How Do Vestas Manufacture Nacelles - PE Rev3

1

How do Vestas manufacture Nacelles

2

V52

V52 – 850 kW – Pitch/Optispeed – 14.00 to 31.40rpm

Weight

Nacelle: ≈22 ton

Rotor: ≈ 10 ton

Sum: ≈ 32 ton

Nacelle factories:

Italy: Taranto V52

Hub factories:

Italy: Taranto V52

_ = Primary factory: Prototype, Working instruction

3

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)

Weight

Nacelle: ≈52 ton

Rotor: ≈ 43 ton

Sum: ≈ 95 ton

Nacelle factories:

Spain: Viveiro V82

India: Chennai V82

Hub factories:

Denmark: Skagen V82

India: Chennai V82


4

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:

Denmark: Ringkøbing V80 2MW

China (2007): Tianjin V80 2MW


5

V90

V90 – 3 MW – Pitch/Optispeed – 8.6 to 18.4 rpm

Weight

Nacelle: ≈70 ton

Rotor: ≈ 41 ton

Sum: ≈ 111 ton

Nacelle factories:

Denmark: Ringkøbing V90 3MW,

Hub factories:

Denmark: Ringkøbing V90 3MW,


6

Nacelles Value Chain

Foundries Machining

Generators

Vestas Nacelles Value Chain

Assembly and test

7

Vestas Nacelles production facilities

Denmark, Norway, Sweden, Germany, Italy, Spain, India and China

8

Vestas Castings

Vestas Castings:Magdeburg, components up to 11 tonKristianssand, components up to 20 tonsGuldsmedshyttan components up to 40 ton

9

Vestas Machining - Lem

•Ca. 20,100 m2

10

Vestas Generator - Lübeck

11

Pictures from Ringkøbing

12

Pictures from LeonViveiro

V82

LeònV90 2MW

13

Pictures from Viveiro

14

Pictures from Taranto

15

Pictures from Chennai

16

Pictures from Tianjin

BeijingTianjin

Shanghai

GuangzhouShenzhen

TEDA WEST

17

Pictures from Tianjin

Land approx. 50.000 sqm

Buildings approx. 13.000 sqm.

18

Pictures from Viborg (1)

19

Factory Viborg

Operation 0100Main foundation Yaw beamYaw gear

Operation 0200Crane column

Operation 0300GearMain shaft/bearingHydraulic station

Operation 0700Assembling of main foundation and rearCrane finish Cables

Operation 0800Final test

Operation 0900Glass fiber cabinReady for shipment

Operation 0400Rear sectionGenerator

Operation 0500Control cabinetTransformer

Operation 0600CablesGenerator finish

Front

Rear

LEAN-Production in Viborg (15-18 turbines/week):

6 step (2x3 parallel + 3) 1 step takes 6 hours. Target is 4 hours

20


21


22


23


24


25


26


27


28


29


30


31


32


33


34

Pictures from Skagen (1)

35


36


37

Responsibility

38

Drawing system

Drawing system: Pro/EArchives system: Intralink

• 3D Assembly drawing

• 3D Part drawing

39

Drawing system

• Assembly drawing

• Production drawings

40

Structure

Level 1 (Nacelle)

Level 2 (Main module)

Level 3 (Sub module)

Level 4-x (Assembly)

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

V80 - 76 Variants:V80/V90, 50 Hz/60Hz, Ral 7035/9010, VCS/VRCC etc.

41

Certificate

A turbine can’t be erected without a certificate.Certificates can be issued by GL, DNV and TÜV 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 testValidation of the calculations.Turbine management.Performance.Noise.Grid compatibility.

42

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/sAnnual average for 80 m V = 10 m/sTurbulence 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

43

Transport Loads

-Transport

44

Certificate – Main parts

Component Approval Issue

Hub Loads: Flex 5Strength: FEM

Fatigue and static strengthDeformations by the bearings.

Machine frame Loads: Flex 5Strength: FEM

Fatigue and static strength

Rear section Loads: Flex5 + AnalyticStrength: Analytic + FEM

Fatigue and static strengthWelded component

Drive train Loads: Flex5 + AnalyticStrength: FEM

Fatigue and static strengthWelded component

Crane with traverse

Loads: AnalyticStrength: Analytic + FEM

Static strengthWelded component

45

Certificate – Main parts

46

Certifikate – Small parts

Component Approval Issue

Bearings Loads: Flex 5Strength: Approved by supplier


Main bearing housing

Loads: Flex 5Strength: FEM


Rotor lock Loads: Flex 5Strength: Approved by supplier

Static strength

Coupling and breake

Loads: Flex 5Strength: FEM / Supplier


Gear box torque arms

Loads: Flex 5Strength: FEM / Supplier


47

The rest

• ≈ 1000 drawings of different parts for one Turbine

For example:

Tread platesGlass fiber cabinet/nose cone supportSupport for hydraulic and electrical partsCoolersLaddersAnemometerCover platesHatchesEtc.

48

Standards - Why?

The components shall be produced global without problems.Knowledge to standards and GPS (Geometrical product specification) is therefore important

Chinese supplier

49

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

50

Design - PE

Drawing head - assembling:

Bulk items in the BOM: Georoil etc:

Accessories not separate in the BOM: Cable Stripper, lock oil etc

51

Design - PE

Verdana 12 pt, font colour white

Drawing head - part:

52

Design - PE


Make it cheaper –

The redesign displayed below gives savings of 10.000 DKK/week in Viborg

53

Design - PE

Improve assembling.

54

Design - PE

Improve drawings - GPS

55

Design - PE

Improve drawings – GPS – 3D measuring (Tolerance 0,003)

56

Design - PE

Improve drawings – GPS Lasertracker

57

Design - PE


See failures before they occur

Fatigue crack

58

Remember: Fatigue


59

Remember: Fatigue

60

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.

61

NCR - PE

62

Surface treatment


Inside Nacelle: C3Hot dip galvanizing acc. ISO 1461:1999 minimum local thickness 45 µm Thermal spraying acc. ISO 2063:2005 (ISO 14919:2001 ZnAl15) 70 µm Thermal spraying acc. ISO 2063:2005 (ISO 14929:2001 ZnAl 15) 50 + S3.17

Indvendig Inside Hub: C4Hot dip galvanizing acc. ISO 1461:1999 minimum local thickness 85 µm Thermal spraying acc. ISO 2063:2005 (ISO 14919:2001 ZnAl15) 110 µm Thermal spraying acc. ISO 2063:2005 (ISO 14929:2001 ZnAl 15) 100 + S4.20

Outside Nacelle: C5MHot dip galvanizing acc. ISO 1461:1999 minimum local thickness 170 µm Thermal spraying acc. ISO 2063:2005 (ISO 14929:2001 ZnAl 15) 100 + S7.02

63

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 theQuality of the product, Environment, SafetyAssuranceLegislation prescribes calculations, safety evaluations, production documentation

B-item are items (including catalogue items), that defects only marginally affect the Product quality, EnvironmentSafety 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 affectsEnvironmentProduction qualityDefects and lacks will bee corrected before use.

64

Material - Welding - Cast

Quality requirements - WeldingDepending 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 turbineThe 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 MPaStrength of aluminium may be reduced with max. 20%Strength of other materials may be reduced with max. 10%

65

Temperature

Production stop:Alarm 19: Ambient temperature too low : -30 °CAlarm 83: Gear oil temperature too low : -10 °CAlarm 94: Nacelle temperature too low : -15 °C

66

Tower

67

Local content percentage distribution

on componentsName of component NDRC

[%]Possible NDRC [%]

Tower 16.9 9.0

Electrics in Wind Farm 7.2

Nacelle cover 4.4 4,0

Generator 7.4 8.0

Blade 22.5 19.0

Gearbox 15.4 15.0

Main shaft, (incl. Bearings, coupling) 3.4 4.0

Hub (incl. Pitch regulated system) 4.2 7.0

Yaw system 1.3 5.0

Central control and monitoring system 3.5 3.0

Electrical control sys. (SCADA) incl. inverter 3.5 16.0

Hydraulic system 2.2 2.0

General assembly 3.0 3.0

Spareparts 1.0 5.0

Others 4.1

SUM 100.0 100.0

How Do Vestas Manufacture Nacelles - PE Rev3

Documents