How do Vestas manufacture Nacelles

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

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

_ = Primary factory: Prototype, Working instruction
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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: Ringkbing V80 2MW

China (2007): Tianjin V80 2MW _ = Primary factory: Prototype, Working instruction
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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: Ringkbing V90 3MW, Hub factories: Denmark: Ringkbing V90 3MW, _ = Primary factory: Prototype, Working instruction

Nacelles Value Chain

Vestas Nacelles Value Chain

Foundries Generators Machining Assembly and test

Vestas Nacelles production facilities

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

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Vestas Castings
Vestas Castings: Magdeburg, components up to 11 ton Kristianssand, components up to 20 tons Guldsmedshyttan components up to 40 ton

Vestas Machining - Lem

Ca. 20,100 m2

Vestas Generator - Lbeck

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Pictures from Ringkbing

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Pictures from Leon

Viveiro V82 Len V90 2MW

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Pictures from Viveiro

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Pictures from Taranto

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Pictures from Chennai

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Pictures from Tianjin

Beijing Tianjin

TEDA WEST

Shanghai

Shenzhen

Guangzhou

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Pictures from Tianjin

Land approx. 50.000 sqm Buildings approx. 13.000 sqm.

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Pictures from Viborg (1)

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Factory Viborg
LEAN-Production in Viborg (15-18 turbines/week): 6 step (2x3 parallel + 3) 1 step takes 6 hours. Target is 4 hours

Front

Operation 0100 Main foundation Yaw beam Yaw gear

Operation 0200 Crane column

Operation 0300 Gear Main shaft/bearing Hydraulic station

Rear

Operation 0400 Rear section Generator

Operation 0500 Control cabinet Transformer

Operation 0600 Cables Generator finish

Operation 0700 Assembling of main foundation and rear Crane finish Cables

Operation 0800 Final test

Operation 0900 Glass fiber cabin Ready for shipment

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Pictures from Viborg (2)

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Pictures from Viborg (3)

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Pictures from Viborg (4)

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Pictures from Viborg (5)

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Pictures from Viborg (6)

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Pictures from Viborg (7)

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Pictures from Viborg (8)

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Pictures from Viborg (9)

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Pictures from Viborg (10)

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Pictures from Viborg (11)

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Pictures from Viborg (12)

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Pictures from Viborg (13)

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Pictures from Viborg (14)

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Pictures from Viborg (15)

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Pictures from Skagen (1)

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Pictures from Skagen (2)

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Pictures from Skagen (3)

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Responsibility

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Drawing system
Drawing system: Pro/E Archives system: Intralink 3D Assembly drawing

3D Part drawing

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Drawing system
Assembly drawing

Production drawings

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Structure
V80 - 76 Variants: V80/V90, 50 Hz/60Hz, Ral 7035/9010, VCS/VRCC etc.
Level 1 (Nacelle) Level 2 (Main module) 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
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Level 3 (Sub module)

Level 4-x (Assembly)

Certificate
A turbine cant be erected without a certificate. Certificates can be issued by GL, DNV and TV 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 test Validation of the calculations. Turbine management. Performance. Noise. Grid compatibility.

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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/s Annual average for 80 m V = 10 m/s Turbulence 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

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Transport Loads

-Transport

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Certificate Main parts

Component Approval Issue

Hub

Loads: Flex 5 Strength: FEM

Fatigue and static strength Deformations by the bearings.

Machine frame

Loads: Flex 5 Strength: FEM

Loads: Flex5 + Analytic Strength: Analytic + FEM Loads: Flex5 + Analytic Strength: FEM Loads: Analytic Strength: Analytic + FEM

Fatigue and static strength

Rear section

Fatigue and static strength Welded component Fatigue and static strength Welded component Static strength Welded component

Drive train

Crane with traverse

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Certificate Main parts

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Certifikate Small parts

Component Approval Issue

Bearings

Loads: Flex 5 Strength: Approved by supplier Loads: Flex 5 Strength: FEM Loads: Flex 5 Strength: Approved by supplier Loads: Flex 5 Strength: FEM / Supplier Loads: Flex 5 Strength: FEM / Supplier

Fatigue and static strength

Main bearing housing Rotor lock

Fatigue and static strength

Static strength

Coupling and breake Gear box torque arms

Fatigue and static strength

Fatigue and static strength

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The rest
1000 drawings of different parts for one Turbine
For example: Tread plates Glass fiber cabinet/nose cone support Support for hydraulic and electrical parts Coolers Ladders Anemometer Cover plates Hatches Etc.

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

Chinese supplier
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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

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Design - PE
Drawing head - assembling:

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

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Design - PE
Drawing head - part:

Verdana 12 pt, font colour white

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Design - PE
Make it cheaper The redesign displayed below gives savings of 10.000 DKK/week in Viborg

Verdana 12 pt, font colour white

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Design - PE
Improve assembling.

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Design - PE
Improve drawings - GPS

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Design - PE
Improve drawings GPS 3D measuring (Tolerance 0,003)

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Design - PE
Improve drawings GPS Lasertracker

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Design - PE
See failures before they occur

Fatigue crack

Verdana 12 pt, font colour white

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Remember: Fatigue

Verdana 12 pt, font colour white

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Remember: Fatigue

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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.

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NCR - PE

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Surface treatment
Inside Nacelle: C3 Hot dip galvanizing acc. ISO 1461:1999 minimum local thickness 45 m Thermal spraying acc. ISO 2063:2005 (ISO 14919:2001 ZnAl15) 70 m Thermal spraying acc. ISO 2063:2005 (ISO 14929:2001 ZnAl 15) 50 + S3.17

Indvendig Inside Hub: C4 Hot dip galvanizing acc. ISO 1461:1999 minimum local thickness 85 m Thermal spraying acc. ISO 2063:2005 (ISO 14919:2001 ZnAl15) 110 m Thermal spraying acc. ISO 2063:2005 (ISO 14929:2001 ZnAl 15) 100 + S4.20

Outside Nacelle: C5M Hot dip galvanizing acc. ISO 1461:1999 minimum local thickness 170 m Thermal spraying acc. ISO 2063:2005 (ISO 14929:2001 ZnAl 15) 100 + S7.02

Verdana 12 pt, font colour white

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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 the Quality of the product, Environment, Safety Assurance Legislation prescribes calculations, safety evaluations, production documentation B-item are items (including catalogue items), that defects only marginally affect the Product quality, Environment Safety 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 affects Environment Production quality Defects and lacks will bee corrected before use.

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Material - Welding - Cast

Quality requirements - Welding Depending 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 turbine The 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 MPa Strength of aluminium may be reduced with max. 20% Strength of other materials may be reduced with max. 10%

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Temperature

Production stop: Alarm 19: Ambient temperature too low Alarm 83: Gear oil temperature too low Alarm 94: Nacelle temperature too low

: -30 C : -10 C : -15 C

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Tower

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Local content percentage distribution on components

Name of component NDRC [%] 16.9 7.2 4.4 7.4 22.5 15.4 3.4 4.2 1.3 3.5 3.5 2.2 3.0 1.0 4.1 4,0 8.0 19.0 15.0 4.0 7.0 5.0 3.0 16.0 2.0 3.0 5.0 Possible NDRC [%] 9.0

Tower Electrics in Wind Farm Nacelle cover Generator Blade Gearbox Main shaft, (incl. Bearings, coupling) Hub (incl. Pitch regulated system) Yaw system Central control and monitoring system Electrical control sys. (SCADA) incl. inverter Hydraulic system General assembly Spareparts Others

SUM

100.0

100.0
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