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China National Offshore Installation Helps Huaneng Make Key Technical Breakthroughs in Localizing Large Capacity Offshore Wind Turbines!

China National Offshore Installation Helps Huaneng Make Key Technical Breakthroughs in Localizing Large Capacity Offshore Wind Turbines!


China National Offshore Installation Helps Huaneng Make Key Technical Breakthroughs in Localizing Large Capacity Offshore Wind Turbines! North Star Wind Power Network News: As July 1st approaches, China Huaneng Group's Shengdong Rudonghai Wind Power Project site is exceptionally busy. The domestically produced 5 megawatt large capacity offshore wind turbine, jointly developed by China Huaneng and China National Offshore Installation Corporation, is undergoing intensive debugging work.

This offshore "giant" has achieved a 100% localization rate of primary components and a complete machine localization rate of over 95%, representing the highest level of localization of large capacity offshore wind turbines in China. With a significant breakthrough in the localization of key equipment for offshore wind turbines, it is a tribute to the centenary of the founding of the Communist Party of China.

Seizing New Opportunities for Innovative Development

The development situation of offshore wind power is promising, with a decade of rapid development, rich experience accumulated, and many challenges faced. Now, we need to be problem oriented, seize opportunities, and embark on a path of independent innovation. "said Li Weidong, Secretary of the Party Committee and Chairman of the Huaneng Clean Energy Technology Research Institute.

China's offshore wind power is growing rapidly, and the cumulative installed capacity of offshore wind power has become the second largest in the world by the end of 2020. It is expected to reach the world's first by the end of this year. For the operating units, research institutions, and manufacturers in China's offshore wind power industry chain, this is a rare opportunity that drives all participants in the offshore wind power industry, including owners, research institutes, host manufacturers, and component manufacturers, to unite and explore every technology to the extreme. At the same time, the mastery of key technologies for offshore wind turbines is receiving increasing attention, and attempts to localize key components have gradually become a focus of attention.

Achieve new breakthroughs in technological research

As one of the largest offshore wind power developers in China, China Huaneng Group continues to carry out a lot of work, play the role of "chain leader" in the industrial chain, form an innovative consortium, and consider the future development of China's offshore wind power from the perspective of the overall industrial chain. Through detailed evaluation and demonstration, the localization of large-scale offshore wind turbines will be one of the important measures for the future development of offshore wind power in China, and also an important guarantee for national energy security.

In response, Huaneng Group has established a domestically produced offshore wind turbine development project, focusing on the industry's technological advantages, leveraging organizational functions, forming an overall effect, and breaking through key technologies for the localization of offshore wind turbines. Relying on the Huaneng Clean Energy Technology Research Institute (hereinafter referred to as "Huaneng Qingneng Institute"), we have collaborated with multiple technical units such as China National Offshore Engineering Corporation to carry out the research and production of domestically produced units, and have demonstrated their application at the wind farm in Shengdong, Jiangsu, China. During the development process of the unit, strong support was received from Huaneng Jiangsu Company and Xi'an Thermal Engineering Research Institute, as well as assistance from Huaneng Zhejiang Company.

Domestically produced offshore wind turbines are catching up with the peak delivery period in 2021, and every link from upstream component suppliers to downstream unit assembly and offshore lifting is under tremendous pressure. With the arrival of the peak delivery period, the localization of offshore wind turbines in China has reached an imperative level. We must take this opportunity to overcome difficulties and inject sufficient momentum into the sustained and high-quality development of offshore wind power. "said Guo Xiaojiang, the leader of the project technology research team and member of the Party Committee and Vice President of Huaneng Qingneng Institute.

The project team adheres to the principle of "two hands grasping, two hands hard" and one hand

Pay attention to quality and progress at the same time, ensuring that technical skills are not passed and not released, while working overtime to seize time nodes. From the overall design of the unit, the unit was successfully taken offline. The project team held weekly supervision meetings to supervise the progress of the project without interruption, "said Tang Wei, Deputy Director of Huaneng Qingneng Institute.

The project team closely follows the established goals, adheres to problem oriented approach, starts with basic technical details, and carefully examines the localization plan of the unit to eliminate every potential hazard. At the same time, we are vigorously advancing the development progress, directly implementing each problem to the relevant technical responsible person, quickly developing countermeasures, concentrating our efforts to solve it, and minimizing time costs. The staff of various research units have taken on strong responsibilities and missions to ensure the smooth progress of research and development.

Promote the localization of key components

In the process of tackling key problems in the project, the project team overcame one technical difficulty after another, broke through the localization of a series of core key components such as large offshore wind turbine blades, main bearing, gearbox bearings, master control PLC, converter IGBT, etc., and applied technologies such as master control system, unit tower foundation integrated design, digital intelligent perception detection system, etc. independently developed by Huaneng, We have achieved remarkable results in localizing all key core components of the unit.

——Blades are important components of wind turbines, just like the heart of a wind turbine, and are the source of power for wind turbine power generation. It is not easy to completely replace the main beam carbon fiber with domestically produced blades from non domestic ones. The localization technology of carbon fiber materials for blades suitable for high alternating loads lacks reference and reference. Through the process of going from scratch, the familiar technical route has undergone significant changes, and scientific and technological personnel can only start from scratch. The WB171 blades equipped with domestically produced units have a length of 83.6 meters, which is the longest in China at the 5 megawatt level. The difficulty of development can be imagined, "said Ye Zhaoliang, a specialist in the Science and Technology Department of Huaneng Group.

Especially for the first time using domestically produced carbon fiber fabric materials, the weaving method of carbon cloth is different from that of foreign countries. The weaving method not only affects the performance of carbon cloth, but also may affect the effect of vacuum injection, which is a severe test of our existing process route. "said Feng Wei, Deputy General Manager of Luoyang Shuangrui Wind Turbine Blade Company.

To this end, the project team conducted in-depth research on the plan, fully innovating the existing technical route, and boldly adopting new processes. The application of automated laying technology in blade manufacturing reduces the impact of human errors in carbon cloth laying and reduces the risk of layer wrinkles and grouting defects. At the same time, precise control of the weaving process, customized development of process methods based on the characteristics of domestic carbon fibers, reduces fiber wear, makes fiber layout more uniform, and better ensures material performance.

——The main shaft and bearing are like the joints of the wind turbine, which transmit the power generated by the blades to the generator, which is crucial to the reliable power generation of the wind turbine. Previously, main bearing of large MW wind turbines were monopolized by foreign manufacturers, which restricted the rapid development of large MW offshore wind turbines.

"The outer diameter of the main bearing manufactured this time has reached 3200mm, which is the most difficult design and manufacturing of the domestic main bearing of wind power," said Xiao Changyuan, an engineer of CNOOC. I have never produced such a large wind turbine before

Group of main bearing, which is a great test for our design, processing, heat treatment capacity and material performance. " Hu Zhanquan, the R&D director of Luoyang New Qianglian, said. For this reason, the project team, together with relevant units, has jointly promoted the improvement of the existing bearing steel, checked the basic data, nuclear chemistry composition, and synthesis mode. Through countless repeated experiments, the R&D personnel finally improved the hardenability and low-temperature performance of the bearing material significantly, which has become a strong support for the localization of the main bearing of wind turbines.

——The main control, like the brain of a wind turbine, directly affects the power generation capacity and operation of domestically produced wind turbines. However, the main control PLC hardware of wind turbines is still subject to foreign manufacturers. This wind turbine unit has broken through the localization of PLC technology, with key core chips completely using domestic products, and the control system is also independently developed by Huaneng Xinrui Company.

Realizing the localization of the main control system is simple to say, but difficult to do. The development of domestically produced PLCs requires a lot of development and testing work to be carried out from scratch, "said Chu Xiaoguo, Secretary of the Party Branch and General Manager of Huaneng Xinrui Company. The localization of the main control system of wind turbines is a key link in the development of wind power in China, "said Yang Wei, Vice President of China National Offshore Installation Research Institute. The project team, in collaboration with relevant research and development units, aimed to meet the application requirements of the first domestically produced offshore wind turbine, fully promoted the development of the main control system and improved its information security. At the same time, the project development team has designed various engineering contingency plans to ensure the achievement of the predetermined goals. Design redundant protection logic to ensure maximum safety.

——The design method, wind turbine tower foundation integrated design technology, dynamically reflects the overall support structure stress law of offshore wind turbines under wind wave current soil dynamic coupling action. However, due to a lack of validation of the application of this technology, as well as a lack of overall technical planning and coordination with manufacturers and design institutes, its role has not been fully utilized.

The integrated design technology standard is formulated by the owner, and the collaborative design model between the host factory and the design institute has not been truly implemented in the industry. This integrated design method adopts the core technology independently developed by Huaneng Clean Energy Technology Research Institute. After multiple rounds of iterative design by the host factory and the design institute, it has been successfully applied to 5 MW domestically produced wind turbines and will be further promoted in future offshore wind power projects Zhang Bo, Deputy Chief Engineer of the Offshore Wind Power Department of Huaneng Qingneng Institute, said.

——Monitoring methods and digital intelligent perception monitoring technology provide solid support for improving the power generation performance and fault diagnosis and early warning capabilities of offshore wind turbines. As a complex mechanical and electrical system, wind turbines, especially offshore wind turbines, are also affected by the coupling of multiple environmental characteristics such as wind, waves, and currents. Their power generation capacity is influenced by internal and external factors of the unit, and the mechanisms of fault generation are complex and diverse. They are limited by the current constraints on complex nonlinear signal processing capabilities and the low accuracy of fault warning and identification.

This time, more than 180 measurement points have been added to the blades, pitch, hub, spindle, gearbox, generator, tower and foundation of the domestically produced offshore wind turbine, as well as the underwater environment where the unit is located. Laser radar feedforward and structural safety testing have been adopted

More than 10 intelligent monitoring and operation and maintenance systems Sun Caixin, the business manager of Huaneng Qingneng Institute, said. This technology enhances the active perception of offshore wind turbines towards the body and environment, and enhances the ability of offshore wind turbines to actively control and optimize.

——The lifting of offshore wind turbines requires thorough planning and proper arrangement, with the lifting process being interconnected. In addition, the sea conditions and complex weather in the Rudong Sea area in May this year, coupled with strong winds and fog, have made it even more difficult to control the already tight schedule due to the peak installation period. After the domestically produced 5 MW unit landed on May 22nd, there were strong winds and waves on site, forcing ships that had already departed to return to the port for shelter. The lifting of the tower only started on June 4th, "said Bai Liang, assistant manager of the project department at Huaneng Jiangsu Shengdong Rudong

Under such harsh on-site conditions, the Huaneng Jiangsu Shengdong Rudong project department faced difficulties and formulated a detailed lifting special construction plan, overcoming many difficulties such as the changing marine environment, difficult operating conditions, and complex lifting processes. Through scientific prediction and bold promotion, they firmly grasped the window period of component lifting and successfully completed the lifting task after 7 days of offshore operation. The success of this lifting has laid a solid foundation for the final grid connected power generation of domestically produced units.

Great causes all begin with dreams, are based on innovation, and come true through practical work. The success of domestically produced 5 MW offshore wind turbines symbolizes another victory for China's independent innovation in the energy field, and is of great significance for the development of offshore wind power pricing. It can be foreseen that China's wind power technology will inevitably embark on a path of self-reliance and self-improvement. At the same time, China's offshore wind power industry will continue to contribute greater wisdom and strength to the goal of carbon peaking and carbon neutrality.