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V52
V52 850 kW Pitch/Optispeed 14.00 to 31.40rpm
Rotor: 10 ton
Sum: 32 ton
Nacelle factories: Italy: Taranto V52 Hub factories: Italy: Taranto V52 _ = Primary factory: Prototype, Working instruction
V82
V82 1,65 MW Active-Stall 14.4 rpm (1 speed generator)
V82 1,65 MW(900kW) Active-Stall 14.4/10.8 rpm (2 speed generator)
Nacelle factories:
Spain: Viveiro V82 India: Chennai V82 Hub factories: Denmark: Skagen V82
V80-V90
V80 2 MW Pitch/Optispeed 9 to 19 rpm
V90 1,8-2 MW Pitch/Optispeed 9 to 14.9 rpm V80 1,8 MW Pitch/Optislip 15.5 to 16.8 rpm
Weight
Nacelle: 67 ton Rotor: 37 ton Sum: 104 ton
Nacelle factories:
Denmark: Viborg V80 2MW Spain: Leon V80 2MW China (2007): Tianjin V80 2MW Hub factories:
V90
V90 3 MW Pitch/Optispeed 8.6 to 18.4 rpm
Rotor: 41 ton
Sum: 111 ton
Nacelle factories: Denmark: Ringkbing V90 3MW, Hub factories: Denmark: Ringkbing V90 3MW, _ = Primary factory: Prototype, Working instruction
Vestas Castings
Vestas Castings: Magdeburg, components up to 11 ton Kristianssand, components up to 20 tons Guldsmedshyttan components up to 40 ton
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Beijing Tianjin
TEDA WEST
Shanghai
Shenzhen
Guangzhou
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Factory Viborg
LEAN-Production in Viborg (15-18 turbines/week): 6 step (2x3 parallel + 3) 1 step takes 6 hours. Target is 4 hours
Front
Rear
Operation 0700 Assembling of main foundation and rear Crane finish Cables
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Responsibility
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Drawing system
Drawing system: Pro/E Archives system: Intralink 3D Assembly drawing
3D Part drawing
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Drawing system
Assembly drawing
Production drawings
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Structure
V80 - 76 Variants: V80/V90, 50 Hz/60Hz, Ral 7035/9010, VCS/VRCC etc.
Level 1 (Nacelle) Level 2 (Main module) Main foundation mod Rear foundation mod Generator mounted Generator module Slip-ring module Yaw module Nacelle cover module Mainshaft-gear mod. Mainshaft module Gearbox brake offl.filt. Rotating transfer mod. Torquearm module Torquearm left Torquearm right
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Certificate
A turbine cant be erected without a certificate. Certificates can be issued by GL, DNV and TV based on documentation from Vestas. Guidelines and standards: IEC 61400, DS 472, NVN 11400, GL, DIBt etc. Three elements in the certificate: - Design assessment. Verification of the design and engineering documents. Turbine management and safety. Load calculation. Strength calculation. - Quality management ISO 9001 covers the majority of the requirements . - Prototype test Validation of the calculations. Turbine management. Performance. Noise. Grid compatibility.
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Operational Loads
Wind Loads etc. (Flex5) Gravity (9,82 N/kg) Horizontal acceleration - Extreme: 5 N/kg Fatigue: 1 N/kg (m=5, n=10^7)
Loads based on GL category 1A Extreme wind speed for 80 m V = 70 m/s Annual average for 80 m V = 10 m/s Turbulence intensity for category A1 = 18 % (3. december 1999 51,4 m/s) (Katrina Hurricane 2005 77,8 m/s) Extreme moment at blade flange V80: 6000kNm = 1000kg at 600m
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Transport Loads
-Transport
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Hub
Machine frame
Rear section
Fatigue and static strength Welded component Fatigue and static strength Welded component Static strength Welded component
Drive train
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Bearings
Loads: Flex 5 Strength: Approved by supplier Loads: Flex 5 Strength: FEM Loads: Flex 5 Strength: Approved by supplier Loads: Flex 5 Strength: FEM / Supplier Loads: Flex 5 Strength: FEM / Supplier
Static strength
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The rest
1000 drawings of different parts for one Turbine
For example: Tread plates Glass fiber cabinet/nose cone support Support for hydraulic and electrical parts Coolers Ladders Anemometer Cover plates Hatches Etc.
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Standards - Why?
The components shall be produced global without problems. Knowledge to standards and GPS (Geometrical product specification) is therefore important
Chinese supplier
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Design - PE
Add standards:
Not add better requirements than necessary! Not all requirements are mentioned on the drawings. Remember to check the bill of material in INFOR
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Design - PE
Drawing head - assembling:
Bulk items in the BOM: Georoil etc: Accessories not separate in the BOM: Cable Stripper, lock oil etc
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Design - PE
Drawing head - part:
Design - PE
Make it cheaper The redesign displayed below gives savings of 10.000 DKK/week in Viborg
Design - PE
Improve assembling.
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Design - PE
Improve drawings - GPS
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Design - PE
Improve drawings GPS 3D measuring (Tolerance 0,003)
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Design - PE
Improve drawings GPS Lasertracker
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Design - PE
See failures before they occur
Fatigue crack
Remember: Fatigue
Remember: Fatigue
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NCR - PE
BP 04.03.00. This procedure is valid for the handling of non-conformity items/products detected during Vestas' manufacturing, storage, transport, installation and commission activities until the after sales system/procedures takes over.
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NCR - PE
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Surface treatment
Inside Nacelle: C3 Hot dip galvanizing acc. ISO 1461:1999 minimum local thickness 45 m Thermal spraying acc. ISO 2063:2005 (ISO 14919:2001 ZnAl15) 70 m Thermal spraying acc. ISO 2063:2005 (ISO 14929:2001 ZnAl 15) 50 + S3.17
Indvendig Inside Hub: C4 Hot dip galvanizing acc. ISO 1461:1999 minimum local thickness 85 m Thermal spraying acc. ISO 2063:2005 (ISO 14919:2001 ZnAl15) 110 m Thermal spraying acc. ISO 2063:2005 (ISO 14929:2001 ZnAl 15) 100 + S4.20
Outside Nacelle: C5M Hot dip galvanizing acc. ISO 1461:1999 minimum local thickness 170 m Thermal spraying acc. ISO 2063:2005 (ISO 14929:2001 ZnAl 15) 100 + S7.02
Documentation
Documentation demand, see BP 08.16.00 Work instruction, Purchase specification, Quality Specification, Control instruction, Inspection scheme, Supplier approval A-item are items where defects affect the Quality of the product, Environment, Safety Assurance Legislation prescribes calculations, safety evaluations, production documentation B-item are items (including catalogue items), that defects only marginally affect the Product quality, Environment Safety The defect will be detected in the prescribed inspections Only capable of affecting processes and reliability of supply briefly. Items not classified as A-item, which are designed by Vestas and must be purchased, are classified as B-items. U-item are items where defect not affects Environment Production quality Defects and lacks will bee corrected before use.
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Quality requirements - Welding Depending on consequence and use (Loads etc). See nacelle notes guideline
QS 993667 (Elementary quality requirements) QS 993665 (Comprehensive quality requirements)
If there is a reference to TPS 901529 or TPS 901530 it is allowed to manufacture the item in an substitute material for example Chinese standardized steel. TPS 901528: Casting quality requirements TPS 901529: Parts - Certified components (Approved by DNV, GL etc.) / Component which are important for the safety of the turbine The substitute material has at least the same strength as the specified material. TPS 901530: Parts - Non certified components / Non-important components. The substitute material may be weaker than the specified strength of the parent material: Strength of steel S355 (EN 10025) may be reduced with max. 10% Strength of steel S235 (EN 10025) may be reduced with max. 5% Strength of stain less steel is min. 150 MPa Strength of aluminium may be reduced with max. 20% Strength of other materials may be reduced with max. 10%
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Temperature
Production stop: Alarm 19: Ambient temperature too low Alarm 83: Gear oil temperature too low Alarm 94: Nacelle temperature too low
Tower
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Tower Electrics in Wind Farm Nacelle cover Generator Blade Gearbox Main shaft, (incl. Bearings, coupling) Hub (incl. Pitch regulated system) Yaw system Central control and monitoring system Electrical control sys. (SCADA) incl. inverter Hydraulic system General assembly Spareparts Others
SUM
100.0
100.0
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