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Overview of IWES Grid Simulator Testing Activities” WIND ASSURING CONFIDENCE THROUGH COMPETENCE

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Overview of IWES Grid Simulator Testing Activities” WIND ASSURING CONFIDENCE THROUGH COMPETENCE “Overview of IWES Grid Simulator Testing Activities” WIND ASSURING CONFIDENCE THROUGH COMPETENCE Christian Mehler, Torben Jersch, Mohsen Neshati 4th International Workshop on Grid Simulator Testing of Wind Turbine Drivetrains April 25 – 26, 2017 NREL’s Energy Systems Integration Facility (ESIF), Golden, Colorado, USA © Fraunhofer Short profile of Fraunhofer IWES North-West Managing Director Prof. Dr.-Ing. Andreas Reuter Research spectrum Wind energy from material development to grid connection Operational budget 2015 € 15 million Staff 150 employees Located in Bremerhaven, Oldenburg, Bremen, Hanover Investments to date in the establishment of infrastructure € 60 million Strategic Alliance with ForWind and the German Aerospace Center (DLR) © Fraunhofer 2 / 23 Short profile of Division Wind Turbine and System Technology Division Manager Prof. Dr.-Ing. Jan Wenske Research spectrum Structural durability, mechatronics, power electronics and control in the area of entire wind turbines Large scale test benches for mechanics, electronics and Power mechatronics Staff 30 employees Division location Bremerhaven – Hannover © Fraunhofer 3/ 23 DyNaLab – 10 MW full nacelle testing Hydraulic load application unit Simulation of mechanical wind loads 1.2 MW Hydraulic Power Thrust: ± 1900 kN Radial loads: ± 2000 kN Bending moments: ± 20000 kNm (rotaing y-, z-axis) Dynamic: 0-2 Hz 0-G System Drive 5° inclined Drivetrain 10 MW (15 MW Overload) Direct drive 8.600 kNm (13.0000 kNm Overload) Torque Flexible Coupling Hydraulic safety clutch Gridsimulator 10/20/36 kV nominal voltage levels 44 MVA installed converter power LVRT & HVRT Simulation < 2% THD at 50 Hz © Fraunhofer 4 / 23 Adwen AD8 - 180 One of the worlds largest offshore turbines Source: www.adwenoffshore.com © Fraunhofer 5 / 23 Adwen Testing at DyNaLab 8 MW platform / 18 months extensive validation campaign individual and fully integrated subsystems tests de-risk the technology: speed-up the certification of the platform Source: www.adwenoffshore.com © Fraunhofer 6 / 23 Prototype Adwen AD8 - 180 Full nacelle test of prototype at IWES DyNaLab Source: www.adwenoffshore.com © Fraunhofer 7 / 23 Installation of the AD8 - 180 prototype Source: www.adwenoffshore.com Foundation: 51 piles and 1,700 m³ of concrete In addition, the first three sections of the tower have been installed, including the power section. The fourth will be installed in the coming days. The fifth and final section will be installed at the same time as the nacelle. © Fraunhofer 8 / 23 Testfield Bremerhaven Blade testing facilities Former airfield, near shore site Prototype erection in 2017 Possible WEC 2 location Grid connection to DyNaLab Validation of Test Benches WEC 1 location Validation of Grid Emulation Tests in combination with Field Tests Research platform (even for third parties) … DyNaLab © Fraunhofer 9 / 23 Grid Connection Testfield Bremerhaven – Pre Studies Challenge: Layout of flexible filter design for multipurpose testing Normal operation (with different customer configuration), LVRT - Dynamics © Fraunhofer 10 / 23 HiL-GridCoP Hardware-in-the-Loop Grid Compliance Test Bench Why don‘t use the turbine Test Bench? DyNaLab incl. Grid-Emulator Costs! Test bench i.a. for type certification HiL-GridCoP (Hall C) Test Bench for gearbox equipped WEC... © Fraunhofer 11 / 23 .. for testing electrical drivetrains Testing of a minimized System ! Converter DUT*: Generator Converter Transformer Switch gear PLC Auxilarysystems or DFIG * Device Under Test © Fraunhofer 12 / 23 New Test Bench (DyNaLab-Extension) ACS 6000 3,3kV IGCT-Converter 3~ 2= 2= 3~ 2= 3~ 3~ 2= 11-13MVA 11-13MVA Torque Up to 7,5MW WEC 9MW @1500rpm measurement Generator drivesystem 100kNm 1200-1800rpm Y ASM DFIG 9MVA + zus. WEA-Verbraucher - Eigenversorgung Switch gear 20kV, 630A PCC DyNaLab 20kV AC-busbar Junction-Box IWES / DyNaLab Grid - Emulator (Isolation/Earthing & Measurement) DUT 2x3~ 2= 10/20/36kV IWES Test Bench 2= 3x2~ Tappings (new installation) 2x9MVA 44MVA IWES DyNaLab ACS 6000 3,3kV IGCT-Converter N (existing) © Fraunhofer 13 / 23 CertBench – Motivation / Certification Process Advantages • reproduceability OEM • adjustable Operational release Construction boundary conditions • defined effort WEC Test • additional Grid operator Bench Operators testopportunities Disadvantages Prototype Measuring certificate procedures • So far not accepted Certification Measurement body institute Since 2015 Technical Commitee „Test Test- Bench“ for the extension of FGW TR 3 Source: CWD report „Bestimmung der elektrischen Participants: Manufacturer of Wind Turbines, Eigenschaften von Erzeugungseinheiten Measurement Institutes, Certification und –anlagen […]“ Companies, Research Institutes © Fraunhofer 14 / 23 CertBench – work plan Source: CWD © Fraunhofer 15 /23 CertBench - Utilization 1.2 1 0.8 0.6 0.4 0.2 Committee activities 0 0 0.05 0.1 0.15 0.2 0.25 0.3 Simulation TR3 / AG-Test Bench turbine Forschungs- FNN … • Shortening of type certification Combining interests of Fieldtests comercial • New test infrastructure? certification process (even industry driven) Source: CWD Manufacturer of Wind Turbines, Measurement Institutes, Certification Bodies, Research Institutes © Fraunhofer 16 / 23 Increase Acceptance of Electrical certification on Test Benches Technical Guideline FGW TR3 – Technical Committee electrical certification on test benches Objective: Defining the process of certification electrical characteristics on test benches and include them in national standard Defining the requirements of Wind Turbine and requirements for Test Benches Participants: Manufacturer of Wind Turbines, Measurement Institutes, Certification Bodies, Research Institutes © Fraunhofer 17 / 23 Hardware-in-the-loop Test Operation Goal: Realistic test environment to fulfill electrical certification requirements Realistic emulation of rotor characteristics in Torsional DOF Real-time interaction between virtual rotor model and test rig (+ DUT) Active consideration of test rig characteristics by HiL controller Desired frequency response in and around torsional modes Verification against field measurements / load simulation results Certification Requirements ? © Fraunhofer 18 / 23 Hardware-in-the-loop Test Solutions Goal: Realistic operating point of flange Speed controlled test rig drive train Speed control with torque reference setting in an allowed range Torque controlled test rig drive train Torque reference setting in an allowed speed range Verification with Field Measurements / Load Simulation Results © Fraunhofer 19 / 23 Grid Drop Test Simulation Grid compliance tests for electrical certification Time-domain response 18 m/s turbulent wind speed HiL configuration simulation result for 5MW NREL DUT Similarities / Differences regarding PHiL operation? Actuator Dynamics vs. Feedback Dynamics Time (sec) © Fraunhofer 20 / 23 Summary Short profile Fraunhofer IWES Testfield Bremerhaven HiL – Grid CoP CertBench Certification Activities HiL – Operation Source: www.adwenoffshore.com © Fraunhofer 21 / 23 Acknowledgements Fraunhofer IWES is funded by the: Federal Republic of Germany Federal Ministry for Economic Affairs and Energy Federal Ministry of Education and Research European Regional Development Fund (ERDF): Federal State of Bremen Senator of Civil Engineering, Environment and Transportation Senator of Economy, Labor and Ports Senator of Science, Health and Consumer Protection Bremerhavener Gesellschaft für Investitions- Förderung und Stadtentwicklung GmbH Federal State of Lower Saxony Free and Hanseatic City of Hamburg © Fraunhofer 22 / 23 Thank You For Your Attention Any questions? [email protected] © Fraunhofer 23 / 23.
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