Global presence and local excellence with a global technology partner

The outlook for wind power is strong, despite the pressures facing the industry right now. The global wind industry has passed the landmark figure of one terawatt (TW) of global installed capacity. It has taken more than 40 years to reach this milestone, but data from the Global Wind Energy Council (GWEC) indicate that with the wind industry continually gaining momentum, the next TW will take less than 7 years to install.

Inflationary pressures and rising costs have tempered instincts to invest in new manufacturing without certainty and visibility around future wind volumes. This has led turbine manufacturers (OEMs) to increase their reliance on supply chain partners with global footprints, including servicing operations.

They also require component suppliers to work with them to come up with products and innovations that address challenges to deliver the energy transition.

Ingeteam believes this can be achieved through customer engagement to establish long-term partnerships with OEMs, using its technological expertise to deliver high-quality products and also supporting them closely in their key markets with regional after-sales services.

Technological innovation to enable the energy transition

Technological innovation is a key factor in Ingeteam’s operations and is the driving force behind its growth, development and leadership. Its products and solutions are as custom-made as needed. Its global presence provides its customers the flexibility of sourcing components and building products locally, or rapidly shifting production to other locations as demand or regulations change.

The company is a complete solutions provider, adding value at every stage. Being the #1 independent supplier of wind power converters and a world-leading wind generator partner, Ingeteam can help manage the full product life cycle and is committed to providing high-quality and reliable products and solutions for wind turbines up to 18 MW for onshore and offshore applications.

With its services and aftermarket solutions, it can also help improve wind turbine performance, reduce O&M costs and extend the fleet’s lifetime.

Lean manufacturing practices to help reduce costs

The company is headquartered in Spain and operates from 5 state-of-the-art manufacturing locations on 4 continents with a global workforce of approximately 5,000. Its footprint runs from Europe to Asia and North and South America, offering both local and global capabilities, and delivering reliable and flexible solutions and services while scaling as efficiently and sustainably as possible.

At its sites, the company prioritizes continuous improvement and regulatory compliance. It uses top-notch advanced manufacturing tools, processes, and methodologies. Moreover, a multi-product manufacturing process and the Zero Defects Methodology, supported by the APQP4Wind methodology boost efficiency, agility, and time-to-market.

Its products and solutions are custom-made to enhance reliability, both technically and from a manufacturing standpoint. This guarantees the most optimized LCoE throughout the product’s lifecycle.

Ingeteam is also committed to minimizing any negative impact that its operations could cause on the environment because ensuring sustainability is at the core of its DNA. Its contribution to the decarbonization of society and energy transformation towards an increasingly electrified society is the basis of the company.

As markets continue to evolve, the need for global services and aftermarket solutions is more important than ever. Ingeteam partners with customers to create a competitive and sustainable advantage by optimizing the product value chain and lifecycle.

Meeting customers’ needs to ensure their success

Ingeteam actively listens to its customers to deeply understand their needs and deliver the unique solutions that ensure their success.

The company is flexible in designs and R&D solutions, operations, different business models or additional value-added services.

With 25 years in the industry, Ingeteam has established close relationships with customers, often participating in the early-stage development of new designs and using its experience to give feedback to customers on products, topologies and market requirements.

An advantage of maintaining a diversified product portfolio is that the company can support its customers’ more complex requirements. As renewable growth continues, hybridizing different technologies and resources is becoming more common. This is done to maximize grid connection capacities, optimize battery storage solutions, harness the complementary profiles of wind and solar for integrating more renewable output into grids, and increasingly, to use renewable electricity for hydrogen production.

Investing in R&D and nurturing innovative thinking to stay ahead

Research, development and innovation play a fundamental role in the company and that’s why more than 400 people are dedicated to R&D. The economic investment that the company allocates to this area exceeds 5% of annual turnover.

Ingeteam has a business unit and a technology centre dedicated to long-term research, with a team that explores new applications and new markets for Ingeteam technology from a cross-sectoral perspective.

Additionally, the company currently has 7 testing laboratories to test all new developments for its subsequent application in the various sectors in which it operates.

Ingeteam also has a pioneering laboratory, a benchmark in the wind industry, which combines large electrical machines with converters. The company continues to invest heavily in R&D, and will soon begin the construction of a new, high-power laboratory to accommodate future new developments.

All of this makes it today the world’s number one independent supplier for the wind industry, standing out for its industrial capacity strategically distributed in different countries globally to provide service to multiple projects. With a firm commitment to sustainability and innovation, Ingeteam continues to pioneer the development of technology to generate clean and renewable energy.

For more information about Ingeteam click here.

With over 78 GW of installed wind energy capacity worldwide, Ingeteam is a world-leading independent solution provider for OEMs (Original Equipment Manufacturers), utilities and asset owners in the wind energy sector. Its products and solutions are as custom-made as you need them to be. Each helps to enable the fast-moving clean energy sector.

Ingeteam is committed to providing high-quality and reliable power converters, Indar generators, control cabinets, SCADA systems, overhaul projects, Ingeteam spare parts, repairs and technical support, as well as multibrand repair and refurbishment services for onshore and offshore wind turbines up to 18 MW.

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Ingeteam, an independent global supplier of electrical conversion and turbine control equipment, announced that a recent in-house R&D study has allowed them to work out the optimal electrical power conversion designs for offshore wind turbines up to 18MW.

Ingeteam says it designed its new medium voltage full power converter range ‘as a response to some of the most important challenges facing the offshore wind market today’. The next generation of converters for giant offshore wind turbines must be able to guarantee the fulfilment of the most demanding grid codes, while meeting ever increasing power quality standards.

“We wanted to provide our OEM customers working on next-generation offshore turbines with a power conversion solution that combines optimised cost, high efficiency, easy maintainability and improved reliability – all combined into one rugged product,” says Carlos Gironés, R&D director of converters & controls at Ingeteam.

“Years of R&D have led to a power conversion solution that, by parallelising two conversion lines, can push the previous power rating boundaries at medium voltage past the 13MW limit to reach 18MW. Such a cutting-edge solution in the sector is already emerging as the new standard for future offshore wind mega turbines.”

Simplified electrical diagram of the Power Converter based on two conversion lines

Ingeteam’s new converter range continues the development of HV IGBT semiconductors technology. This widely used technology has been proven during years of operation in harsh environments such as traction, marine propulsions and dredging applications. The assembly of the HV IGBT does not need any additional tooling which eases the mounting process of the BPMs and as the package of the semiconductor includes insulation to the cooling circuit there is no need for deionized water.

Helping to lower LCOE

Ingeteam says its latest converters can help contribute to the lowering of LCOE by maximising reliability and minimising the maintenance requirements of its key components. The converter has maintenance-friendly characteristics such as front access and easily removable key components which help to reduce operational costs.

Ingeteam’s MV full power converters have been specially designed for the offshore market with a fully enclosed cabinet that guarantees the safe operation of the converter in harsh offshore weather. It is designed to resist the most demanding mechanical, electrical or ambient operating conditions, even in the worst grid conditions.

State-of-the-art controls

Ingeteam has developed the control algorithms of its full-power converters to guarantee the fulfilment of the most demanding grid codes. The control algorithms have been developed under SIL simulation and HIL validation before test bench validation and commissioning.

The converter’s controls are based on a distributed control topology to effectively manage different conversion lines. With this topology the conversion lines can manage redundancy under faulty conditions, which increases each turbine’s availability.

“One of the main electrical drive train topologies is based on two electrically independent connections, one per conversion line. The power converter redundancy provides the benefits of increasing availability of the turbine if one of the conversion lines fails – which is a key factor in the offshore market as it increases the energy yield and the return of investment,” says Gironés.

About Ingeteam

Ingeteam, is a team of more than 4,000 people in 24 countries, with more than 80 years of experience in providing creative solutions to specific problems to electrify society in an innovative and sustainable way through cutting-edge technology specialised in the conversion of electrical energy. Ingeteam’s complete product range in the onshore and offshore wind power sector includes power converters, wind turbine controllers, electric switchboards, Indar generators, Condition Monitoring Systems (CMS), SCADA and analysis systems for wind turbines up to 18 MW, in addition to multi-technology and multi-brand operation & maintenance services. Ingeteam is the world’s #1 independent supplier of wind power converters with 55 GW of installed wind power capacity, a world-class wind generator partner and the first ISP (Independent Service Provider).

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By Ion Etxarri, R&D Quality & Innovation Manager of Ingeteam Wind Energy

As market demand for wind turbines has grown, so too have the demands for quality and performance. This is especially the case for critical components such as power converters because the performance of the whole turbine depends on them.

The response is focused on increasing the reliability and durability of these components, making wind turbines more economically viable assets. High quality design and extended validation methods of power converters are key to guarantee the reliability and durability of the turbines in wind farms facing the toughest operating conditions.

Ingeteam’s new-generation power converters have been validated using the toughest test scenarios and most realistic configurations, to prove in advance that the converter will be properly integrated within the turbine and operate correctly under the most demanding situations.

The market demands continuous performance improvement and regulatory innovations take this factor into account. Ingeteam participates in the committees which issue these requirements and integrates the latest regulatory developments at the design phase of the company’s new generation power conversion solutions.

This method is also applied to the company’s manufacturing plants to comply with all marking requirements. Indeed, the certification of the converter facilitates the certification process for the whole wind turbine.

New-Generation Power Converters developed for High Power DFIG Application

To this day, DFIG converters remain the most proven, efficient and cost competitive drive train topology for onshore applications. Ingeteam’s DFIG converter series offer cost-optimized products for each market and application. Our wind converters are extremely grid-friendly, and include FRT, SCR and SSR features, enabling them to be deployed anywhere in the world. In particular, they are very well suited to emerging markets such as India or Brazil.

Our DFIG converters can be modulated to bring customized solutions that will effectively minimize wind turbine LCoE. Ingeteam’s vast knowledge and experience have been mobilized to generate design processes that combine development and validation, to ensure the supply of optimized DFIG Power Converters in the wind market for high power applications in the range of 6 to 8 MW.

Because of the application’s particularities, the grid integration of the system is one of the most sensitive elements to keep the technology competitive and reliable while increasing the turbines’ rated power. DFIG generators and the core components of the converter are the key factors that ensure a robust and reliable solution regarding the various grid events that could occur, such as harmonic fulfilment, FRT, weak grids or SSR. The capability of managing these events in virtually all locations is a key added-value that Ingeteam has successfully achieved, with a high-quality model correlation that allows analyzing any event or location that could arise in the future.

Validation process

As a critical wind turbine component, Ingeteam’s new-generation power converters must meet the highest quality requirements for wind turbine performance is dependent upon them.

Ingeteam’s new power conversion solutions have been subjected to the tests required by IEC61400 for wind turbines, and IEC62477-1 and IEC61800-3 for power converters, verifying the correct performance and the highest level of safety.

Within this validation process, a large number of tests are focused on the assessment of energy and temperature hazards. For example, the behaviour of the converter in the event of failure of a cooling system or insulation components is assessed by means of functional tests, simulating these failures or in temperature rise tests. In addition, mechanical tests such as IP degree, corrosion, impact, or vibration also form part of the validation. All these tests guarantee the safety and the correct performance of the power conversion solutions.

Based on its experience in the wind turbine market, Ingeteam considers that an “extended validation” of power converters is appropriate in order to optimize the design and minimize any potential issues that may arise during the integration of the component within the wind turbine.

The objective of this “extended process of validation” can be summarized as follows:

• To identify design improvements or detect any design failures of the converter at the earliest stage of development, thereby minimizing subsequent design and manufacturing costs due to modifications at a later stage of implementation that would imply the use of more resources.
• To test the converter under the most realistic conditions to validate the design under all possible scenarios and to verify it complies with requirements. The more accurate the test is regarding the behaviour onsite inside the turbine, the greater the reliability of the tests and the results obtained.

Ingeteam carries out four types of test to provide accurate data about the behaviour of its converters when installed onsite:

• Combination tests in full-scale test benches.
• Extreme climatic condition tests.
• Extreme mechanical condition tests.
• Electromagnetic compatibility tests.

Combination Tests in Full-Scale Test Bench

The correct behaviour of a power converter can be verified without the use of a generator by means of external power supplies and passive components; however, this kind of validation process cannot fully guarantee the correct integration in the field.

Specific characteristics of the generator could affect the behaviour of the converter, and combination tests make it possible to anticipate them. Some processes are not possible to simulate and assess by means of calculations, and empirical methods are the best way to do that. In addition, combination tests with power-limited generators or mock-ups may not allow the required points to be assessed.

Ingeteam carried out these tests, using the same generator as in the final application, which is critical.

Final layout of the test bench

Combination tests with a generator at full scale enable the correct performance assessment of the converter at any desired point. Thus, a full validation process is obtained as the converter operates along the whole operation ranges. This process includes at least the following variable parameters including grid voltage and frequency, generator speed, reactive or active power, or temperature.

Extreme Climatic Condition Tests

A critical point of a validation process is the climatic one. To be able to verify empirically the correct behaviour of a converter and its components along the whole climatic range is important in order to detect unexpected behaviours that cannot be predicted by means of calculations. Ingeteam is able to carry out a detailed validation thanks to its test benches which are able to control the temperature and the humidity over a very wide range, and where the converters can operate at rated conditions.

Executing tests at the extreme limits of temperature and humidity allows the observation and understanding of the specific behaviour of components when they operate close to their limit, and to define the best options regarding functionality and cost. Without this empirical analysis, the selection of components would be based on theoretical calculations and datasheets, making a conservative selection that would imply overrun, more likely. With this validation the optimum design is obtained.

Ingeteam climatic (Temp & RH) chamber

In addition, the performance in case of failure can be assessed in detail. Without this kind of test infrastructure, it would be impossible to know how the converter really reacts when a component such as a fan or a cooler fails. The behaviour at a specific room temperature or humidity value could differ drastically from another value. This uncertainty is overcome by carrying out failure tests at several climatic points to identify the real performance at each point without depending on assumptions and calculations that could provide erroneous conclusions and lead to designs that do not fulfil the requirements or could even be dangerous.

The climatic extreme conditions validation includes heat run tests, cold climate tests, full condensation tests and damp heat tests.

Extreme Mechanical Condition Tests

Another critical part of the validation process of the converter for its final application is the assessment of its behaviour and response to low frequency vibrations. Incorrect behaviour could cause severe damage to the converter and the wind turbine.

Depending on the wind turbine, the location of the converter and the fastening structure, the response could change drastically. Thus, this is a process to be carried out for each wind turbine-converter combination.

Vibration test

Prior to the test, Ingeteam develops detailed Finite Elements Models (FEM) to predict the response of the converter and to assess the different design options.

The main test consists in sinusoidal sweeps using the specific “Frequency-Acceleration profiles”.  These profiles are defined based on accelerated test processes with the aim of simulating the whole accumulated damage along the life of the turbine in only a couple of hours.

During the tests, the resonances are checked because any change on their frequencies could lead to structural damage.

In addition, shock tests with extreme acceleration values are carried out.

Following these tests, the converter must remain operational. No damage affecting safety can be accepted.

Passing these tests guarantees that the combination of converter and wind turbine is correct and will withstand the lifetime of the turbine. The results are also correlated with the FEM models developed.

Electromagnetic Compatibility Tests

The immunity of the converter against the emissions of the environment or generated by nearby devices is critical to guarantee the maximum availability of the turbine. Also, the converter itself can generate emissions that could affect the correct operation of nearby items (within or outside the turbine). To confirm that the converter is able to operate in an environment within the expected emissions limits, compatibility tests according IEC61800-3 standard are included in Ingeteam’s validation process. These tests are carried out in the manufacturing plant, using the most representative configuration, and by certification bodies.

Passing them minimizes drastically the risk and uncertainty regarding EMC.

Radiated emissions test

Certification Process

Another cornerstone of Ingeteam’s design process is certification. Achieving the combined requirements of maximum durability and reliability with cost-optimization, is essential, but Ingeteam understands that different international standards can present a barrier for wind turbine installation.

Therefore, Ingeteam considers the strictest international standards for all its designs.

Ingeteam participates in the committees that issue these requirements and thus it stays up to date with the latest regulatory innovations and implements them from the design phase of the converter. Being proactive regarding regulatory demands leads to the improvement of new converter designs and avoids late modifications that could delay a project. Any new design within the company integrates the strictest standards for all the applicable marks and labels including CE, UL or DNV-GL.

The participation in IEC committees such as TC22 (Electronic Power Conversion) and TC88 (Wind Energy Generation Systems), IECRE (IEC Renewable Energy), as well as in specific working groups within IEC including WG05 (Hazardous Substance) or WG26 (SW testing), or STP UL groups for development of standards like UL508 (Industrial Control Equipment), proves the commitment of Ingeteam to the quality of its products.

Moreover, this approach is not only applied to product design, but also the manufacture of the products in its plants. For that purpose, the plants are certified for the manufacture of any component and marked with the main wind mark labels. These certifications confirm international compliance and avoid project delays due to any marking regulations and barriers.  In addition, they facilitate the certification process of the wind turbine.

Ingeteam has already certified its plants for power converter within DNV-GL and UL scopes, and in addition has been trained for APQP4Wind.

Conclusion

Extended validation of Ingeteam’s new generation of power converters confirms their operational performance under the most severe conditions. The use of full-scale test benches for integration assessment and climatic behaviour evaluation are key to optimize the design and detect potential improvements at an early stage. The information obtained from the tests assures the optimization of the design and guarantees that the converter is going to operate properly in the field.

The incorporation of the latest and most stringent regulatory requirements at the design phase and also in the certification of the manufacturing for plant, allows Ingeteam to facilitate the wind turbine certification process, wherever the geographical location, thereby reducing the project time-to-market and saving costs throughout the development and validation design processes. Clients can be confident that thanks to extended validation, Ingeteam’s new products deliver the best onsite value for money.

Ingeteam is an international technological Group specialized in electric power conversion. Its state of the art developments in power and control electronics (inverters, frequency converters, controllers and protections), rotative electric machines (Indar motors, generators and submersible motor & pumps sets), systems (electromechanical engineering and automation projects), and services (operation & maintenance services), enables it to provide the best solutions in different sectors, namely: wind, solar PV, hydro and fossil fuel power generation; metal and mineral processing; mining; marine; rail traction; waters; e-vehicle charging and power grid automation, always achieving sustainable and efficient energy generation, transmission, distribution and consumption.

The company operates throughout the world, and is permanently based in 22 countries, with a headcount of 4,000. R&D is the backbone of its business activity, in which 5% of its turnover is annually invested.

For more information: https://www.ingeteam.com

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