DEHN protects Wind Turbines.

Transcription

1 DEHN protects Wind Turbines

2 2 Ensure operation, protect investments: Lightning and Surge Protection by DEHN

3 So that your investment makes a safe profit Renewable sources of energy are most important considering the increasing global power consumption. In Germany 31.7% of the current was generated in 2016 from renewable energies. Wind energy has contributed a share of 13% to the energy mix. According to the German government, the share of renewable energies shall increase to 50% until 2030 and reach 80% by Expansion of wind energy will be continued and pushed during the next decades 1). Lightning and surge protection for wind turbines is, therefore, particularly important: wind turbines are especially vulnerable to lightning strikes due to their complexity, height and exposed location. This particularly affects wind turbines with a height of more than 200 metres because the risk of lightning striking a wind turbine increases quadratically with its height. For offshore wind turbines, high availability is paramount as yield losses resulting from downtime are high. For this reason, comprehensive lightning and surge protection measures are required. This is reflected both in the relevant standards and certificates for wind turbines 2). Rely on lightning and surge protection products from DEHN: We are a worldwide recognised expert in the field of wind energy. Our customers include international manufacturers and suppliers of wind turbines. We develop customised protection concepts for wind turbines and additional equipment for the operation of wind turbines such as HVDC, residential or transformer platforms. In the DEHN test laboratory, sub-components can be tested up to a lightning impulse current of 400 ka (10/350 μs) 3). 1) Source: Bundesverband der Energie- und Wasserwirtschaft, 2) Guideline for the Certification of Wind Turbines, Germanischer Lloyd Industrial Services GmbH, ) pursuant to IEC Lightning Protection of Wind Turbines 3

4 Profit from our expertise in developing lightning protection zone concepts Thanks to our long-standing experience in lightning protection and numerous tests on wind turbines, we know how to develop lightning protection systems for wind turbines. Our aim is to prevent lightning damage to rotor blades, bearings and gearboxes as well as downtime resulting from lightning currents and surges. The lightning protection zone concept for wind turbines described in IEC is based on the IEC standard, which defines the selection and arrangement of lightning and surge protection measures 1). The IEC standard recommends to dimension the lightning protection system of a wind turbine according to class of LPS I 2) unless a risk analysis demonstrates that a lower class of LPS is sufficient for the individual components. The lightning protection system of a wind turbine consists of External lightning protection Internal lightning protection / surge protection Equipotential bonding and earthing For planning the protection measures, a wind turbine is subdivided into lightning protection zones (LPZs) 3). The areas which are vulnerable to lightning strikes (LPZ 0 A ) are determined by means of the rolling sphere method. LPZ 0 is the outer zone where the threat is due to the unattenuated lightning electromagnetic field and where the internal systems may be subjected to the full or partial lightning current. LPZ 0 is subdivided into: LPZ 0 A : Parts of the wind turbine which may be subjected to direct lightning strikes and the full lightning electromagnetic field. LPZ 0 B : Parts of the wind turbine which are protected against direct lightning strikes, but where the full lightning electromagnetic field is present. 1) IEC Lightning Protection of Wind Turbines IEC Protection against Lightning 2) LPS: Lightning Protection System 3) LPZ: Lightning Protection Zone 4

5 * r = 20 m * * Radius r = 20 m corresponds to lightning protection level I (LPL1I) 5

6 6 DEHN lightning and surge protection products in a wind turbine

7 Pitch system, blade sensors and rotor blade heating DEHNguard M TN CI 275 FM BLITZDUCTOR XT ML4 BE 24 base part + protection module DEHNpatch M CLE RJ45B Aircraft warning light DEHNguard M TN CI 275 FM Weather station BLITZDUCTOR XT ML4 BE 24 base part + protection module BLITZDUCTOR XT ML2 BE S 24 base part + protection modulel Voltage supply in the nacelle DEHNguard M TNC 275 FM Generator 3 x DEHNguard SE H 1000 VA FM 1 x Earthing clip Voltage supply in the tower base DEHNguard M TNC 275 FM Transformer low-voltage side DEHNbloc M FM DEHNbloc M 1 CI 760 FM Inverter and main supply DEHNguard M WE 600 FM DEHNguard SE CI WE 440 FM Signal, bus and control lines BLITZDUCTOR XT ML4 BE 24 base part + protection module BLITZDUCTOR XT ML2 BE S 24 base part + protection module Structures mounted on the nacelle Air-termination rods Pipe clamp Transformer medium-voltage side DEHNmid

8 Lightning / surge protection for power supply systems By implementing coordinated surge protection measures for power supply systems, the risk of a system stillstand due to lightning currents and surges can be avoided. This increases the availability of the wind turbine in the long term. DEHNbloc Maxi Coordinated single-pole type 1 lightning current arrester. Vibration and shocktested according to EN DEHNmid Surge arrester of line discharge class 1 for medium-voltage systems. DBM FM* DBM FM* DBM 1 CI 440 FM* DBM 1 CI 760 FM* DMI L DIC DEHNsolid Coordinated spark-gap-based lightning current arrester with an extremely high lightning current discharge capacity up to 200 ka (10/350 µs) and a low voltage protection level U p 2.5 kv. DEHNguard 2 surge arrester. Vibration and shock-tested according to EN Available for various voltage levels up to 1000 V. DEHN V SCP Coordinated single-pole lightning current arrester for busbar or mounting plate. Low voltage protection level U P of V SCP kv and V SCP kv. DSO DG M WE 600 FM* DG SE CI WE 440 FM* DG M TN CI 275 FM* DG M TNS CI 275 FM* DG SE H 1000 VA FM* V SCP V SCP * FM = Floating changeover contact

9 Lightning / surge protection for information technology systems A consistent protection concept prevents damage to information and data systems. Condition monitoring is indispensable for the safe operation and availability of wind turbines. This is ensured by the LifeCheck arrester monitoring system with RFID technology which also allows remote monitoring of arresters, for example via a wireless network. BLITZDUCTOR Modular and universal combined arrester / surge arrester* for data lines, bus systems, measured value transmission, temperature measuring devices, heating systems and weather sensors. Vibration and shock-tested according to EN Optionally available with condition monitoring function. DEHNconnect Terminal block with integrated surge protection. Spring-loaded connection system ensures optimised design as well as fast and safe conductor connection. LifeCheck arrester monitoring via RFID technology DEHNrecord SCM XT monitors up to 10 arresters in a monitoring group, while DEHNrecord MCM XT monitors up to 150 arresters in networked monitoring groups. Fault messages are transferred visually or via remote signalling contact. Vibration and shock-tested according to EN M1+ reader Portable device with LifeCheck sensor for fast testing of LifeCheck -equipped arresters. Robust and easy to use via two keys. Battery capacity for about 2000 tests. BXT ML2 BD BXT ML2 BE HFS BXT ML2 BE S BSP M4 BE DCO SD2 ME DCO SD2 MD DCO SD2 MD HF DRC MCM XT DRC SCM XT DRC LC M DEHNpatch class E / POE+ Universal surge arrester for Ethernet* and similar applications in structured cabling systems according to class E up to 250 MHz. DPA M CLE RJ45B * POE+ according to IEEE 802.3at 9

10 Components for the tower, foundation and equipotential bonding An earth-termination system is required for safe operation of the electrical installations and equipment, as well as for the due functioning of the lightning protection system. This earth-termination system is linked with the equipotential bonding system via the main earthing busbar which is connected to equipment and surge protective devices. Equipotential bonding and earthing Equipotential bonding bar Round wire Rd, Ø 10 mm Strip Fl, 30 x 3.5 mm Fixed earthing terminal of type M Cross unit Connecting clamp U-clamp DEHNclip Rd/Rd DEHNclip Rd/Fl Bridging cable Bridging braid

11 External lightning protection for measurement equipment and signalling devices Air-termination systems from DEHN protect wind measurement equipment and aircraft warning lights on the nacelle from direct lightning strikes. HVI Conductor High-voltage-resistant, insulated down conductor for maintaining the separation distance from conductive parts in compliance with IEC ). HVI power Conductor HVI power long Conductor, 100m HVI long Conductor HVI light Conductor DEHNiso-Combi Sets Robust and ready-to-mount complete unit. Supporting tube Air-termination tip Special applications Components for special application in the field of external lightning protection are available on request. 1) IEC Protection against lightning 11

12 Safe working during service operation We offer adequate work equipment for dead or live working according to the five safety rules. Disconnect completely Switching sticks, fuse tongs, protective gloves. Secure against re-connection Insulating plugs, insulating blades, lock-out systems. Switching stick Fuse tong Protective gloves, size 10 * * in various sizes available Insulating plug Insulating blade Lock-out system Verify that the installation is dead PHE III and PHE4 voltage detectors, DEHNcap A voltage indicators. Carry out earthing and shortcircuiting Configure your earthing and short-circuiting devices online: Typ Art.-Nr. PHE III voltage detector PHE4 voltage detector DEHNcap A EKV R three-pole VVYCLAF earthing and short-circuiting device Earthing stick Provide protection against adjacent live parts Protective shutters for protection against adjacent live parts. Protective shutter

13 Arc fault protection solutions The DEHNshort protection system provides active arc fault protection. Passive arc fault protection is realised with the DEHNcare personal protective equipment. Active arc fault protection: DEHNshort DEHNshort allows to visually detect electric arcs via point sensors or line sensors with optical fibre cables. In addition, DEHNshort can also detect currents. After the arc fault detection unit has activated the arc fault protection system, the short-circuiter causes a metallic short-circuit between the busbars within an extremely short period of time. This short-circuit is disconnected by the circuit breaker. The significantly reduced arc time ensures that the installation is protected. Optionally, the arc detection unit can also directly activate the medium-voltage switchgear installation. DEHNshort DD CPS DEHNshort DD FS DEHNshort DD PS DEHNshort QD Passive arc fault protection: DEHNcare personal protective equipment Maximum protection and unique wearing comfort: DEHNcare personal protective equipment provides both. It is tested in accordance with international standards and consists of the safety helmet for electricians, protective gloves, trousers as well as jacket or coat. The hood can be combined with the safety helmet for electricians. Its 3-zone protective system provides all-around protection for face, head and neck. Safety helmet for electricians DEHNcare Face shield Arc-Fault Protective Hood (APH) Arc-Fault Protective Gloves (APG), Size 10 Arc-Fault Protective Trousers (APT), Size 52 Arc-Fault Protective Jacket (APJ), Size 52 Arc-Fault Protective Coat (APC), Size 52/

14 Impulse current tests up to 400 ka in the DEHN Test Centre For engineering offices and for manufacturers and component suppliers of wind turbines, we offer engineering and test services according to IEC ). The tests show whether the protection measures taken are effective. Our Test Centre - with a floor space of 800 m 2 is equipped with the latest devices and technologies and allows to generate lightning impulse currents up to 400 ka (10/350 μs). It offers test services as follows: Tests are performed in compliance with the latest national and international standards. Due to our representation on standardisation committees over decades, our employees are always up-to-date with the latest standards and technical basics. We use this knowledge for our engineering and test services, thus making protection concepts for wind turbines feasible. Our aim is to ensure long-term operation and availability of wind turbines. Lightning current tests on bearings and gearboxes of the mechanical drive train High current tests on the receptors and down conductors of rotor blades High current and high voltage tests on rotor blades System-level immunity tests of important control systems such as the pitch control or aircraft warning light Tests on customer-specific prewired connection units to protect the electrical installation 1) IEC Lightning Protection of Wind Turbines 14

15 Long-standing experience in protection concepts for wind turbines Wind turbines place special demands on lightning and surge protection measures which must be taken into account already at the design stage. The protection concept and correct dimensioning of surge protective devices are paramount for the safe operation of wind turbines. A lightning and surge protection concept must be integrated in the overall concept of a wind turbine. The earth-termination system concept, for example, must be matched with the external and internal lightning protection measures. When selecting arresters, energy coordination of the different arrester stages must be observed for the internal lightning protection concept to ensure that even sensitive terminal equipment is protected. To achieve the protection goals, special applications of certain lightning and surge protective devices may be required. An overall protection concept requires that a lot of information is collected and centrally evaluated to ensure the availability of the wind turbine. DEHN has long-standing experience in protection concepts for complex systems, also in the field of wind energy. The advantages are obvious: Systematic lightning and surge protection prevents downtime and saves maintenance and repair costs. This ensures a continuous energy yield even in the event of lightning currents and surges. For economic reasons, the protection concept must be implemented already at the design stage to avoid expensive repair and retrofit measures later. Because only a complete, properly functioning protective system allows amortisation of the investment costs as planned. 15

16 DEHN products used in hybrid towers A new generation of wind turbines with greater tower heights, larger rotor diameters and a nominal capacity of more than three megawatts was introduced on the market. The innovative hybrid tower system from the Max Bögl group, which is among the five largest German building companies, is an ideal solution for wind turbines with large hub heights. The Max Bögl group developed a hybrid tower consisting of a combination of precast concrete and steel elements. This hybrid tower system allows hub heights up to 150 m above ground level and a total wind turbine height including the rotor of 200 m. The hybrid tower was adapted and a sophisticated prototype was developed together with leading global wind turbine manufacturers and DEHN. DEHN has been closely involved in the development of the earthing concept. Today numerous DEHN products are used in these hybrid towers. 16

17 DEHN products protect transformers As a leading European manufacturer of transformers, the SGB-SMIT group is a partner of the wind industry. SGB-SMIT offers customized transformers for various wind turbine manufacturers. DEHN provides coordinated lightning and surge protection products for these transformers. SGB-SMIT, a technology partner for the grid connection of offshore wind farms, offers efficient medium-power or large-scale transformers. The transformer is the first component which must be protected in case of lightning-related surges from the supply network. Therefore, tested surge protective devices are indispensable. In cooperation with DEHN and wind turbine manufacturers, SGB-SMIT develops protection concepts for transformers which can be seamlessly integrated in the overall protection concept of the wind turbine. DEHNmid medium-voltage arresters can be installed on the high-voltage side and type 1 DEHNbloc lightning current arresters on the low-voltage side to protect SGB-SMIT transformers against surges. 17

18 Protection concepts for onshore and offshore wind turbines Bachmann Electronic is a worldwide active company offering complete automation system solutions. This high-tech company dominates the market for automation solutions in the field of wind energy. In cooperation with Bachmann Electronic, DEHN developed a concept for protecting the controller from surge damage. Functional safety in the tower is quite differently assessed by wind turbine manufacturers. However, modern safety solutions with programmable safety controllers allow to implement functions that go far beyond the typical emergency off chain: Safe remote monitoring and maintenance in combination with intelligently used redundancies do not only ensure availability, they may even improve it. The protection concept developed by Bachmann Electronic and DEHN is a complete safety package including the protection of all Bachmann interfaces. Depending on the evaluation unit, BLITZDUCTOR XT arresters from DEHN protect and monitor the sensors, which may be situated in different lightning protection zones. The condition monitoring system detects overloaded arresters at an early stage and indicates imminent failure. Up to 10 arresters can be monitored at the same time by means of the DEHNrecord DRC MCM XT module. The status of the arresters can be evaluated at any time via the controller. Bachmann Electronic and DEHN place a high degree of importance to system availability. For this reason, all important interfaces are protected. This protection concept is already successfully implemented under harshest conditions for onshore and offshore wind turbines. 18

19 Protection concept for 3 MW onshore wind turbine The Rostock-based international company Wind to Energy GmbH develops complete wind turbines in the multimegawatt range including certification and testing of prototypes and provides them under licence. In cooperation with DEHN, Wind to Energy (W2E) has prepared a concept for protecting a 3 MW system from surge damage. Based on the lightning protection zone concept from DEHN, W2E and DEHN implement a complete safety package which protects wind turbines from the effects of lightning strikes and surges. The concept includes external lightning protection, protection of the voltage supply and protection of all interfaces. Depending on the evaluation unit, BLITZDUCTOR XT arresters from DEHN monitor and protect different sensors. W2E does not only place a high degree of importance to the protection of the interfaces, but also to the availability of the wind turbine: The DEHNrecord SCM XT condition monitoring system detects overloaded arresters at an early stage and indicates imminent failure. DEHNrecord SCM XT allows W2E to monitor up to ten arresters at the same time and to evaluate their status at any time via the controller, thus ensuring protection of the turbine. Consequently, lightning and surge protective devices from DEHN prevent failure and reduce service and repair costs. 19

20 Surge Protection Lightning Protection Safety Equipment DEHN protects. DEHN + SÖHNE GmbH + Co.KG. Hans-Dehn-Str. 1 P. O. Box Neumarkt Germany Phone Fax info@dehn.de Follow us on Facebook, LinkedIn, YouTube, Google+, Xing. For information on our registered trademarks, please visit We accept no liability for technical modifications, misprints and errors. Illustrations are not binding. DS103/E/0917 Copyright 2017 DEHN + SÖHNE