Title Reference Date Revision AWEA Small Wind Turbine Performance and AWEA 9.1 December 2009 First edition

Transcription

1 Bl. No. 86, 1198 Qinzhou Road (North), Shanghai, China Telephone: Facsimile: Date Report Number SHA-001 Intertek Project No: SHA Mr. Yiming Wang Ph: (+86) Osiris (Shanghai) Technologies CO., Ltd. Fx: (+86) F3, No.3 Building, No.335 Guoding Road, Yangpu District, Shanghai, P.R.China. Subject: Summary Test Report for the Osiris 10 tested at Upper Fleet Farm, Queensbury in West Yorkshire, UK for duration test and safety and function test, and at Sunite Wind Farm of Inner Mongolia, China for power performance test and acoustic test. Dear Mr. Yiming Wang, This test report summarizes the results of the evaluation and tests of the above referenced equipment to the requirements contained in the following standards: Title Reference Date Revision AWEA Small Wind Turbine Performance and AWEA 9.1 December 2009 First edition Safety Standard Original testing was performed by Narec for duration test and safety and function test, and by Intertek for power performance test and acoustic test. Duration testing was performed from March 17th, 2010 to November 15th, Acoustic testing on the Osiris 10 turbine was conducted under Intertek Project No SHA and performed from July 21st, 2013 to July 22nd, Power performance testing on the Osiris 10 turbine was conducted under Intertek Project No SHA and performed from July 25th, 2013 to September 4th, If there are any questions regarding the results contained in this report, or any of the other services offered by Intertek, please do not hesitate to contact the signatories on this report. Please note, this Test Report on its own does not represent authorization for the use of any Intertek certification marks. Completed test reports for Duration, Power Performance, Acoustic, and Strength and Safety, are required to complete the AWEA certification process. Completed by: Mark Dai Reviewed by: Joseph M Spossey Sales Engineer Title: Technical Supervisor Title: Wind Technical Expert Signature: Signature This report is for the exclusive use of Intertek s Client and is provided pursuant to the agreement between Intertek and its Client. Intertek s responsibility and liability are limited to the terms and conditions of the agreement. Intertek assumes no liability to any party, other than to the Client in accordance with the agreement, for any loss, expense or damage occasioned by the use of this report. Only the Client is authorized to permit copying or distribution of this report and then only in its entirety. Any use of the Intertek name or one of its marks for the sale or advertisement of the tested material, product or service must first be approved in writing by Intertek. The observations and test results in this report are relevant only the sample tested. This report by itself does not imply that the material, product or service is or has ever been under an Intertek certification program. Intertek Testing and Certification Ltd Page 1 of 23

2 Wind Turbine Generator System AWEA Summary Test Report for the Osiris 10 Intertek Testing and Certification Ltd. Page 2 of 23

3 Master Reports Reference Report Report Title Date Author /03 Duration Test Report January 14, 2011 Narec SHA-002 Dynamic Behavior Test Report June 21, 2013 Intertek 3 section 11 of report Safety and Function Test Report January 14, 2011 Narec No. 1603/ SHA-001 Acoustic Noise Test Report August 16, 2013 Intertek SHA-002 Power Performance Test Report September 26, 2013 Intertek SHA-003 Strength and Safety Report September 27, 2013 Intertek Intertek Testing and Certification Ltd. Page 3 of 23

4 1.0 Background 1.1 Background This testing was conducted as part of the full AWEA Certification test program for the Osiris 10 horizontal-axis downwind wind turbine. The duration testing and safety and function testing were performed by Narec on the Evoco 10 turbine for MCS certification, the power performance testing and acoustic testing were performed by Intertek on the Osiris 10 turbine. The Evoco 10 was installed at Upper Fleet Farm, Queensbury in West Yorkshire, UK for duration testing and safety and function testing, and the Osiris 10 was installed at Sunite Wind Farm of Inner Mongolia, China for power performance testing and acoustic testing. The Osiris 10 turbine is identical with Evoco 10 turbine according to manufacturer s declaration, and both the Evoco 10 and Osiris 10 are manufactured by Ginlong/Osiris. Safety and Function Test and Duration Test reports were produced by Narec and accepted by Intertek for the Osiris 10, Power Performance Test and Acoustic Noise Test reports were produced by Intertek. 1.2 Description of the wind turbine The Osiris 10 is rated for operation at 10 kw at wind speeds of 9 m/s. The turbine is a 3-bladed downwind horizontal-axis wind turbine (HAWT) with pitch system. The passive pitch system utilizes the aerodynamic torque of the blades to pitch the blades to regulate the power output, and the electric damping regulates the power output too; the active pitch system will utilize the torque moments produced by actuator to pitch the blades to prevent overspeed of the turbine and generator. The generator is a Ginlong GL-PMG-12K synchronous permanent-magnet generator with a rated voltage of 365 V. There are six GCI-2K inverters in total, these inverters are rated for operation at 2 kw. A summary of the test turbine configuration and manufacturer s declared ratings can be found in Table 1 below. Item Description General Configuration Manufacturer Ningbo Ginlong Technologies Co., Ltd. Type/ technology (Double-fed / Direct-drive / semi- Direct-drive/ others ) Direct-drive Wind Turbine Class (e.g. 1A, 3B, S) II Orientation (upwind / downwind) downwind Rotor Diameter (m) 9.7 Hub Height (m) Turbine Serial Number Performance Rated Electrical Power (kw) 10 Rated Wind Speed (m/s) 9 Cut-in Wind Speed (m/s, 10 min. mean) 3 Cut-out Wind Speed (m/s, 30 sec. mean) 25 Cut-out Wind Speed (m/s, 1 sec. mean) 35 Calculated lifetime [y] 20 Ambient temperature range for operation [ C] -30 C 50 C Annual average wind speed Vave (10 min) [m/s] 8.5 Reference wind speed Vref (10 min) [m/s] year extreme wind speed Ve50 (3s) [m/s] 59.5 Rotor Number of Blades 3 Swept Area (m 2 ) 73.9 Intertek Testing and Certification Ltd. Page 4 of 23

5 Rated Rotational Speed (rpm) 120 Design Maximum Rotational Speed (rpm) 140 Rotor Hub Type (e.g. rigid, teeter) rigid Coning Angle (deg) 5 Tilt Angle (deg) 0 Rated Blade Set Angle (deg) 19 Direction of Rotation (clockwise or counterclockwise looking downwind) clockwise Blade Manufacturer Ningbo Ginlong Technologies Co., Ltd. Model GL-BLADE-10K Length (m) 4.35 Material / Construction Fiberglass carbon fiber reinforced composite Mass (kg) 40 Tip speed (m/s) 60.9 Blade Serial Number C C C Pitch System Manufacturer Ningbo Ginlong Technologies Co., Ltd. Model GPC-01 Drive (electric, hydraulic) electric Maximum blade angle 15 Rated pitch speed 0.5 /s Max. pitch speed 0.5 /s Pitch controller serial number Generator Manufacturer Ningbo Ginlong Technologies Co., Ltd. Model GL-PMG-12K Type/technology Permanent magnet generator Rated voltage 365 V Rated power / speed 10 KW Speed range rpm Number of poles 12 Stator rated current 27.5 A Rotor rated current NA Generator insulation class H Class Generator Phase Connection (Delta/Wye) Y Size Φ IP Protection IP55 Cooling Natural cooling Power factor 0.91 Generator Serial Number GL-PMG12KBH Inverter Manufacturer Ningbo Ginlong Technologies Co., Ltd. Model GCI-2K(for three phase) Type/technology Full power Voltage range of Grid-side converter VAC(for three phase) Frequency range of Grid-side converter Hz Capacity of Grid-side converter 10 KW Intertek Testing and Certification Ltd. Page 5 of 23

6 Rated current of Grid-side converter 14.5 AAC(for three phase) Rated voltage of Generator-side converter 400 VDC Frequency of Generator-side converter NA Capacity of Generator-side converter 12 KW Rated current of Generator-side converter 27.5 ADC(Rectified) Cooling method air cool IP Protection IP65 Convertor Serial Number A A A A A A Control / Electrical System Power Regulation (e.g. pitch, stall, active stall) Pitching & Dump Load Over speed Control (e.g. tip brake, pitch, mech. Pitching brake) Controller description Controller (GCB-20K) & Pitch Controller (GPC-01) Safety Chain description Pitching & Dump Load controller serial number Braking System Parking / Service Brake: manufacturer, type, Method: Electrical pitching (through HMI location on the pitch controller) + short-circuit brake (through generator short circuit breaker located in the controller box): Ningbo Ginlong Technologies Co., Ltd. Normal Shutdown Brake: manufacturer, type, location Emergency Shutdown Brake: manufacturer, type, location and torque time history Tower Tower Type (lattice, tubular steel, tubular concrete), manufacturer Height (m) Diameter of head flange Diameter of bottom flange Table 1 Test Turbine Configuration Alternative method: Manual pitching (through pitching handle on the downtower)+ short-circuit brake (through generator short circuit breaker located in the controller box): Ningbo Ginlong Technologies Co., Ltd. Method: Electrical pitching (through HMI on the pitch controller): Ningbo Ginlong Technologies Co., Ltd. Emergency stop pushbutton (on the pitch controller) + short-circuit brake (through generator short circuit breaker located in the controller box): Ningbo Ginlong Technologies Co., Ltd. Tubular steel 12m Φ380 mm Φ900 mm Intertek Testing and Certification Ltd. Page 6 of 23

7 2.0 Objective The purpose of this test report is to provide a summary of the following: Section Summary Results Reference Power Performance Test Summary Acoustic Test Summary AWEA Rated Annual Energy AWEA Rated Sound Level AWEA Rated Power Wind Turbine Strength and Safety Summary Tower Design Summary Duration Test Summary Table 2 Report content Note 1: Reference AWEA 9.1 Small Wind Turbine Performance and Safety Standard December 2009 Intertek Testing and Certification Ltd. Page 7 of 23

8 3.0 Power Performance Test Summary Below is a summary of the power performance test results. Table 3 shows the tabulated power performance results with measurement uncertainty, and Figure 1 shows the power curve normalized to sea-level air density. Measured power curve(database A) Bin no. Reference air density:1.225kg/m^3 Hub height wind speed[m/s] Power Output[kW] Cp No. of Datasets(1 min. avg.) Uncertainty Category A(kW) Uncertainty Category B(kW) Combined Uncertainty(kW) Manufacture: Osiris Total Number: Report Date: Sep 2013 Standard Power Output: Diameter of Wind Turbine: 1 min Averages 10 kw 9.7 m Table 3 Performance at sea-level air density for the Osiris 10; kg/m 3 Source: Reference 5 from page 3 Intertek Testing and Certification Ltd. Page 8 of 23

9 Figure 1 Normalized Power curve and Coefficient of performance at sea-level density for the Osiris 10; kg/m 3 Source: Reference 5 from page 3 Intertek Testing and Certification Ltd. Page 9 of 23

10 4.0 Acoustic Test Summary Below is a summary of the test results for the Osiris 10 wind turbine noise over a range of wind speeds and directions. Characterizations or the turbines apparent sound power level and 1/3 octave bands are made. Figure 2 below shows the measured data pairs. The method of bins was used to calculate the bin average turbine and background sound pressure level. The sound pressure levels at the integer wind speeds were interpolated between bins. The background correction was then applied to the bin averaged values at the integer wind speeds. Figure 2 Ls+n & Ln against 10m height wind speed for the Osiris 10 Source: Reference 4 from page 3 Figures 3 through 4 show the A-weighted one-third octave spectra were calculated for each bin. For several wind speeds, at the high and low frequencies, the separation between turbine and background was insufficient to report a value. Only spectra for bins, in which at least 10 data points were recorded for both turbine and background, are reported. For bands that have no value listed, the difference between the overall noise and the background noise was less than 3dB. Intertek Testing and Certification Ltd. Page 10 of 23

11 Figure 3 One-third octave spectra (4m/s-7m/s) Source: Reference 4 from page 3 Figure 4 One-third octave spectra (8m/s-11m/s) Source: Reference 4 from page 3 Intertek Testing and Certification Ltd. Page 11 of 23

12 Tables 4 and 5 below show one-third octave results and associated uncertainties in tabular format for acoustic testing results. Freq [Hz] Ls 4m/s 5m/s 6m/s 7m/s Uc Ls Uc Ls Uc Ls Uc * * * * * * * * * * * * * * * Table 4 One-third octave spectra in db (A) for several integer wind speeds (4m/s~7m/s) in 10 m height Source: Reference 4 from page 3 Intertek Testing and Certification Ltd. Page 12 of 23

13 Freq [Hz] Ls 8m/s 9m/s 10m/s 11m/s Uc Ls Uc Ls Uc Ls * * * * * Uc * * * * * * * * * * * Table 5 One-third octave spectra in db (A) for several integer wind speeds (8m/s~11m/s) in 10 m height Source: Reference 4 from page 3 Intertek Testing and Certification Ltd. Page 13 of 23

14 5.0 AWEA Rated Annual Energy Table 6 below summarizes the estimation of expected annual energy production (AEP) at sea-level air density. Estimated annual energy production, database A (all valid data) Hub height annual average wind speed (Rayleigh) m/s AEP-measured kwh Reference air density:1.225kg/m^3 Standard Uncertainty in AEP-measured kwh % AEP-extrapolated kwh Complete if AEP measured is at least 95% of AEP extrapolated Complete Complete Complete Complete Incomplete Incomplete Incomplete Incomplete Manufacture: Osiris Standard Power Output: 10 kw Diameter of Wind Turbine: 9.7 m Table 6 Estimated annual energy production of the OSIRIS 10 at sea-level air density Source: Reference 5 from page 3 An indication of incomplete in the far-right column of Table 6 does not imply that the database for the test is incomplete. Incomplete means that AEP-Measured is not within 95% of AEP-extrapolated. AEP-extrapolated is an estimated extrapolation of annual energy production, where: AEP-Measured assumes zero power below cut-in wind speed and between the highest valid wind speed bin and cut-out wind speed, and AEP-Extrapolated assumes zero power below cut-in wind speed and constant power between the highest valid wind speed bin and cut-out wind speed. From the above table: AWEA Rated Annual Energy 23,704 kwh Intertek Testing and Certification Ltd. Page 14 of 23

15 6.0 AWEA Rated Sound Level The AWEA Rated Sound Level, L AWEA, is the sound level that will not be exceeded 95% of the time, assuming an average wind speed of 5 m/s (11.2 mph), a Rayleigh wind speed distribution, 100% availability, and an observer location 60 m (~ 200 ft.) from the rotor center. That means the sound pressure level at a distance of 60 m and at a wind speed of 9.8 m/s using the equation (9) in IEC of the sound power level. First, the sound pressure level at 9.8 m/s is obtained interpolating between the 9 & 10 m/s bins. Then L AWEA is calculated using the following equations: L L WA,(9.8m / s) AWEA = L = L S (9.8m / s) WA,(9.8m / s) log 10 log 2 ( 4π 60 ) 2 ( 4πR ) Using the equations above: AWEA Rated Sound Level, L AWEA : 49.4 db(a) Table 7 gives the calculated apparent sound power levels, with the combined uncertainty for each integer wind speed. V s L s+n [db] L n [db] L aeq,c,k [db] L WA,k [db] U C [db] *35.2 * *57.5 * **56.2 ** **58.0 ** **58.0 ** *62.0 * *63.3 * *64.0 * Table 7. Apparent sound power level. Source: Reference 4 from page 3 If the equivalent continuous sound pressure level of the wind turbine plus background noise, Ls+n, is less than 6 db but more than 3 db higher than the background level, Ls+n is corrected by subtraction of 1.3 db, but the corrected data points are marked with an asterisk, *, in the table above. These data points are not used for the determination of the apparent sound power level or directivity. If the difference was less than 3 db, no data points are required to be reported, and it shall be reported that the wind turbine noise was less than the background noise. In this report, these data points are shown for informational purposes only, and are marked in Table 7 with two asterisks, **. 1 Intertek Testing and Certification Ltd. Page 15 of 23

16 7.0 AWEA Rated Power The AWEA Rated Power is the wind turbine s power output at 11 m/s (24.6 mph) per the power curve from IEC From Table 3 above: AWEA Rated Power: 9.81 kw 8.0 Strength and Safety Test Results The Osiris 10 design file was evaluated during the months of April to July The design file is with regards to simplified load model compliance. The design file indicates ultimate and fatigue loading analysis, as well as final material and load factors of safety, for the Osiris 10 horizontal-axis wind turbine. The design file was found to be in compliance with all requirements of the above referenced standard regarding structural design. All supporting documentation is maintained within the project file. Strength and Safety of the Osiris 10 was confirmed via the combination of the Narec Safety and Function Test Report (section 11 of Report No. 1603/03) in compliance with clause 9.6 of IEC Wind Turbines Part 2: Design requirements for small wind turbines; second edition dated March 2006, and the Intertek Mechanical system Report (Report No SHA-001) for the design documentation and calculation provided by Osiris with the structural design requirements of the above referenced standard. The Osiris 10 has met all of the design requirements for a Class II small wind turbine. Intertek report No SHA-003 provides full detail on strength and safety of the Osiris Tower Design Requirements The report of tower design requirements has been supplied by Osiris. The following tables summarize the tower connections, tower top loads and tower data from Osiris 10 tower design requirements. Tower Type Outer diameter of yaw flange connected to tower top Diameter of bolt circle tubular steel 338 mm 300 mm Minimum blade and tower 595 mm clearance Maximum allowable tower top 110 mm deflection Table 8 Tower design data for the test turbine for the Osiris 10 Intertek Testing and Certification Ltd. Page 16 of 23

17 Drawings of mechanical and electrical connections Main cable needs 10 mm 2 4 core SWA cable and other signal wire and Electrical cable pitch power cable needs 2 mm 2 5 core SWA cable. Table 9 Mechanical and electrical connections of tower for the Osiris 10 Wind turbine type - Osiris 10 F x-shaft (N) Maximum tower top forces Load Case:H Maximum tower top bending moment(fore-aft) Load Case:B Maximum tower top bending moment(sideside) Load Case:G * formula (44) in the IEC standard. F tower (N) C f 1 ρ 2 Ve50 Aproj * 2 F front,nacelle (N) 2114 M shaft (Nm) M x-shaft (Nm) Table 10 Maximum tower top loads for the Osiris 10 Intertek Testing and Certification Ltd. Page 17 of 23

18 10.0 Duration Test Summary 10.1 Operational Time The duration test was started on March 17, The duration test was completed on November 15, 2010, after sufficient data was collected to satisfy the hourly test requirements 10.2 Months of Operation The duration test was conducted over a period of 8 months, or 243 days, from March 17, 2010 through November 15, Hours of Power Production Table 11 below indicates the number of power production hours that were observed during the 8 month test duration Operational Time Fraction Hours of Power Production IEC SWT Class II { 8.5 m/s Vave} Wind Speed Measured Required Pass/Fail > cut in Pass > 1.2 V ave Pass > 1.8 V ave 29 hrs 10 mins 25 Pass > 15 m/s 33 hrs 20 mins 25 Pass Table 11 Duration test hourly power production results for the Osiris 10 The operational time fraction is defined by the following equation: where: T T is the total time period under consideration, T N is the time during which the turbine is known to be non-operational, T U is the time during which the turbine status is unknown, and T E is the time which is excluded in the analysis. The overall operational time fraction of the combined wind turbine system in the total test period was 99.60%. The pass criteria for this parameter is 90% (IEC Wind turbines Part 2:Design requirements for small wind turbine Clause ); therefore the Osiris 10 is deemed to PASS the Duration Test. Intertek Testing and Certification Ltd. Page 18 of 23

19 Table 12 below displays the values that were used for determination of overall operational time fraction. Operational Time Fraction Values Variable Hours T T T N 21 T U T E 65.4 Table 12 Hourly results for operational time fraction values for the Osiris 10 The operational time was 21 hours during which the turbine was non-operational (T N ). Total operational time amounts to hours. As for the time excluded from the analysis, T E, which totalled 65.4 hours, the most prominent problem was due to failure of the grid. It was observed that these failures occurred almost always at the same time. This happened because the circuit breaker protecting the wind turbine disconnected the circuit when the public lighting of the wind farm control booth was switched on for the adjacent wind farm. Likewise, some T E data have been discarded since other tests were being performed while collecting data for the test duration. Some time lost due to DAS inspection was also detected. There were hours of unknown time (T U ). A majority of this time is believed to be due to loss of data from damage to sensor wires from livestock. Narec report 1603/03 provides full details of this analysis Environmental Conditions In order to understand environmental conditions over the testing period, several wind speed statistics were required by the Standard. These values are summarized in Table 13 below. Environmental Conditions During Test Period Description Value Highest instantaneous wind speed m/s Average turbulence intensity at 15 m/s 0.96% Table 13 Environmental conditions during test 10.6 Power Degradation In accordance with section of IEC , the power output in each wind speed bin was plotted over the test duration, and a linear regression line applied to determine if any power degradation is apparent over time. Accordingly several of these plots are reproduced below and on the following pages, which are in the range of 4m/s to 14m/s with the trend line equations shown in red text. Note that these scatter plots have been produced using 1 minute average data rather than 10 minute average, to give a higher resolution particularly at the higher wind speeds. Intertek Testing and Certification Ltd. Page 19 of 23

20 Figure 5 Plot of Power Degradation vs Time Between 4m/s & 5m/s Figure 6 Plot of Power Degradation vs Time Between 5m/s & 6m/s Figure 7 Plot of Power Degradation vs Time Between 6m/s & 7m/s Intertek Testing and Certification Ltd. Page 20 of 23

21 Figure 8 Plot of Power Degradation vs Time Between 7m/s & 8m/s Figure 9 Plot of Power Degradation vs Time Between 8m/s & 9m/s Figure 10 Plot of Power Degradation vs Time Between 9m/s & 10m/s Intertek Testing and Certification Ltd. Page 21 of 23

22 Figure 11 Plot of Power Degradation vs Time Between 10m/s & 11m/s Figure 12 Plot of Power Degradation vs Time Between 11m/s & 12m/s Figure 13 Plot of Power Degradation vs Time Between 12m/s & 13m/s Intertek Testing and Certification Ltd. Page 22 of 23

23 As can be seen from the foregoing scatter plots, the power output of the turbine remains effectively constant within each wind speed bin, until the wind speed reaches approximately 9m/s. At this wind speed a small amount of degradation in power output starts to become noticeable, and even more so with each increase in speed, as can be seen in Figure 11, Figure 12, and Figure 13. Although further detail investigation has not been undertaken, it is felt that this may be due to ageing of the blade pitch spring mechanism. The springs themselves are identified within the manufacturers user manual as a service part, currently scheduled for replacement after a 5 year service life, although this may need to be reconsidered dependent upon projected lifespan and turbine performance Dynamic Behavior During the period of 4 June, 2013 to 12 June, 2013, the turbine and tower were observed for any potentially harmful turbine or tower dynamics by Intertek. The turbine was observed over a wide range of wind speeds. During these observations there was no presence of any observable problems. Here are the observations reports of dynamic behavior: 4 June 2013 The wind turbine was observed to operate at the wind speed of 4-6 m/s from 14:00 to 16:00. There was no excessive vibration. The generator operated smoothly with hums audibly; 7 June 2013 The wind turbine was observed to operate at the wind speed of 8-14 m/s for about one hour from 13:00 to 14:00. There was no observable excessive vibration. In this wind speed range, the turbine tracks wind well; 12 June The turbine was observed to operate in 3m/s- 21m/s throughout the day (10:00 to 17:30). At low wind speeds (wind speed less than 8m/s), the wind turbine operated smoothly and tracked the wind direction well. At high winds, the rotor operated steady and tracks the wind direction well. Overall, there did not appear to be any excessive vibrations. Observation time lasted for two hours below 10 m/s, for one hour above 15 m/s and for 8 minutes near 20m/s. Data Wind speed Duration time (minute) m/s m/s m/s m/s m/s 8 Total Time 127 Table 14 Dynamic behavior observe time statistics Source: Reference 2 from page 3 Intertek report SHA-002 provides full details of this analysis Post-Test Inspection The post test inspection was performed on December 06, There were no significant findings that would relate to excessive wear, degradation, or corrosion that would lead to potentially harmful situations over the expected 20 year life of the Osiris 10. Detailed explanation of post-test inspection results can be found in Narec report 1603/03. Intertek Testing and Certification Ltd. Page 23 of 23