english

foreword 3

foreword

ENERCON began its road to economical/ecological success when graduate engineer

Aloys Wobben founded the company in 1984. Since the company’s launch, research
and development have always determined the extent of innovation. And in 1991
ENERCON pioneered the development and manufacture of the world’s first gearless
wind energy turbine system. This concept gave the decisive impetus for our claim:
Energy for the world.

ENERCON began series production of gearless wind turbines in 1993 in response to

high demand and fundamental advantages in terms of output, reliability and service
life. All key components such as the rotor, the annular generator and the grid feeding
system have always been developed and manufactured in-house. A concept with
which ENERCON has maintained its position as the German market leader and has set
standards in technology, quality and safety on all continents.

ENERCON’s continuing success is marked by the addition of the new E-48 in the
medium power category. With 800 kW rated power and its new rotor blade geometry,
the E-48 is the most efficient wind energy plant in its class. Combined with various
tower types up to 76 m hub height, it is now possible to develop locations which, up
until now, were not economically feasible. In addition, its innovative feeding system
fulfils all new grid connection stipulations and can thus be integrated in all supply and
distribution structures.
 drive system 5

SYSTEM
DRIVE
drive system
ENERCON E-48 rotor blades
 drive system 7

Tip of an E-48 rotor blade

SYSTEM
DRIVE
drive system

ROTOR BLADE CONCEPT

The new rotor blade concept of the ENERCON E-48 sets the benchmark with regard
to yield, noise emission and load-optimisation. Because of their modified design,
the blades also use the inner part of the rotor area and considerably increase the
energy yield. The new E-48 rotor blades are also less susceptible to turbulence and
provide an even flow along the entire length of the blade profile.

The blade tips have also been improved concerning noise emission and energy
yield. Turbulences that occur at the blade tips due to overpressure and
underpressure are effectively removed from the rotor plane. The entire length of the
blade is thus utilised without any energy loss caused by turbulences.

Advantages of ENERCON rotor blades:

A new rotor blade geometry uses the even airflow around the nacelle and increases the energy yield
~ Higher efficiency due to modified blade geometry
~ Less noise emission due to optimised blade tips
The success of the new rotor blade design is based on the fact that the wind flow
~ Longer service life due to reduced stress
is concentrated on the nacelle, exactly where the new blades reap the wind. The
blade is flush with the wide blade connection on the spinner, thus picks up
~ Easier transport due to streamlined blade geometry
additional wind yield from two sides: for one, the wind which is streamlined around
the nacelle and for the other, the wind that up until now was deviated towards the
flange connection to avoid the resistance at the blade root. ENERCON E-48 rotor blades are produced using a vacuum technique with a so-called
sandwich construction. First, the glass fibre fabric laid out in moulds is impregnated
with resin in a vacuum using a pump and hose system.

ENERCON E-48 rotor blade
Compared to the former process in which the resin saturated glass fibre fabric was
laid out in the moulds by hand, the new vacuum infusion procedure guarantees
pore-free material bonding and eliminates air pockets in the laminate. A second
advantage is that this process is clean and odourless and the employees no longer
come directly in contact with the materials. An additional innovation is the use of
balsa wood which, together with high-resistant foam, constitutes the core of the
new ENERCON rotor blades and offers even higher stability. Finally, the blade top
coat finish has been further improved due to the introduction of a spray paint
procedure.
Top layer made of PUR gel coat varnish for optimum weather protection
Fibreglass-reinforced epoxy resin lends the blade its solid structure and
provides the required rigidity
High-resistance foam and balsa wood form the core of the lightweight
blade structure
Fibreglass-reinforced epoxy resin for solid structure and rigidity
Structure of an E-48 rotor blade (sandwich construction)
drive system 9
SYSTEM
DRIVE
DIRECT DRIVE
The drive system of the ENERCON E-48 is simple: fewer rotating components reduce
mechanical stress and increase the technical service life of the equipment. Main-
tenance and service costs for the wind turbine are lower (fewer wearing parts, no gear
oil change etc.) and operating expenses are reduced.
In the E-48, the rotor hub and the annular generator are directly connected to each
other as a fixed unit without gears. The rotor unit is mounted on a fixed axle, the so-
called axle pin. Compared to conventional geared systems that have a large number of
bearing points in a moving drive train, the drive system of the E-48 has just two slowly
moving roller bearings. The reason for this is the low speed of the ENERCON direct
drive.
ENERCON E-48 direct drive
 drive system 11

E-48 nacelle assembly

SYSTEM
DRIVE
Several years ago only the rotor hub was made
of cast steel, nowadays the use of modern
spheroidal graphite cast iron makes it possible
to manufacture other major components such
as blade adaptors, axle pins and main carriers
with this process.

ENERCON always collaborates closely with the

POWER FLOW CONCEPT
In addition to the ENERCON direct drive, the mechanical load is further reduced by
a specially developed power flow concept that carries dynamic loads directly away
from the rotor unit to the tower. In order to avoid possible excessive stress at
welded seams, only cast parts are used for major components.
foundries to further develop cast parts. All cast
components are drawn on a 3D CAD system
and calculated using the finite element method
to simulate strain increases at the critical
points. Functionality is tested and optimised by
the designer during the entire prototype phase
with inhouse measurements. In order to
guarantee the identification and traceability
of each cast component when the goods are received by ENERCON, each part is
given a specific bar code, from which the serial number can be obtained in the
event of quality problems, for example. The cast components are not released for
further steps in the ENERCON manufacturing process until comprehensive quality
testing has taken place. This guarantees that the high ENERCON quality standards
are also fulfilled in the cast component supply sector.

Quality testing procedure at ENERCON for

cast components:
~ Structural investigation on the component
~ Ultrasound test
~ X-ray test
The ENERCON power
flow concept reduces
mechanical loads
 annular generator 13

annular generator
ENERCON E-48 annular generator production

GENERATOR
ANNULAR

annular generator
The ENERCON annular generator is of primary importance in the gearless system
design of the E-48. Combined with the rotor hub it provides an almost frictionless
flow of energy, while the gentle running of fewer moving components guarantees
minimal material wear. Unlike conventional asynchronous generators, the ENERCON
annular generator is subjected to very little mechanical wear, which makes it ideal
for particularly heavy demands and a long service life. Time-consuming repair work
and the associated turbine downtimes are also prevented.
The ENERCON annular generator is a low-speed synchronous generator with no
direct grid coupling. The output voltage and frequency vary with the speed and are
converted for output to the grid by a DC link and inverter. This achieves a high
degree of speed variability.
Advantages of the ENERCON annular generator:
~ Yield-optimised control
~ High level of grid compatibility
~ No gear
~ Low wear due to slow machine rotation
~ Low machine stress due to high level of speed variability
annular generator 15
ENERCON E-48 annular generator
rotor and stator
GENERATOR
ANNULAR
STATOR AND ROTOR
According to ENERCON’s service life requirements the copper winding in the stator,
the stationary part of the annular generator, known as closed, single-layer basket
winding is produced in insulation class F (155°C). It consists of individual round
wires that are gathered in bundles and varnish insulated. The copper winding is
installed by hand at ENERCON. In spite of increasing automation in other
manufacturing areas, preference has been given to manual labour in this case for
good reason. It ensures that the materials used can be fully tested. Furthermore, a
special processing method also allows for continuous windings to be produced.
Each winding strand is without interruption from the point of insertion to the exit.
Advantages of continuous winding:
~ Prevents processing faults in the production of electrical
connections
~ Maintains the high-quality copper wire insulating system
~ No contact resistance
~ No weak points susceptible to corrosion or material fatigue
 annular generator 17

Pole shoes on the

ENERCON E-48 disk rotor

QUALITY ASSURANCE
In order to guarantee high ENERCON quality standards, the annular generators are
all manufactured in the company’s own production facilities. Top grade materials are

GENERATOR
always used. Close collaboration with supplier companies has proved to be a reliable

ANNULAR
way of providing maximum material quality. For example, the enamelled copper
wires are subjected to more testing than is specified in the standard and samples
are archived. Surge voltage tests are performed on the pole shoes and chokes and
then documented in the computer system.
The magnetic field of the stator winding is excited via so-called pole shoes. These
are located on the disk rotor, the moving part of the ENERCON annular generator.
Since the shape and position of the pole shoes have a decisive influence on the
noise emission of the annular generator, the ENERCON Research & Development
department has dedicated particular attention to this aspect. The result: optimum
adaptation of the pole shoes to the running of the slowly rotating ENERCON annular
generator means that no noise is generated.

TEMPERATURE BEHAVIOUR
The ENERCON annular generator features optimised temperature control. The
hottest areas in the annular generator are constantly monitored by a large number
of temperature sensors. The sensors’ activation temperature is well below the
continuous temperature resistance of the insulating materials used in the annular
generator. This means that overloading caused by excessive temperature is
prevented.

Temperature
Limit, enamelled
copper wire (200 °C)
200 Limit, impregnating
resin (180 °C) Limit, insulation
class F (155 °C)
Actual temperature,
copper conductor
Actual temperature,
superficial insulation
100

Actual temperature,
impregnating resin Actual temperature,
winding surface

– Limits for the insulating materials used – Operating temperatures in the annular generator

The highest operating temperature in the ENERCON E-48 annular generator is well below the limits applicable Surge voltage test on pole shoes
to the materials used
 system control 19

system control
ENERCON electronic components assembly hall

CONTROL
SYSTEM
 system control 21

Wind sensor on the ENERCON E-48 nacelle

system control

ENERCON E-48 wind turbines are equipped with state-of-the-art microelectronic

control technology developed in-house. The MPU (main processing unit), the central
element of the E-48 control system, is in continuous contact with the peripheral
control elements, such as the yaw control and active pitch control system. Its
function is to adjust the individual system parameters to ensure that the ENERCON
E-48 operates at optimum yield in all weather conditions.

CONTROL
SYSTEM
ENERCON control system for a yield-optimised turbine
operation under all weather conditions

~ Adaptive yaw control of the nacelle by means of constant

evaluation of the measurement data from the wind sensor MONITORING GRID CONNECTION

~ Variable speed for optimal efficiency of the wind turbine at
every wind strength, and elimination of undesirable output
peaks and high operating loads
~ Active pitch control system to set the ideal flow angle at the
rotor blades ensures maximum yields and load reductions for
the entire wind turbine
~ ENERCON brake system for extreme turbine reliability by
means of three independently operating pitch mechanisms with
standby power supply in case of grid failure
~ Tower and generator monitoring by means of vibration and
acceleration sensors to check the deflections in the tower
~ Temperature and air gap sensors between rotor and stator
ensure reliable operation in the annular generator
Ensuring correct feeding of electricity from the ENERCON E-48 into the grid requires
grid connection monitoring. Grid parameters such as voltage, current and frequency
are measured on the low-voltage side between the ENERCON inverter and the
system transformer. The measured values are continously transmitted to the E-48
system control, enabling the turbine to react immediately to changes in the grid
voltage or frequency. If the defined limit values of the system protection are
exceeded, the E-48 wind turbine is reliably shut down and the service teams
informed. As soon as the voltage and frequency return within the permissible
tolerances, the E-48 wind turbine is automatically started up again. Prolonged
downtimes are thus avoided.
System
control
Grid
measurement
Voltage
Frequency

Generator Rectifier Inverter Transformer

Monitoring the grid feeding

on ENERCON wind turbines
 system control 23

ENERCON STORM CONTROL ENERCON E-48 wind turbines operate

ENERCON E-48 wind turbines are operated with a special storm control, which on a different principle at high wind
enables reduced turbine operation in the event of very high wind speeds. This pre- speeds. They are equipped with special
vents the otherwise frequent shutdowns and considerable yield losses that result. storm control software which prevents
sudden shutdowns.

The power curve diagram of a wind turbine without ENERCON storm control looks
like this:
Power

CONTROL
SYSTEM
Power P(rated)

P(rated)

V1 V2 VStorm Power curve of a

Wind speed
wind turbine with
ENERCON storm control

V1 V2 V4 V3 Power curve of a
Wind speed
wind turbine without
ENERCON storm control The power curve diagram with ENERCON storm control demonstrates clearly that
the E-48 wind turbine does not shut down automatically when a certain wind speed
VStorm is exceeded, but merely reduces the power output by lowering the rotational
The diagram shows that the wind turbine stops at a defined shutdown speed V 3. speed. This is achieved by turning the rotor blades slightly out of the wind. Once the
The reason being that a specified maximum wind speed has been exceeded. In the wind speed drops, the E-48’s blades turn back into the wind, and the turbine
case of wind turbines without storm control, this occurs for example at a wind immediately resumes operation at full power. Yield-reducing shutdown and start-up
speed of 25 m/s within the 20 second mean. The turbine only starts up again when procedures are thus avoided.
the average wind speed drops below the shutdown speed or a possibly even lower
restart speed (V4 in the diagram; so-called strong wind hysteresis). In gusty wind,
this may take some time, which means that considerable yield losses are incurred.
Example:
Yield loss due to two days of gusty wind per year
2 days x 800 kW
= 38,400 kWh
2 – 4 % of yearly income
 grid connection 25

grid connection

CONNECTION
GRID
 grid connection 27

grid connection

In collaboration with German and foreign grid operators, ENERCON Research and
Development has developed a grid connection system that provides problem-free Typical requirements for wind turbines in transmission grids
integration of E-48 wind turbines into existing power supply and grid structures.
The ENERCON grid connection system meets all the new connection stipulations for
~ Wind turbines must be able to remain connected to the grid

wind turbines, such as those of E.ON Netz GmbH, and has been classified as very without power reduction even if considerable voltage and
good by power supply companies because of its adaptability and grid-supporting frequency deviations occur.
effect. E-48 wind turbines are available for integration in transmission grids
(“Transmission” version) or distribution grids (“Distribution” version).
~ If voltage dips occur because of grid problems, wind turbines
must remain connected to the grid for a defined period.

The energy generated in the ENERCON annular generator is fed to an inverter via a
~ Short circuit current feeding may be demanded during a grid

rectifier and a so-called DC link. This ensures that the output power is regulated in problem.
accordance with grid specifications. This is where the stipulated requirements for ~ After a fault has been remedied, a wind farm must resume its

CONNECTION
each individual turbine in a wind farm, such as voltage, frequency and reactive power feed as quickly as possible and within specified maxi-

GRID
power, are implemented. The wind turbine’s transformer makes the conversion from mum times wind farms must be able to be operated with redu-
400 V to the suitable grid voltage.
ced power output without any time restrictions.
~ For coordinated load distribution in the grid, the increase in
power output (power gradient), for example when the wind
Wind farm 3 Wind farm 2 Wind farm 1
farm is started up, must be able to be restricted in accordance
with the grid operator’s specifications.
~ Wind farms must make a contribution to the reserve power in
the grid. If the grid frequency increases, the power output of a
Wind farm Wind farm Wind farm wind farm must be reduced.
SCADA 3 SCADA 2 SCADA 1

~ If necessary, wind farms must be able to make a contribution to

ENERCON 20 kV maintaining voltage stability in the grid by supplying or accep-
Umspannwerk
substation control
ting reactive power.
Operating technology
~ Wind farms must be able to be integrated in the grid control
110 kV centre for telemonitoring and remote control of all systems in
Control station the grid.
grid operator

Connecting ENERCON wind farms to the grid

 tower and foundation 29

tower and foundation

Unloading of an ENERCON tubular steel tower section

FOUNDATION
TOWER AND
 tower and foundation 31

Manufacturing of ENERCON
tubular steel towers

tower and foundation

TOWER CONSTRUCTION From an aesthetic point of view, ENERCON towers have a sophisticated design.
The load dynamic design of materials and structure used in ENERCON towers Streamlined structures with gradually inclined angles stand for an highly developed
provides the best conditions for transport, installation and use. Over and above the optical concept and have nothing more in common with the huge and bulky
binding national and international norms (e.g.: DIN and Eurocode) ENERCON sets its traditional cylindrical structures.

FOUNDATION
own specifications which surpass quality and safety standards.

TOWER AND
TOWER VERSIONS
Virtual 3D models of the tower designs are produced during the development phase Depending on the location and the service conditions, four different tower versions
using the finite element method (FEM), with which all the stresses to which the made of steel are available for the ENERCON E-48.
wind turbine is subjected in reality are simulated. This means that accurate
predictions concerning the stability and service life of the towers are not left to
chance before building a prototype. The evaluation of additional measurements, Hub height
which ENERCON continuously carries out on existing turbines, contributes to
50 m
providing further verification of the calculated data. ENERCON’s calculations are
56 m
confirmed by the results produced by specially commissioned certification bodies,
65 m Segment 1
research institutes and engineering firms.
76 m

ENERCON tower options for E-48

wind energy turbines are produced Segment 2
in three segments

Segment 3
 tower and foundation 33

ENERCON foundation
section to connect steel towers
with the foundation

TUBULAR STEEL TOWER

ENERCON tubular steel towers are manufac-
tured in several individual tower sections,
which are connected using component-pro-
tecting L-flanges. Unlike conventional flange
connections (such as those used in steel chim-
ney construction), the welding seam of the
L-flange is outside the stress area. Other
advantages of this connecting technology are:

• dispenses with complex and costly welding work on site
• rapid, reliable assembly to the highest quality standard
• full corrosion protection, applied under best production engineering conditions
Due to the smaller circumference on shorter steel towers, ENERCON uses a so-
called foundation basket to connect the tower to the foundation. It is made up of
numerous threaded steel bolts which are aligned in two circular rows. The exact
position for each of the bolts is held in place with a circular positioning device
which corresponds to the exact measurements on the tower flange. Once the foun-
dation is completed, the lower tower section is set on the bolts and fastened with

FOUNDATION
connecting nuts.

TOWER AND
A specially developed foundation connection system is used for taller ENERCON
steel towers. The cylindrical structural element is set on the blinding layer and pre-
cisely aligned with adjusting bolts. Once the foundation ist completed, the tower is
flanged together with the foundation section.
In the case of the L-flange
used by ENERCON, the
welding seam is located
Like all other components, the tubular steel towers are subject to the strict
outside the tension range ENERCON quality standards. Quality assurance is already integrated in the
development of new tower types during the construction phase. This determines
whether the prototype meets all requirements before it goes into series production.

Conventional flange
connections with a
welding seam (red) in the
tension range
 tower and foundation 35

Reinforcing steel in
ENERCON circular foundations

FOUNDATION CONSTRUCTION Since the ground can only absorb a certain amount of compressive strain depending on
The foundation transmits the weight and the load of the wind from the turbine into the location, the foundation surfaces must be adapted accordingly. The design of the
the ground. ENERCON foundations are mostly circular. ENERCON round foundations, usually installed as shallow foundations, is based on this
extremely simplified finding.

If necessary, (in soft soil) a special deep foundation provides force distribution down to
Advantages of ENERCON round fundations
deeper load-bearing soil strata. The piles are arranged symmetrically and slightly
~ The forces are equal in all wind directions, where as inclined so that the imagined extended pile centre lines meet at a point above the

FOUNDATION
asymmetrical foundation pressure can occur in square bases or centre of the foundation. This provides optimum power/load flow distribution over the

TOWER AND
cross-shaped foundations. entire surface.

~ The circular design has been proven to reduce the amount of

reinforcement and concrete that is required. The circular design
reduces the size of the formwork area.
~ Filling the foundation with the soil from the excavation pit goes
into the structural analysis as a load. This means that less
reinforced concrete is needed to make the foundation stable.

Both pictures:
Weight distribution in the case of shallow and deep
ENERCON round foundations
 service and maintenance 37

service and maintenance

ENERCON on-site service

MAINTENANCE
SERVICE AND
 service and maintenance 39

service and maintenance SERVICE MANAGEMENT

DECENTRALISED SERVICE STRUCTURE
The aim of the ENERCON Service Department is to ensure and maintain the operational
readiness of all ENERCON wind turbines. In accordance with the “Speedy service
through local presence” principle, approximately 1100 employees at 113 service
centres worldwide (as at 12/2004) provide the quickest possible maintenance and
servicing of the wind turbines. This guarantees short distances for the service
technicians and provides a high degree of availability (average in the last years more
than 98.5%).
A well-coordinated office team is also an important factor for an efficient field service
organisation. More than 100 employees coordinate global service operations at
ENERCON, from both a technical and commercial point of view. Each customer has a
designated service centre contact. This generates trust and ensures that detailed
knowledge of the local conditions of the wind turbines is available.
Each ENERCON E-48 wind turbine has a modem link to the central remote data
transmission facility. If the turbine signals malfunction, the service centre and the
service branch in charge are notified via the SCADA remote monitoring system. The
message is automatically transferred into the ENERCON deployment planning
software and displayed on the screen of the office employee. With the aid of a
specially developed locating system (GIS – Geoinformation System), the deployment
planning system automatically locates the service team that is closest to the wind
turbine. The service teams can access all the turbine-specific documents and data
using so-called pentops (robust, portable computers with a link to the service
centre). This guarantees that all maintenance is dealt with as quickly and efficiently
as possible. A new standard in service management.
Wind farm
Meteorological Customer Power Pentop service
analysis interface PDI management technicians

ENERCON Service performance profile: Wind farm Prescribed set

Set values
display value, utility

~ Servicing and maintenance of all wind turbines erected by

ENERCON
~ Turbine monitoring via remote data transmission
SCADA
management

~ Maintenance of technical availability of wind turbines serviced Customer

Telephone
Remote control IP | Tel | GSM

by ENERCON … SMS | Fax | E-mail

CONTROL CENTRE
…

~ Customer care in all technical and commercial matters … SIP | WWW SMS | GSM | GPRS

MAINTENANCE
SERVICE AND
~ Operator training ENERCON Call-out planning
development

ENERCON service management sets new benchmarks

 service and maintenance 41

Each customer has a designated service centre contact

http://sip.enercon.de

Service Information Portal (SIP)
The Service Information Portal (SIP) provides ENERCON customers with a simple
and rapid way of obtaining all the information they require about their own wind tur-
bines via the Internet from anywhere in the world. All that is needed to do this is a
computer with a so-called Web browser (e.g. Microsoft Internet Explorer) and an
Internet connection. A changing PIN, an individual password and encrypted trans-
mission routes provide three levels of data protection in accordance with the latest
security criteria.
The clear menu structure of SIP provides rapid and individual access to all turbine
data. Work processes that would normally take hours, such as producing analyses
of wind turbines, checking maintenance logs or producing up-to-date yield
overviews can be done in a matter of minutes using SIP. A boost to efficiency that
Damage caused by unforeseeable events such as acts of nature and vandalism can
be covered by a specially developed EPK additional insurance policy. Significantly
cheaper than conventional machine failure insurance, the EPK additional insurance
is now available through all well-known insurance companies.
EPK at a glance:
~ Guarantee of at least 97% technical availability
~ All servicing costs covered
~ All maintenance costs covered (including wear costs etc.)
~ All repair costs covered

not only increases customer satisfaction but also improves the flow of information ~ Agreement term of twelve years (with possible extension)
(among partners in a wind farm, for example). ~ Agreement can be terminated with three months’ notice at any

MAINTENANCE
SERVICE AND
time; ENERCON can only terminate the agreement at the end
of the term
ENERCON PARTNERKONZEPT (EPK)
The ENERCON PartnerKonzept (EPK) gives customers the guarantee of consistently
high turbine availability for the first twelve years of operation with calculable oper-
ating costs. From servicing to safety work, maintenance and repairs, all eventualities
are covered by a single agreement. Because of its economical service reliability, the
EPK has long since become an acknowledged ENERCON quality feature.
 stand alone system 43

Shipment of an ENERCON Stand Alone System stand alone system

(Utsira/Norway)

STAND ALONE
SYSTEM
 stand alone system 45

Components in the ENERCON Stand Alone System

• Wind turbine - main energy source

• Flywheel - short-term energy storage to compensate the

wind energy fluctuations in the seconds range
- frequency controller in the stand alone grid
(diesel-parallel and diesel-off mode)

• Battery storage - emergency back-up in the stand alone grid (diesel-

off mode) for power supply in the minute range
- frequency control in emergency cases

• Master Synchronous Machine used in diesel-off mode for

- voltage control
stand alone system - supply of reactive power
- short circuit current supply
- flicker filtering
APPLICATIONS
Due to its size and rated power, the E-48 turbine is well-suited for locations on • Controls - power management in the stand alone grid
islands or in smaller rural communities to complement the diesel stations that - safe and economic automatic operation of the
usually supply the energy there. system (manual mode also possible)
- data processing and process visualisation
In order to achieve a high penetration of wind in the energy-mix (diesel-paral-
lel mode), ENERCON has developed the necessary equipment for grid stabilisa- • Diesel generator - system start-up
tion and system control. With the components of the ENERCON stand alone sys- - power supply at lack of wind and empty
tem it is possible to achieve a wind energy penetration of up to 100% (diesel- storage facilities
off mode, zero-emission), depending on the system layout, i.e. balance
between wind turbine rated power and load demand.

Diesel
generators ENERCON
With this technology, ENERCON can also supply a complete power station Flyweels
(based on wind energy) to provide consumers with power at locations where no
energy supply was available thus far. ENERCON

STAND ALONE
Wind turbines

SYSTEM
In all configurations and operational modes the system delivers stable and
uninterruptible power with very high grid quality. The ENERCON Stand Alone
System provides energy precisely according to demand. Only the required
amount of energy is produced and dump loads to dispose of excess energy are Back-up storage for
diesel-off mode
not necessary.

Consumers
Schematic system
layout
 stand alone system 47

ENERCON flywheel storage system

Advantages of the ENERCON Stand Alone System

~ The wind turbine is the main energy source, wind penetration

up to 100% is possible (diesel-off mode, zero-emission).
No dump loads required.
~ Continuous power supply is guaranteed, all emergency
scenarios are backed-up. FLYWHEEL STORAGE SYSTEM

~ Excellent grid quality through use of the well-proven ENERCON In the year 2000 ENERCON decided to develop an energy storage system specially
suited to compensate wind power fluctuations. It has been designed according to
IGBT inverter technology.
the following requirements:
~ High reliability, long service life, easy maintenance and good
availability for spare parts due to the use of standard, robust, • Low cost
well-tested components. • Low maintenance

~ Ideal mix of mechanical and chemical storage systems. Each •

•
Robust design
Long lifetime
type of storage is used according to its intended purpose,
• Standard components and materials as far as possible
therefore long service life guaranteed. • Possibility for individual applications (modular, containerised etc.)
~ Fully automatic control with state-of-the-art hardware technology. • Rated power 200 kW
~ Compact modular containerised design for easy transport and •
•
Energy storage capacity 5 kWh
High efficiency / low losses
simple extension.
• Extremely fast reaction time
~ Quick on-site installation of pre-assembled components fully
• Optimum grid behaviour
tested before delivery.
~ All components from one supplier (wind turbine, flywheel, The ENERCON flywheel is a very simple and robust system, which is proven by
controls etc.) with long-term experience in wind turbine behaviour more than 10.000 operating hours without maintenance work. The mechanical
design using standard materials and well-proven components for example
and controls.
bearings and other machine parts ensures a reliable operation and a long-term
~ Existing or new components can easily be integrated
supply with spare parts. Access to e.g. bearings is easy and for their replace-
(e.g. diesel generators, photovoltaic systems, desalination units, ment no specially trained personnel is required.
hydrogen equipment etc.).
The use of standard well-proven ENERCON inverters ensures very high grid

STAND ALONE
SYSTEM
quality and allows for the use of standard spare parts necessary for wind turbine

SYSTEM
maintenance.

GRID
The ENERCON flywheel comes in a standard 20ft sea container convenient to
transport and ready for connection to the grid. All components are installed and
completely cabled. The system undergoes extensive testing before delivery.
Thus the time for installation and commissioning on site is very short.
 stand alone system 49

ENERCON Stand Alone System (Utsira/Norway)

Its tasks are:

• Process visualisation of all details
The picture shows the main menu which gives an online overview of the com-
plete system with the status of all individual components. From there the sub-
menus for each single component can be selected, showing all sensor data
monitored (online).

POWER MANAGEMENT SYSTEM AND HMI/SCADA

The core component of the sophisticated power management system is the
main control unit. It manages all components efficiently to ensure a reliable
power supply under all operating conditions.

The main controller for the power management of the overall system is a stan-
dard industrial state-of-the-art controller. Because of its modular design it
can be adapted to the specific requirements of each system. • Data processing
On a 10-min basis, a selection of data, as well as all status messages is stored
The strategy for running the complete system in safe and economic automatic (starts, stops, alarms, etc.)
mode is implemented in the software of this controller. This software of course
has to be adapted to each individual application (number and type of energy • Manual operation
sources and consumers etc.). Via the HMI, the operator has access to the main control panel and is able to
give commands to all system components (start, stop, power set-point, oper-
A manual mode is also possible where all functions of the controller can be ating mode etc.)

STAND ALONE
activated by the operator. For this, a so-called HMI (Human-Machine-Interface)

is available. This is realised with an industrial PC with touch-screen connected
via Ethernet-link to the main controller.
SYSTEM
• Scada
The HMI is connected to an ISDN line offering the possibility of remote commu-
nication. The following functions are available:
• sending alarm messages via SMS and/or email
• online monitoring of the whole system from any office PC
• access to the complete data stored in the system database
 technical specifications 51

technical specifications

SPECIFICATIONS
TECHNICAL
 technical specifications 53

TECHNICAL DATA

Rated Power: 800 kW

Rotor diameter: 48 m

ANTRIEBS
SYSTEM
Hub height: 50–76 m (tubular steel tower and various foundations)

Turbine concept: Gearless, variable speed, variable pitch control

Rotor
Type: Upwind rotor with active pitch control
Direction of rotation: Clockwise
Number of blades: 3
Swept area: 1810 m2
Blade material: Fibreglass (epoxy resin); integrated lightning protection
Rotational speed: Variable, 16 - 32 rpm
Tip speed: 40–80 m/s
Pitch control: ENERCON blade pitch system, one independent pitching
system per rotor blade with allocated emergency supply 3 1
4
Drive train with generator 2
Hub: Rigid
Main bearings: Single-row cylindrical roller bearings
Generator: ENERCON direct-drive synchronous annular generator
5
Grid feeding: ENERCON converter

Braking systems: – 3 independent blade pitch systems with emergency supply

■1 Main carrier
– Rotor brake
■2 Yaw motors
– Rotor lock
■3 Annular generator
■4 Blade adaptor
Yaw control: Active via adjustment gears, load-dependent damping ■5 Rotor hub
6 ■6 Rotor blade
Cut-in wind speed: 3 m/s

SERVICE &&
WARTUNG
Technik
PLANUNG
Rated wind speed: 13 m/s

Cut-out wind speed: 28–34 m/s

Remote monitoring: ENERCON SCADA

SPECIFICATIONS
TECHNICAL
E-48, ENERCON, Energy for the world, the ENERCON Logo and the different shades
of green in the lower tower part are trademarks of ENERCON GmbH.
International Dept.
ENERCON GmbH
Otto-Lilienthal-Strasse 25 · 28199 Bremen · GERMANY
Phone +49 421 244 15 20 · Fax +49 421 244 15 39
sales.international@enercon.de
ENERCON GmbH · Austria
Hauptstrasse 19
2120 Wolkersdorf · AUSTRIA
Phone +43 2245 828 28
Fax +43 2245 828 38
ENERCON Benelux B.V.
Paxtonstraat 1 a
8013 RP Zwolle · THE NETHERLANDS
Phone +31 38 422 82 82
Fax +31 38 422 80 10
ENERCON GmbH · France
8, Chemin d’ Armancourt
60200 Compiègne cédex · FRANCE
Phone +33 3 44 37 35 10
Fax +33 3 44 37 35 20
ENERCON GmbH · Great Britain
Axiom House, Station Road
Stroud, Glos. GL5 3AP · GREAT BRITAIN ENERCON Hellas S.A.
Phone +44 1493 78 20 18
Fax +44 1493 78 90 94
ENERCON GmbH · Denmark
Bredkær Parkvej 62
8250 Egaa · DENMARK
Phone +45 87 43 03 88
Fax +45 87 43 03 44
ENERCON GmbH · Sweden
c/o Energy Converter AB
Stenåldersgatan 19
21376 Malmö · SWEDEN
Phone +46 40 14 35 80
Fax +46 40 22 24 20
ENERCON GmbH · Dreekamp 5 · D-26605 Aurich · Phone +49 4941 92 70 · Fax +49 4941 92 71 09 · www.enercon.de
ENERCON GmbH · Italy
Via Luciano Manara, 5
00044 Frascati (Roma) · ITALY
Phone +39 06 94 01 69 1
Fax +39 06 94 01 69 299
ENERCON GmbH · Portugal
c/o Gellweiler, S.A.
Travessa do Alecrim, 3–2°
1200-019 Lisboa · PORTUGAL
Phone +351 21 340 71 60
Fax +351 21 340 71 69
ENERCON GmbH · Spain
València Parc Tecnològic
Av. Juan de la Cierva, 27
46980 Paterna (València) · SPAIN
Phone +34 961 36 62 90
Fax +34 961 36 78 75
20, Pentelis Avenue
15235 Vrilissia, Athens · GREECE
Phone +30 210 683 84 90
Fax +30 210 683 84 89
ENERCON Servis Ltd. Sti.
Bagdat Cad. No 187 A Blok daire 5
Selamicesme Kadikoy
Istanbul · TURKEY
Phone +90 216 385 47 15
Fax +90 216 360 64 92
ENERCON GmbH · Australia
Export Drive
Darwin Business Park Berrimah
0828 Northern Territory · AUSTRALIA
Phone +61 889 47 09 33
Fax +61 889 47 09 25
ENERCON GmbH · Brazil
Wobben Windpower Lda.
Av. Fernando Stecca nº 100
Distrito Industrial CEP 18087450
Sorocaba · São Paulo · BRAZIL
Phone +55 15 21 01 17 00
Fax +55 15 21 01 17 01
ENERCON GmbH · Egypt
c/o Zaki International Trading
23 Kasr El-Nil Street
Cairo 11111 · EGYPT
Phone +20 2 392 36 70
Fax +20 2 417 00 23
ENERCON India Ltd.
Kolsite House, Plot No. 31
Shah Industrial Estate
Veera Desai Road, Andheri (West)
Mumbai 400 053 · INDIA
Phone +91 22 56 92 48 48
Fax +91 22 26 73 00 85
ENERCON GmbH · Canada
Wind Power Inc.
Suite # 222 Lebel Mansion
696 Kettles Street, Pincher Creek
Alberta TOK 1WO · CANADA
Phone +1 403 627 29 23
Fax +1 403 627 32 39