Largest wind turbine components seen in the UK arrive for testing at Narec

23rd August 2013

Shipment signifies next step in evolution of UK’s Offshore Wind industry

• Largest wind turbine components seen in the UK arrive for testing at Narec

• On-shore testing set to boost viability of offshore wind power generation

The arrival of a giant shipment in the UK this week marks the next step in the evolution of the country’s offshore wind power generation that would see turbines with double the power output of those currently operating out at sea. It also strengthens the prospect of a home-grown manufacturing industry developing.

The 450-tonne shipment will see the delivery of a wind turbine nacelle, the gearing and generator mechanism that sits on top of the turbine tower behind the blades, which converts power from the wind into electrical energy.

The nacelle, the biggest of its kind in the world*, will be delivered to Blyth Docks in Northumberland, where it will undergo a rigorous on-shore testing programme within the World’s largest test rig facilities at the National Renewable Energy Centre (Narec).

Samsung Heavy Industries (SHI) has developed the giant prototype as part of its plans to manufacture 7MW turbines, which would have double the wind-generating capacity of the current largest offshore wind turbines operating in the UK. Just one of the super-size turbines would have the potential to generate enough power for 5,700 homes annually.

If the tests are successful it will boost the confidence of developers to invest in SHI’s technology for the next round (Round 3) of offshore wind developments that will be sited further out at sea. This in-turn will increase the likelihood of SHI investing £100 million in a new manufacturing plant in the UK, potentially creating 500 jobs in the area.

This will be the first commission for Narec’s pioneering new independent testing facility which has seen a £25 million investment by the Energy Technologies Institute (ETI), a public-private partnership between global energy and engineering companies and the UK Government. The ETI has invested in the design, development and commissioning of the indoor test rig by GE Energy-Power Conversion and MTS Systems Corporation. The overall project cost £47M to develop.

During the six-month testing programme of the nacelle, which begins this autumn, some of the harshest climatic conditions will be simulated within the Narec facility, including wind gusts of up to 150mph and once-in-a-lifetime events, to ensure any performance issues can be identified and rectified before the turbines are constructed and put offshore. The programme will include performance verification and accelerated life testing of the complete drive train system.

In this way, Narec and SHI will be able to gather performance data far more quickly than waiting for the same range of conditions to occur naturally offshore. Importantly, this also offers the potential for reducing the cost of developing and operating the next-generation technology because ironing out performance issues on-shore is significantly less costly than having to fix issues out at sea.

Andrew Mill, Narec’s Chief Executive said: “We’re delighted to be working with SHI on the accelerated lifetime testing of their next-generation turbines.

“The information we gather during testing will contribute significantly to SHI’s understanding of the design and performance of their technology that will ultimately help reduce the manufacturing and operating costs of the turbines and make energy production through offshore wind power far more competitive with other energy sources.”

Universities and Science Minister David Willetts said: “It’s good to see that Samsung’s nacelle uses a gearbox that has been designed and built in the UK. Our Offshore Wind Industrial Strategy sets out how we aim to grow the supply chain so that more of the work and jobs can be done here. The Government is helping UK supply chain companies to become more competitive through a Manufacturing Advisory Service programme called GROW, funded by £20 million from the Regional Growth Fund.”

Dr David Clarke, CEO of the Energy Technologies Institute said: “The delivery by Samsung Heavy Industries of its turbine is a major milestone for Narec and the wider UK Offshore Wind industry. This is evidence that the UK can create world leading engineering facilities that can attract global industry operators providing welcome economic stimulus into the country and advancing technology innovation in a growing industry.”