Ministry of Electricity & Energy (MEE)

New & Renewable Energy Authority (NREA)

Welcome

To ZAFARANA Wind Farm

Eng. Ibrahim Abdou

Chief Engineer of Operation Dep.

Ibrabdo_eg@yahoo.com za.ibrahim@nreaeg.com

Mobil: 002 01062725923

Web Site: www.nrea.gov.eg

Ministry of Electricity & Energy (MEE)

New & Renewable Energy Authority (NREA)

Contents :

1- Why Zafarana?

2- Zafarana On-land & Future Projects.

3- Availability and capacity factor in Zafarana.

4- Routine and Predictive Maintenance.

5- Dust Contamination and Blades cleaning.

6- Projects in near future.

7- Other plan for Zafarana.

Egypt enjoys excellent wind

regimes, particularly in the Suez

Gulf where the average wind

speed reaches 10.5 m/sec.

The wind energy resource is

available in large regions on the

Nile banks in the Eastern and

Western Deserts and parts of Sinai.

Resource Assessment

Wind Atlas of

Egypt, 2005 Wind Atlas of Gulf

of Suez, 1991 - 2001

Egypt Wind Map,

1987

In cooperation with

USAID

In cooperation with

Risoe (Denmark) &

EMA

In cooperation with

Risoe (Denmark) &

EMA

Av. Wind

Speed (m/s) Region

7.5

8.8

9.5

9.0

7.5

8.4

10.0

5.6

10.5

6.7

Ras Sedr

Abu Aldarag

Zafarana (North)

Zafarana

Zafarana (west)

St. Paul

Ras Ghareb

El Tour

El Zeit Gulf (Average)

Hurghada

In 2003, a detailed Wind Atlas of Suez Gulf area

which includes accurate wind data over period

from 1991 – 2001 for ( 10 ) sites was finalized by

cooperation with RISǾ

Zafarana site location

In the south east of Cairo by

190 km

Zafarana site features:-

* Average wind speed ( 9.5 ) m/s * Flat area * Low turbulence * High capacity factor

ZAFARANA

Zafarana wind rose

Wind Rose NREA

Site layout for Zafarana wind farms

Danish

German

Japan

Spain

Substation

120 MW

80 MW 33 MW

85 MW

120 MW 30 MW

Unused Area

47 MW

30 MW

NREA

Zafarana Wind Farm

8 Projects

On Land Running

and in Operation.

On Land Running and in Operation Projects

Zafarana-2 (KFW1) 33 MW

55 Nordex N43 Turbines.

600 KW each.

In cooperation with KFW .

Was handed over on May. 2001

Zafarana-1 (DANIDA1) 30 MW

50 Nordex N43 Turbines.

600 KW each.

In cooperation with DANIDA.

Was handed over on Apr. 2001

On Land Running and in Operation Projects

Zafarana-3 (DANIDA2) 30 MW

46 Vestas V47 Turbines

660 KW each

In cooperation with DANIDA

Was handed over on Nov. 2003

Zafarana-4 (KFW2,3) 47 MW

71 Vestas Turbines V47

660 KW each

In cooperation with KFW .

Was handed over on June 2004

On Land Running and in Operation Projects

Zafarana–5 (SPAIN) 85 MW

100 Gamesa G52 Turbines

850 KW each

In cooperation with Spain

Was handing over

on Sep. 2006

On Land Running and in Operation Projects

Zafarana–6 (KFW4) 80 MW

94 Gamesa G52 Turbines

850 KW each

In cooperation with KFW.

Was handed over

on Mar. 2008

On Land Running and in Operation Projects

Zafarana–7 (Japan) 120 MW

142 Gamesa G52 Turbines

850 KW each

In cooperation with JBIC

Started in Sep 2008

Under construction Projects

Zafarana–8 (DANIDA4) 120 MW

142 Gamesa G52 Turbines

850 KW each

In cooperation with DANIDA

Started in Feb 2010

The last project in Zafarana

Next Will be in el Zeit Gulff

Zafarana Wind Farm Last Finance year 2009-2010

Total Number of Turbines : 700 WTG

Total Instaled Capacity : 545 MW

Total Produced Energy :1152450 MWh

Capacity Factor : 32.7 %

Performance Availability : 97.6 %

Average Measured W.S : 8.2 m/s

FUEL SAVED : 252357 TON

CO2 EMMISION : 633848 TON

High Availability in Zafarana

Zafarana Wind Farm achieved high Availability and

Performance factors for the following reasons :-

1- High qualified Operation and maintenance staff.

2- High advanced Predictive maintenance: (Vibration,

Balance, Alignment and Oil analysis)

3- Local repair for main components (generator, gearbox).

4- Spare parts stock.

ZAFARANA Wind Farm Development

ZAFARANA Wind Farm Development

ZAFARANA WIND FARM DATE 2009-2010

ZAFARANA MONTHLY PRODUCTION VS WIND SPEED

79101

48920 51200 52260

130840

123412

115866

138501

111151

127347

114859

87145

5.65.4

8.28.5

7.8

8.78.38.4

6.4

5.5

6.8

7.7

0

20000

40000

60000

80000

100000

120000

140000

160000

Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10

Pro

d (

MW

h)

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

W.S

(m

/s)

Production Wind Speed

ZAFARANA WIND FARM DATE 2009-2010 ZAFARANA MONTHLY WIND SPEED

7.8

8.7

8.38.4

6.4

5.5

6.8

7.7

5.6 5.4

8.28.5

0 . 0

1 . 0

2 . 0

3 . 0

4 . 0

5 . 0

6 . 0

7 . 0

8 . 0

9 . 0

1 0 . 0

Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10

WIN

D S

PE

ED

(m

/s)

ZAFARANA WIND FARM DATE 2009-2010

ZAFARANA MONTHLY CAPACITY FACTOR

36.0%37.8%

19.6%

16.1%

37.1%

27.0%

16.7%

28.8%

42.1%

38.5%

44.2%

36.2%

0 . 0 %

5 . 0 %

1 0 . 0 %

1 5 . 0 %

2 0 . 0 %

2 5 . 0 %

3 0 . 0 %

3 5 . 0 %

4 0 . 0 %

4 5 . 0 %

5 0 . 0 %

Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10

CA

PA

CIT

Y F

AC

TO

R C

.F

%

94.6%

96.4%

95.3%

94.7% 95.2%

94.7%

96.0% 96.4%

96.5%

96.1%

95.2%

96.0%

75.0%

80.0%

85.0%

90.0%

95.0%

100.0%

Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10

Av

ailab

ilit

y%

ZAFARANA WIND FARM Avilability% 2009-2010

Nacelle Wind van Wind anemometer Blade Low speed shaft

Gearbox Generator Disc brake Hydraulic system

Nacelle

housing

Yaw system

../../Desktop/Billede%20stort.ppt

1- Manual Control.

2- Automatic Control.

3- Operation Status.

4- Data Collecting , Calculating, Analyzing, & storing.

5- Data & Error log.

6- Grid behavior sensors .

7- Remote Control (SCADA System – Monitoring, Data

managements, WTG Controlling).

Group A

Auto start Group B

Remote Start Group C

Manual Start

Control and monitoring system

Collecting data from the turbines to CMS through fiber optic cables

Control system for turbine

Control unit for turbine with many microprocessors

Build-up of WP3000 Controller WP3000 Controller

Build-up of WP3000 Controller WP3002 digital Input / Output board

Power supply 24VAC

Power supply 24DC

(inputs)

Bus cable for power

supply WP3001

and digital I/O

Opto couplers

Ditgital Inputs surge

protection

Internal power

conversion

Connection for

WP3053 display

Relays

Build-up of WP3000 Controller WP3001 Mother Board with CPU

Power supply 24VDC

analogue I/O’s

Pressure input

Temp. input

Display interface

Park com. interf.

PC connection

DSP (grid)

Slave

Master

Grid measurem.

Analogue output

Counter input

Internal battery

Build-up of WP3000 Controller WP3001 Mother Board

Operation the turbine from control room

Control and monitoring system

Preventive Maintenance

Corrective Maintenance

Predictive Maintenance

Visual Maintenance

Mechanical Maintenance

Electrical Maintenance

Electronic Maintenance

NORDEX

MAINTENANCE

TYPES

TYPE 2

AFTER FIREST

6 MONTHES AND, THEN ANNUALLY

LUBRICATION INSPECTION CLEANING

TYPE 3 AFTER FIREST

12 MONTHES AND,

THEN ANNUALLY

LUBRICATION INSPECTION

CLEANING RETORQUE

TYPE 4

0NCE EVERY FIVE YEARS

LUBRICATION INSPECTION

CLEANING

RETORQUE REPLACING……

VESTAS

MAINTENANCE

TYPES

TYPE 1

AFTER FIREST 3 MONTHES

LUBRICATION INSPECTION CLEANING

RETORQUE

TYPE 2

AFTER FIREST 6 MONTHES AND,

THEN ANNUALLY LUBRICATION INSPECTION

CLEANING

TYPE 3

0NCE EVERY YEAR LUBRICATION

INSPECTION CLEANING

MEASURMENTS

RETORQUE

690 V side 22 kV side

Turbine connection with

Transformer

In the middle of the line

To Next

Turbine

From prev.

Turbine

Under ground

cable

Ground

cabinet

Transform

er

26 32 33 41 42 50

1 10 25 11 18 19

To Zafarana

Substation

S.V.D

Power Cables distributions for Z1

Feed

e

r 1

Feed

e

r 2

Feed

e

r 3

Power Management & Grid Connection.

Generation Voltage is 690 VAC.

The voltage is stepped up to 22KV by local transformer

in each Turbine.

Power Factor and Grid frequency are kept synchronized with the

grid by each unit.

Lines are connected to Zafarana Substation by under ground Power

cables.

The voltage is stepped up to 220KV in the substation which is by

sequence linked through El-Sukhna Substation by overhead lines.

Zafarana Substation

Substation Capacity :- ( 7 Transformers ) 775 MVA

Egyptian Electricity Transmission Company

Transformer 1 :- 75MVA ( J6,J7,J8,J9,J10)

Transformer 2 :- 75MVA ( J25,J26,J27,J28,J29,J30)

Transformer 3 :- 125MVA ( J14,J15,J42,J51,J52,J36,J36,J38,J40)

Transformer 4 :- 125MVA ( J55,J57,J61,J65,J69,J70, J71)

Transformer 5:- 125MVA (J75,J76,J78,J84,J85,J88,J89)

Old Zafarana S/S Capacity (5 Transformers) 525 MVA

New Zafarana S/S Capacity (2 Transformers) 150 MVA

Transformer 3 :- 125MVA ( J16,J21,J30,J31,J37)

Transformer 4 :- 125MVA ( J9,J10,J11,J40,J41,J42)

Devided to 2 beldings

Zafarana Old Substation Layout Voltage 220/22 K.V.

2*75 MVA + 3*125MVA

Trefo (1)

75 MVA

Trefo (1)

75 MVA

Trefo (5)

125 MVA

Trefo (5)

125 MVA

Trefo (5)

125 MVA

From Zafarana Wind Farm

1 2 To Ghareb To sukhna 1 2

Cleaning

DUST & CONTAMINATION

** Prototype Washing Machine.

** Lifted by Crane.

** Remote controlled From Ground.

** Washing Auto

Not used Tell now ( Under test )

* Traditional way ( Platform )

* Hanged by two steel wires

* Controlled by Electric Hand switch

* Washing Manual by Two persons

inside

Used & Effective

Future Projects

Will be in

El-zeit Gulf

NREA Future Contracts

1- Maintenance Management System.

2- NEW SCADA Control system.

Future works and expansions

National Strategy up to 2020

•In February 2008, the Supreme Council of Energy approved an

ambitious plan to:

Satisfy 20% of the generated electricity by

renewable energies by 2020, including 12% from

wind energy,

i.e., reaching more than 7200 MW grid-connected

wind farms.

Pos

sibl

e tr

acks

Governmental projects

Private investments

35% 65%

SEE YOU

Next time in

El-zeit Gulf