Ultracapacitor Energy Storage Retrofit System for Emergency Pitch Control in GE 1.X and GE 2.x Turbines (20Nm & 30Nm)
Ultracapacitor Energy Storage System
Energy Storage Requirements
6 cells in series, 3000F 2.7V cells, Operating at 2.42V/cell
500F Module (6 modules per axis)
IEC 60529, IP20 - No exposed PCBA's
Passive balancing system
Turn-off voltage @ 2.4V per cell
GE 20Nm uses 4 ultracapacitor modules, same charger box (CCU)
Mounting bracket hardware for charger box CCU (not shown) - TBD
Lower Maintenance Cost
Retrofit is a drop-in replacement
Retrofit interfaces with the existing Emergency Power Unit (EPU) and Turbine controller (SCADA System)
Eliminates costly maintenance and battery replacements
Reduces battery related pitch faults
Approximately 10-15 year life
Wider operating temperature range -40°C to +65°C
Minimizes turbine downtime
Reduces operational safety concerns
Can be fully discharged to provide safer working conditions
Reduces number of climbs for technicians
No lead or acid
No change to lock-out tag-out procedures
IP20 rated - No exposed PCBA's
The 6 cell capacitor modules are the same dimensions and use the same mounting locations as the batteries
Each blade pitch system will use 6 modules for GE30Nm and 4 modules for GE20Nm
LiCAP ultracapacitor modules feature laser welded bus bar connections to ensure a robust and reliable connection for the life of the installation VS. threaded cells with nuts that can be over torqued or come loose over time
Loose nuts can cause higher resistance which can lead to increased temperatures at the terminal. Increased temperature can shorten life and/or lead to failure of the module.
LiCAP Activated Dry Electrode®:
Lower ESR, since binder is non-conductive.
Higher capacitance. Since we use less binder, we can add more carbon in the mixture, which results in higher capacitance.
Note : Activation also enables finer binding fibers and higher fiber quantity, so we achieve the same strength electrode as the other dry method.
Windurance Capacitor Charging Unit (CCU)
The Windurance CCU is designed to monitor and manage 4 or 6 ultracapacitor modules
1 Charging Unit per blade pitch actuator vs. 1 per ultracapacitor module. A cost-effective solution.
Fewer parts + fewer connections =higher reliability
The CCU can be used either for GE30Nm or GE 20Nm interchangeably.
Drop-in replacement conveniently interfaces to existing cables, harnesses and RS-485 communication protocol.
IP20 rated – no exposed PCBA’s.
Windurance Capacitor Charging Unit (CCU) 710-70004
Robust Electrical Design: The Windurance CCU design ensures reliable operation under extreme conditions. - The tests conducted in development exceed the IEC standards as follows: - IEC 61000-4-2 Electrostatic discharge immunity test - Level IV+ - IEC 61000-4-4 Electrical fast transient/burst immunity test - Level IV+ - IEC 62000-4-5 Surge immunity test - Level IV+
Universal: The Windurance CCU serves all 20Nm and 30Nm configurations without modification, enabling fleet-wide compatibility for streamlined inventory management.
Lightning Strike Protection: Our CCU is certified to IEC 62305-1 Edition 2.0, 2010.
Wide Operating Voltage Range: To protect against fluctuations in supply line voltage that can be common in remote locations, the CCU is designed and tested to operate from 40% low to 30% highline continuously. The CCU retains full charging capability down to 10% below nominal line voltage and continues to communicate all the way down to 40% below nominal.
Ultracapacitor Monitoring: The CCU can monitor individual module voltages and total string voltage. Any ultracapacitor module low voltage condition is communicated to the wind turbine controller for action.
Charge time: The CCU can charge the ultracapacitor string in one blade from 0V in 45 minutes (30Nm) or 40 minutes (20Nm). Both versions can recharge completely within 5.5 minutes after a single pitch event, worst case.