How do Vestas manufacture Nacelles

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How do Vestas manufacture Nacelles
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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
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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 Ringkøbing 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 Ringkøbing V90 3MW,
Hub factories Denmark Ringkøbing V90 3MW, _
Primary factory Prototype, Working instruction
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Nacelles Value Chain
Vestas Nacelles Value Chain
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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
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Vestas Machining - Lem

• Ca. 20,100 m2

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Vestas Generator - Lübeck
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Pictures from Ringkøbing
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Pictures from Leon
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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
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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
Operation 0100 Main foundation Yaw beam Yaw gear
Operation 0200 Crane column
Operation 0300 Gear Main shaft/bearing Hydraulic
station
Front
Operation 0400 Rear section Generator
Operation 0500 Control cabinet Transformer
Operation 0600 Cables Generator finish
Rear
Operation 0700 Assembling of main foundation and
rear Crane finish Cables
Operation 0900 Glass fiber cabin Ready for
shipment
Operation 0800 Final test
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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) 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
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Certificate

• A turbine cant 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 test
• Validation of the calculations.
• Turbine management.
• Performance.

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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 (m5, n107)

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 Fatigue and static strength
Rear section Loads Flex5 Analytic Strength Analytic FEM Fatigue and static strength Welded component
Drive train Loads Flex5 Analytic Strength FEM Fatigue and static strength Welded component
Crane with traverse Loads Analytic Strength Analytic FEM Static strength Welded component
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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 Fatigue and static strength
Main bearing housing Loads Flex 5 Strength FEM Fatigue and static strength
Rotor lock Loads Flex 5 Strength Approved by supplier Static strength
Coupling and breake Loads Flex 5 Strength FEM / Supplier Fatigue and static strength
Gear box torque arms Loads Flex 5 Strength FEM / Supplier 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 14611999 minimum
  local thickness 45 µm
• Thermal spraying acc. ISO 20632005 (ISO
  149192001 ZnAl15) 70 µm
• Thermal spraying acc. ISO 20632005 (ISO
  149292001 ZnAl 15) 50 S3.17
• Indvendig Inside Hub C4
• Hot dip galvanizing acc. ISO 14611999 minimum
  local thickness 85 µm
• Thermal spraying acc. ISO 20632005 (ISO
  149192001 ZnAl15) 110 µm
• Thermal spraying acc. ISO 20632005 (ISO
  149292001 ZnAl 15) 100 S4.20
• Outside Nacelle C5M
• Hot dip galvanizing acc. ISO 14611999 minimum
  local thickness 170 µm
• Thermal spraying acc. ISO 20632005 (ISO
  149292001 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.

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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

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Temperature
Production stop Alarm 19 Ambient temperature
too low      -30 C Alarm 83 Gear oil
temperature too low      -10 C Alarm 94
Nacelle temperature too low       -15 C
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Tower
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Local content percentage distributionon
components
Name 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