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Michael Kennedy
Lead Electrical Engineer
Vestas Americas
Wind Turbine Design Requirements and
Control Considerations
A brief look at the modern wind turbines for power generation.
vestas.com
The major parts of a turbine
• Tower
• Nacelle (the box at the top)
• Blades
• The Central Plains project site consists
of 33 V90-3.0MW wind turbines in
Kansas, USA.
• Wind farms are often located in remote
locations and one important factor is the
proximity a power transmission system
for the turbines to connect to.
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The scale of power generation turbines
• Rough dimensions
• Tower height ~ 67 - 115m (in about 4 or 5
sections)
• Tower Maximum diameter ~4.2m
• Nacelle ~ 50 – 70 tons
• Blades ~40m long (one piece)
• Constraints
• Shipping the turbines to site. Ships, Roads.
Rail.
• The grid connection.
• Available transmission lines.
• Fault levels
• System stability.
• Wind speed
•
•
•
•
Cut – in ~ 4m/s (9mph)
Peak Power ~ 15m/s
Cut – out ~ 25m/s
Withstand speed 155MPH (Flat out in a fast
Mercedes!)
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What the
Vestas model
name means.
• V90 has a 90 meter
diameter blade swept
area.
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The Nacelle
V90-3.0 MW
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Circuit configurations
• Simple Induction Turbine (V82 – 1.65MW)
{Type A}
• Advantage: Simple and robust
• Disavantage: Not all new grid
requirements can be met.
• Rotor Controlled Turbine (V80/90 – 2.0MW)
{Type B}
• Advantage: More control for better
energy harvest.
• Disavantage: More complex than Simple
Induction Generator
• Double Fed Induction Generator (V90 – 3MW)
{Type C}
• Advantages: Yet more control for better
performance
• Disavantage: More expensive.
• Full Converter – Permanent Magnet Generator
(V112 – 3MW) {Type D}
• Advantages: Best energy capture and
grid performance
• Disavantage: More expensive. Complex
logistics (56m blades)
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Why so many models? There’s more to the wind than
meets the eye!
• Different site conditions - Average and Maximum wind speed
conditions. Sound power restrictions.
• Different Types of terrain. Cliffs or rising slopes. Onshore or
Offshore. Trees of vegetation. Turbulence?
• Climatic extremes – Arctic or Tropical. Ice days. Lightning days.
• Different grid conditions – Voltage support required (variable
power factor). Power constrants. Flicker constraints. Harmonic
emmissions. Weak connection – STATCOM required.
• Area available – many hectares of few. Turbine spacing wake
effects.
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The power
curve.
• The energy
yield.
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Each turbine is a stand-alone power station!
• Automatic synchronization.
• Full electrical protection.
• Power regulation and voltage support are avaliable on some
models.
What we measure at each turbine...
•
•
•
•
•
•
Wind speed and wind direction.
Temperature and humidity.
Blade pitch angle.
Rotational speed of the generator.
Grid conditions – voltage, phase balance, frequency.
Turbine output – current, power factor and power.
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What we measure at each turbine...
The measured temperatures are:
• Generator G temperature
• Generator g temperature
• Transformer temperature
• Ambient temperature
• Nacelle temperature
• Yaw rim temperature
• Pitch oil temperature
• Pitch oil accumulator temperature
• Water temp. before cooler
• Water temp. after cooler
• Water temp. after cooler 2
• Gear oil temp. after exchanger
• Gear oil temperature
• Thyristor temperature
• Main panel temperature
• UPS panel temperature
• Gear bearing front temperature
• Gear bearing rear temperature
• Gear bearing rear gen. side temp.
• Interm. gear front temperature
• Interm. gear rear temperature
• Generator bearing front temp.
• Generator bearing rear temp.
• Main bearing temperature
• Main bearing oil temperature
• Transformer W1 temperature
• Transformer W2 temperature
• Transformer W3 temperature
• Control panel temperature
• Top box panel temperature
• Phase comp. panel temperature
• Tower base temperature
• Hub panel temperature
• Generator G W1 temperature
• Generator G W2 temperature
• Generator G W3 temperature
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The measured pressures are:
• Disc brake
• Disc brake accumulator tank
• Yaw brake
• Yaw brake accumulator tank
• Gear oil
• Gear oil level pressure
• Accumulators for blade A,B and C
(measured by hub computer)
• Feeding pump for blade hydraulics
(measured by hub computer)
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What we control at each turbine...
Blade Angle
• The hub computer continuously monitors the angle of the blades, also
called the blade position. The blade position is determined by the main
computer, which continuously sends a wanted blade position to the hub
computer.
Rotational Speed
• The rotational speed is constantly monitored. If an overspeed situation
occurs, the wind turbine is stopped by the computer. The same applies to
the generator rotational speed. If the speed exceeds a previously set
limit, the computer stops the wind turbine.
Acceleration
• The acceleration used during the start up procedure is calculated by
means of the rotational speed measurements. To achieve a cut-in to the
grid as soft as possible, the acceleration is softened by turning the
blades until the wanted acceleration is reached.
Cut-in to the Grid (The rotational speed is also used to decide when to cut
in the generator. )A cut-in sequence is as follows:
• The speed is controlled to a few rotations over the synchronous
rotational speed for the generator. The computer starts the thyristors with
a small opening angle and then the opening angle is controlled until the
thyristors are completely open. While the thyristors are opening, the
blades are turned into starting position. When the thyristors are
completely open, the thyristor by-pass switch is connected.
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Protecting the turbine...
Electrical over-voltage protection.
• The wind turbine control system is protected against transients occurring via the
main cables (the grid) . The over-voltage protection system is installed in the power
cabinet and has a nominal protection level of 15 kA and a maximum current
equalization capacity of 40 kA per conductor. The voltage protection level is 2 kV.
The remaining voltage is equalized by further protection barriers built into the
control system.
Induced Transients.
• The computer is protected from transient over-voltage from the multi-cable in the
nacelle by means of barriers installed in the connector box for sensor inputs in the
nacelle. The barriers couple transient over-voltages into earth. Barriers on the
communication cable will protect the computer when they are fitted with internal
analogue modem or current loop interface. The barrier couples the differentials and
transient over-voltages into the computer earth connection.
• Insulation barriers are integrated into the control system. They insulate input and
output signals from the measuring point by means of transformers or opto-electric
barriers. These barriers are designed to withstand a 2kV potential. Controller inputs
can withstand at least +- 1kV 1.2/50 μS surges.
• Thyristors are protected against over-voltage transients with a barrier at the
snubber board.
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Protecting the turbine...
Lightning protection system (LPS)
The lightning protection system consists of:
• Lightning receptors in the blade.
• Down conducting system. A system to conduct the lightning current down through
the wind turbine to help avoid or minimise damage to the LPS system itself or other
parts of the wind turbine.
• Protection against over-voltage and over-current.
• Shielding against magnetic and electrical fields.
• Earthing (Grounding) System – bonding
• Bonding for all components ensures that lightning energy is conducted to earth.
The machine base frame performs protection of the components in the nacelle. The
components, which are not directly mounted to the bed, are connected with earthing
cables. At the rear of the nacelle there is also a lightning conductor that extends
considerably higher than the wind sensors.
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Standards for the turbines...
High Voltage ac circuit breakers IEC 60056
High Voltage testing techniques IEC 60060
Power Capacitors IEC 60070
Insulating bushings for ac voltage above 1kV IEC 60137
Insulation co-ordination BS EN 60071
AC Disconnectors and earth switches BS EN 60129
Current Transformers IEC 60185
Voltage Transformers IEC 60186
High Voltage switches IEC 60265
Disconnectors and Fuses IEC 60269
Flame Retardant Standard for MV Cables IEC 60332
Transformers IEC 60071/IEC 60076
Generator IEC 60034
Specification for sulphur hexafluoride for electrical equipment IEC 60376
Rotating electrical machines IEC 34
Dimensions and output ratings for rotating electrical machines IEC 72 & IEC 72A
Classification of insulation, materials for electrical machinery IEC 85
Safety of machinery – Electrical equipment of machines IEC 60204-1
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Standards for the turbines...
Design Codes – I/O Network System
•Salt Mist Test IEC 60068-2-52
•Damp Head, Cyclic IEC 60068-2-30
•Vibration Sinus IEC 60068-2-6
•Cold IEC 60068-2-1
•Enclosure IEC 60529
•Damp Head, Steady State IEC 60068-2-56
•Vibration Random IEC 60068-2-64
•Dry Heat IEC 60068-2-2
•Temperature Shock IEC 60068-2-14
•Free Fall IEC 60068-2-32
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Main
Control
3 blocks called
• main
controller,
• pitch
regulator and
• power
controller.
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The main controller is responsible for...
Maximization of the
amount of produced
energy
Limitation of
mechanical loads
according to design
limits
Limitation of acoustical
noise
Maintaining of high
power quality
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Less Noise,
Igor!
• Some
turbines are
capable of
power
reduction to
control the
noise.
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More power, Igor!
• 2 Scenarios for control
• Partial Load Operation
• Full Load Operation
• External power control factors
• Nominal power or
• User setpoint
Too much, Igor!
Decrease power due to
•
•
•
•
high generator temperature.
high gear temperature.
high transformer temperature.
high or low voltage.
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Controls
• Active Tower Damping
• turbines with low tower natural inherent frequency are equipped with
accelerometers, - turbines are paused, if acceleration level exceeds
maximum allowable value. Thrust Limitation.
• Individual Pitch – tower wake
• Start-up and Shutdown
• Star- / Delta Connection
• Inrush reduction
• Anti-massive start
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Pitch control
Maximization of the
amount of produced
energy
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What the authorities want.
National Authorities
• Federal Energy Regulatory
Commission (FERC)
• North American Electric
Reliability Corporation
(NERC)
• Regional Transmission
Organizations
(RTO)/Independent System
Operators (ISO)
Rules and Regulations
• FERC 661/A – Low Voltage
Ride Through. (LVRT)
• Reliability region rules
• Utility connections are
guided by the Large
Generator Interconnection
Agreement.
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To survive...
• Low Voltage Ride Through
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Within limits.
• Reactive Power Control
• Fixed capacitors or
• Variable within the limits of the generator/transformer.
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The control system layout.
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Processor & I/O Controllers
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Measurement of lightning
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Counters & I/O
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CT6211/15 – Serial Communication fibre/electrical
RS422/RS485
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Converter Processor & Interface.
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Vestas
VPN
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Interface options – Hardwire or DNP3
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Interface Options – Modbus or OPC
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SCADA – Vestas Online Business
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Vestas Online Business
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Vestas Online Business
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Vestas Online
Business
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Trending the Data.
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Michael Kennedy
Lead Electrical Engineer
Vestas Americas
Thank you for your attention
vestas.com
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