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Suzlon Energy Ltd.

1 S128 – Mexico WindPower 2017

© 2017 by Suzlon Energy Limited. All rights reserv ed

Suzlon Energy Ltd.



Agenda • Suzlon Technology

• Suzlon product evolution towards S128

• Critical drive train design features

4-point rotor suspension

Main bearing O-layout

Casted main shaft

Drive train assembly

High Speed + DFIG vs. Medium Speed + Full converter

• Q & A

Suzlon Energy Ltd.



Suzlon Technology

Suzlon Energy Ltd.



Suzlon Technology Locations & Skills

Germany Hamburg - Management - Development & Integration - Certification

Rostock - Development & Integration - Design & Product Engineering - Innovation & Strategic Research

The Netherlands

Hengelo - Blade Design and Integration

India Pune - Design & Product Engineering - Turbine Testing & Measurement - Technical Field Support

Vadodara - Blade Testing Center

Denmark Aarhus Vejle

- SCADA - Blade Science Center

Over 400 Technology Professionals in Germany, Netherlands, India & Denmark

Hamburg

Ham

burg

R

ost

ock

H

enge

lo

Pune

A

arhu

s

Suzlon - Technology

Suzlon Energy Ltd.



Seamless collaboration of teams is key to the success

SG1 SG2 SG3 SG4 SG5 SG6 SG7 SG8 SG9 SG10

B-Components and detailed parts

System and Main components

WTG Development &

Integration

Platforms

Design and Product Engineering Test,

Verification &

Integrity Technical Fleet Services

Technical Advisory

Innovation & Strategic Research

Technical Guidance & Support

Coordination & Control

Suzlon – Development process

Suzlon Energy Ltd.



45% of installations outside India are in USA

Suzlon - 15 GW of installations worldwide

Suzlon Energy Ltd.



S52 - S82 S88 S9X S97 – 120 S111 S128 DFIG S128 MS

MW Rating 0.6 – 1.5

MW 2.1 MW 2.1 MW 2.1 MW 2.1 MW 2.6 MW 3.0

Hub Height Available

75m 80-100m 80/90m 120m 90-140m 90/140m 90/120m

Wind Class IEC II A /

IIIA IEC II A IEC II A IEC III A IEC III A IEC III A IEC II A

Global Installation

7.1 GW 5.7 GW 1.9 GW 600 MW >500 MW

Sold Proto

assembly In design

Rotor Diameter 52-82 m

Hub Height 75 m

Rotor Diameter 88 m

Hub Height 90 m

Rotor Diameter 95 / 97 m

Hub Height 90 m

Rotor Diameter 97 m

Hub Height 120 m

Rotor Diameter 128 m

Hub Height 90 - 140m

Rotor Diameter 111 m

Hub Height 120 m

20 Years of “Hard Work & Innovation”

Technology Evolution - 600 kW to 3.0 MW

Suzlon Energy Ltd.



Critical drive train design features

Suzlon Energy Ltd.



New platform in development – 30%+ more yield

3 models optimized for its target market sharing a common concept & blade

Low wind Site specific & class III turbine Class II

Attribute India site spec. 60Hz Version for USA All Geographies

S128-2.6 S128-2.6 S128-3.0

Rotor (m) 128 128 128

Rating (MW) 2.6 2.6 3.0

Noise <105dBA* <105dBA*

Wind conditions

Class S India spec. Vavg=7.25m/s, Vref=37.5m/s

max.1.16kg/m³

Full Class IIIA Full Class IIA

Gear Box (GB ) 3 Stage 2 stage

Blade SB63 – hybrid carbon/glass fibre blade

Generator 50 Hz, 6 pole, DFIG 60Hz, 6 pole, DFIG Medium Speed, full

conversion

S128 Platform: Configuration overview

Suzlon Energy Ltd.



Medium Speed Concept 3.0MW

2 Stages Gear box (same base design like 3 stage)

Medium Speed Generator Electrically Excited Synchronous Generator (EESG)

Or (fully interchangeable) Permanent Magnet Generator (PMG)

Full Scale Converter

Small support girder for cabinets

High Speed Concept 2.6MW

3 Stages Gear box

DFIG Generator

Coupling between the generator and gear box

Partial converter

Large Girder for full generator support

S128 Medium Speed vs. High Speed

4 point suspension with casted shaft

Low RPM concept

Suzlon Energy Ltd.



1st MB 2nd MB Coupling Shrink D GB GEN coupling GB Mounts Rotor Shaft

S128 2.6 vs. S111 drive train

Suzlon Energy Ltd.



S111 - 3 Point Suspension

S111

Not Overdetermined system:

Bearing points coupling does not matter

bending moment and vertical forces

transferred to gear box

Suzlon Energy Ltd.



S128 2.6 - 4 Point Suspension

S128 2.6

Overdetermined system:

Bearing points coupled by main frame

elasticity

Reduced bending moment and vertical

forces on gear box

Suzlon Energy Ltd.



S128 3.0 – 4+1 Point Suspension

1

2

3

4 MB1

MB2

GBM1

GBM2

WS 5

Fx

Overdetermined system:

Bearing points coupled by main frame elasticity

Reduced bending moment and vertical forces on gear box

Additional Weight Support (WS) in comparison to S128 2.6

Suzlon Energy Ltd.



S128 – 2 Main Bearings

4-point rotor suspension system uses two

single row tapered roller bearings in O-arrangement

Suzlon Energy Ltd.



Main bearing mounting – 4 point susp.

Mounting step

- Step 1: - Rotate frame 180° that yaw flange is on top - To be settled on a support rack and transported

to assembly plant for mounting

- Step 2: - Mounting of the outer main bearing rings in

horizontal position.

Suzlon Energy Ltd.



Main bearing mounting – 4 point susp.

Mounting step

- Step 3: - Jig on the rear of the main frame - Approximate height of main frame on rack ~6.5 m - Step 4 - Assembling in vertical position - Rotating shaft on table

Suzlon Energy Ltd.



Components:

• 3 phase 3 winding system

• Machine side converter – diode

operation

• 3 independent stages PMSG

~900V AC

~1200V DC

690V AC OUTPUT TO TRAFO

Advantages:

• 3 MVA STATCOM capabilities

• 3 independent ACB protection

• Active and reactive power control

• Increased availability and redundancy

• No spend on extra park equipment

S128 3.0 full scale converter topology

Suzlon Energy Ltd.



The SUZLON Software portfolio covers:

• SC Trinity

• Reporting

• Online monitoring

• 24/7 monitoring

• Configuration management

• Enterprise customer interfaces (Hist. data & Online) etc.

• SC-Commander

• SC-Power Plant Controller

SUZLON SC Trinity SCADA

SUZLON has a centralized SCADA Server platform

Suzlon Energy Ltd.



• Designed and manufactured by Suzlon

• New generation profiles from Risø Technical University of Denmark, rigorously tested in the wind tunnel facility in France

• Long slender blade design with a pre-bent

• Improved Lift to Drag ratio & lighter weight

• Use of Carbon Girder & High Tensile Glass

• Performance enhanced with vortex generators

• Superior leading edge protection coating for longer maintenance cycles and less wear & tear

Thick Airfoils towards the root for high structural strength

Thin Airfoils along the tip for high lift/drag ratio

SB63 Rotor Blades: Key Features

Designed and manufactured by Suzlon using latest profiles and materials

Suzlon Energy Ltd.



First key components for India version are already built

Type certificate targeted for beginning 2018

S128 2.6MW in manufacturing

Hub pattern

Casted main shaft

Blade main mould

converter

Suzlon Energy Ltd.



Benefits of design advances

129m carbon girder rotor Higher AEP : 15109 MWh/a

Full power converter Global grid compatibility and FRT capabilities

Integrated Medium Speed drive train Reduced life cycle cost (low OMS cost)

4-point rotor suspension Higher availability (no bending on GB)

Towers hub heights up to 140m more site viable

SC Trinity SCADA and Visualization Higher availability (more effective OMS)

Low rotor RPM Standard Sound power level below 105dB(A)

Suzlon Energy Ltd.



Suzlon wind farm in Paracuru, Brazil

Thank you

Suzlon Energy Ltd.



The information contained in this presentation is the property of Suzlon Energy GmbH and Suzlon Energy Limited India. This presentation and extracts thereof may only be duplicated or forwarded to third parties following explicit written approval by Suzlon Energy GmbH and Suzlon Energy Limited India. All product names used in this documentation are trademarks or otherwise protected by law, even if not specifically indicated. © 2017 by Suzlon Energy Limited All rights reserved.

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