Company confidential © DB Gear Systems Limited 1 David Brown Wind Energy Servicing the Supply Chain for Offshore Environment Alfonso Garcia Business Development Manager – Renewable Energy [email protected] 28 th February 2012
Company confidential © DB Gear Systems Limited 1
David Brown Wind Energy
Servicing the Supply Chain for
Offshore Environment
Alfonso Garcia
Business Development Manager – Renewable Energy
28th February 2012
Company confidential © DB Gear Systems Limited 2
150 Years of Assurance Critical Solutions
‘To provide customised transmission solutions for
applications where customers demand absolute assurance’
Company confidential © DB Gear Systems Limited 4
UK• Land defence transmissions
• Naval applications
• Renewables – wind, tidal
• High speed drives – oil & gas
• Custom designed ‘low speed,
high torque’ drives
• Rail
Eastern Europe• Sales office
USA• Precision ‘double
enveloping’ worm drive
• Renewables - solar, wind
• Packaging/food & beverage
• Machine tools, medical and
high precision applications
• Mining, steel & energy
Brazil• Sales office
France• Renewables – wind, hydro
• Rubber & tyre industries
• Cement, metals & mining
• Overhaul & upgrade
South Africa• Girth gear and mill drives
• Mining
• Power generation (coal)
• Overhaul & upgrade programmes
• Heavy duty conveying systems
India• Business & design centre
• JV with Bharat Forge
Indonesia• Sales Office
Australia• Overland conveyor &
Port handling
systems
• Mining
• Renewables – wind
• Power generation
(coal)
• Sugar processing
• Service contracting
• Rail
China JV• Rail
• Renewables - wind
Dubai• Oil & gas, power, metals,
cement, port handling
• Spares manufacture
• Service, repair and
upgrade
Chile• Mining
• Service ,repair and
upgrade
A Worldwide Capability
Company confidential © DB Gear Systems Limited 5
David Brown Gear Systems Product Groups
Products & Services
Land & NavalDefence
IndustrialAftermarket
IndustrialEngineered
Product
RenewableEnergy
Solar
Mill Drives & Girth Gears
High Speed & Rail
Low Speed, High Torque
Specialist Spares
High Integrity Repair & Overhaul
Site Services
Tracked/wheeled transmission New
Build
Tracked transmission
upgrade programmes
High Integrity Naval Drives
Tidal
Wind
Company confidential © DB Gear Systems Limited 6
Since 2009…
• Aftermarket Services – Globally
European repair contract with Vestas
25% UK market share in gearbox services
UK Wind Service & Upgrade Research Facility announced
Wind Service operating on 5 continents
• New Build Onshore – Joint Venture, China
1.5MW gearbox in production, 3MW in development
State-of-the-art manufacturing facility with 550 staff
• New Build Offshore
Selected as gearbox partner for 2 Wind Turbine OEM
Programmes for UK Round 3
Product development 7-10MW
Wind Energy – Activities & Progress
Company confidential © DB Gear Systems Limited 7
Wind Research & Development
• Existing technology – Total Life Cost
• Condition Monitoring
• Wave Energy
Feasibility analysis for geared solutions.
• Gearbox Bearing Technology
• Permanent Magnet / Hybrid Technology
Company confidential © DB Gear Systems Limited 8
• New paradigm - Offshore wind is a different challenge to onshore
– New entrants can take a leading role
• Offshore wind demands new & innovative thinking
– Environment is harsh – safety considerations are paramount
– Development costs are very high – a different model for investment is required
– Operators need to know that their turbines are reliable - exacting testing standards are required
– Deployment is challenging – standardisation & simplified logistics required
– Reactive offshore maintenance is expensive & prohibitive
– Planned interventions require predictive technology
Offshore Wind – A New Challenge
Company confidential © DB Gear Systems Limited 9 9
Existing GBX performance
• Most of the problems with the current fleet of wind turbine gearboxes
are generic in nature, meaning that the problems are not specific to
a single gear manufacturer or turbine model. Over the years, most
wind turbine gearbox designs have converged to a similar
architecture with only a few exceptions. (*)
• The majority of wind turbine gearbox failures appear to initiate in the
bearings. (*)
• Problems that manifested themselves in the earlier 500kW to
1000kW, still exist in many of the larger 1 to 2 MW gearboxes being
built today with the same architecture. (*)
• Many of the gearbox problems are the direct result of institutional
barriers that hinder communication and feedback during the design,
operation, and maintenance of turbines. Hence, a collaborative is
needed to bring together the various portions of the design process,
and to share information needed to address the problems.
(*) Musial W., and Butterfield S. “Improving Wind Turbine Gearbox Reliability “. National Renewable Energy Laboratory , 2007
Imperative for change
Company confidential © DB Gear Systems Limited 10 10
Existing offerings in the market
• Normally, GBXs are manufactured in different facilities and locations.Then, they are sent Nacelle assembly plant.
• Existing fix warranty periods for WTG components (normally 2 years).
• Maintenance is currently done by WTG manufacturers. Wind Turbinetechnicians basically perform simple visual inspections every sixmonths. Lack of GBXs specialists on site.
• There are sporadic GBX assistances on site, performed by GBXmanufacturers, when it is specifically required by WTG manufacturersor wind farm owners.
• When a GBX is damaged, it must be replaced completely in most of thetimes.
• Condition Monitoring Systems are rarely installed and, in those caseswhere it is, there is not a proper data analysis performed by operatorsat the remote control centre. Lack of knowledge.
• GBX manufactures are reluctant to share data about performance andfailure analysis.
• Reactive response way of working with WTG OEMs and final users.
Imperative for change
Company confidential © DB Gear Systems Limited 11 11
David Brown approach to Offshore
‘Assured’ UK Gearbox Design & Supply Chain Partner to
OEM’s looking to UK Round 3 development:
• UK presence & established supply chain. David
Brown is the only British company with the know-how &
immediate capability to engineer, source, handle,
manufacture & assemble the large components and
functionally test very large MW gear units.
• Product Innovation. Modular design for reliability and in
nacelle maintenance. Gearbox flexible designs for 6 to
10MW wind turbine generators. Scope includes design,
verification, manufacture and testing
• Rapid Prototyping capability. Already prepared to meet
2012/13 Demonstrator sites.
• High degree of engineering capability. DB has a long
history in delivering mission critical solutions where the
consequences of failure are extremely high; defence,
marine, airspace and offshore oil & gas.
• Willing to invest in the necessary facilities/assets.
Company confidential © DB Gear Systems Limited 12
Technical differentiation for assurance
Planet gear &
flexpin assembly
1st stage carrier & fixed
pin assembly
Individual planet gears
& flexpin assemblies
MANTAINABILITY DIFERENTATION
Example of Wind Gearbox that can be completely disassembled from downwind end
2nd stage carrier & fixed
pin assembly
Discrete,
integrated rotor
bearings1st stage
annulus
2nd stage
annulus
2nd stage
sun pinion
shaft
1st stage sun
pinion shaft
All removable
components
<10T
Company confidential © DB Gear Systems Limited 13
• In December 2011, the 1MW Hammerfest Strøm
HS1000 tidal turbine (1 MW) was successfully
deployed in the North Sea, signaling a major step
forward for the global marine renewable energy
industry.
• The HS1000 tidal turbine is fitted with a three
stage David Brown gearbox which was designed,
manufactured and tested at our Huddersfield
facility and delivered in April last year.
• Following successful load testing, the turbine was
installed at the European Marine Energy Centre
(EMEC) in Orkney. The HS1000 device will now
enter a test period to confirm its performance and
reliability, in preparation for larger scale production
and deployment.
Tidal Energy
Company confidential © DB Gear Systems Limited 14
David Brown Summary
• David Brown is rapidly establishing itself as a trusted Supply Partner
in Renewable Energy
• R&D programmes give significant innovation in products and services
• Collaborative approach ensures OEMs get a gearbox specifically
designed for multi MW wind turbine applications with lowest cost of
energy
– Reduced transmission weight and length from structurally efficient
architecture
– High reliability from reduced component count
– Innovative design for up-tower maintenance
• Global supply chain in place for multi MW gearbox components
• Facilities in the UK and China and supply chain investments make it an
ideal partner for supplying the Northern European and Asian Markets
– Wind
– Tidal
– Any other technical solution (Waves)