Transformers) 150 MVA

Transformer 3 :- 125MVA ( J16,J21,J30,J31,J37)
Transformer 4 :- 125MVA ( J9,J10,J11,J40,J41,J42)

Zafarana Old Substation Layout

To sukhna 1 2
Voltage 220/22 K.V. 2*75 MVA + 3*125MVA

To Ghareb

Trefo (5) 125 MVA

Trefo (5) 125 MVA

Trefo (1) 75 MVA

Trefo (1) 75 MVA

Trefo (5) 125 MVA

From Zafarana Wind Farm

Cleaning DUST & CONTAMINATION

** Prototype Washing Machine.

** Lifted by Crane. ** Remote controlled From Ground. ** Washing Auto

Not used Tell now ( Under test )

* Traditional way ( Platform ) * Hanged by two steel wires * Controlled by Electric Hand switch * Washing Manual by Two persons inside
Used & Effective

Future Projects
Will be in

El-zeit Gulf

Future works and expansions

NREA

Future Contracts

1- Maintenance Management System. 2- NEW SCADA Control system.

National Strategy up to 2020

In February 2008, the Supreme Council of Energy approved an ambitious plan to: Satisfy 20% of the generated electricity by renewable energies by 2020, including 12% from wind energy, i.e., reaching more than 7200 MW grid-connected wind farms.

Possible tracks

Governmental projects

65%

35%

Private investments

SEE YOU
Next time in

El-zeit Gulf