Engineering Careers
Content
It takes the brightest minds to be technology leaders
Engineering careers at Siemens Wind Power
Answers for energy.
Our global headquarters are located in Brande, Denmark, accessible from the Billund airport and the freeway extension between Herning and Vejle.
About us
Siemens is a leading supplier of highquality wind turbines and related services. We are the global leader in the offshore wind power market. With robust and reliable turbines and highly efficient solutions for power transmission and distribution, Siemens provides clean power along the entire energy conversion chain. Drawing on 160 years of experience and nearly 30 years as a major innovator in the wind power industry, Siemens has proven itself a trustworthy and reliable business partner. The global head office in Brande houses the main engineering department, in close proximity to nacelle production. The technology center for blade development is located at the blade factory in Aalborg, Denmark, and other factories, sales offices, and service offices are situated throughout Europe, USA, and Asia. Attractive terms of employment, pension and insurance plans, canteen arrangements, and many social activities coordinated by an active staff association make Siemens Wind Power an attractive and flexible place of work. For current job openings visit: www.siemens.com/jobswindpower or send us your application.
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“At Siemens you can be part of the technological development of a rapidly expanding industry.”
Peder Nickelsen Director, Engineering Siemens Wind Power A/S
Siemens has played a leading role in modern wind power generation from the development of our first 22 kW turbine in 1980 to our current state-of-the-art turbines. Our visionary, enthusiastic, and professional employees ensure that we stay at the forefront of wind power technology.
Our engineering department – one of the largest R&D organizations in Denmark – forms the core of our technological leadership. We continuously support employee development through project work and supplementary training, and are always welcoming new faces to the team. This brochure will give you an insight into the various tasks performed in the Siemens Wind Power engineering department.
3
“Working with wind turbines and being at the hub of the development environment is extremely exciting. It is motivating to be part of a production company where you track projects all the way from design to handover to the customer.”
Rune Rubak MSc, Civil Engineering
Loads
Wind turbine development requires measurement of extreme loads and fatigue loads relevant to the structural design of main components.
Load calculation is a fundamental aspect of development projects, and also part of many sales projects. Work focuses on refinement of existing turbine and blade designs, development of turbine controls, and development and testing of new computation methods. In offshore projects load computations are important at an early stage in the design and sales work, thus providing opportunities to cooperate with customers and foundation designers throughout the course of the project.
Load computations must be approved by an impartial third party, presenting further challenges. Another central function of load calculations is to gain an overview of the inputs and postulates for simulations, and understand, control, and communicate results based on fundamental knowledge of dynamics and wind loads.
Work is performed individually, in groups, and in cross-divisional projects. Loads are primarily determined through dynamic time domain analyses carried out using our FEM-based aeroelastic program BHawC. Models and computations are verified with the aid of full-scale measurements on prototype turbines. The engineering department develops all of its own software tools and adapts them to the tasks at hand.
4
Construction
The construction work is divided into four groups: mechanical design, tower design, PTA, and service documentation.
Construction staff contribute significantly to development and sales projects. Responsibilities include drawings and specifications for all turbine components, participation in development projects, maintenance optimization of series-produced turbines, as well as modification or new design for sales projects. Additionally, problemsolving related to production tools, shipping and lifting equipment, turbine manuals, and spare parts catalogs is entailed in construction.
Work is group-oriented, and involves various teams within the engineering department. The duration of a project varies greatly, lasting from a few weeks to several years. 3D Inventor is the program used for design. FEM (Ansys) is used for computations and analysis. The editing and publishing tool for service documentation is FrameMaker, and the ERP system is SAP.
5
“We are highly motivated by having such a great influence on the development work. We help come up with solution proposals, develop them, and make decisions. In principle, we set our own limits to the level of responsibility we want.”
Martin Hansson MSc, Civil Engineering
Structure
Structural design of wind turbine components is an exciting challenge.
The challenge is to design the components for optimal strength while minimizing price and weight. In addition to design of components, structural work includes development of concepts for shipping the massive components from the manufacturing plant to the installation site. In both areas creativity and ingenuity are essential.
Tools used include a wide range of software such as FEM for static analyses, complete non-linear analyses, buckling analyses, contact analyses, transient and modal analyses, and in-house codes for processing large time series. Our computation methods and in-house codes allow us to design all components precisely in relation to extreme loads and fatigue loads as well as the overall dynamics of the turbine.
6
“As a mechanical engineer, it is very inspiring to work with wind turbines, because a turbine, from a mechanical point of view, has everything you could want in the machine industry. Things never get too theoretical because the production and development workshop is right next to the engineering department. So you can perform practical tests and monitor the changes in production at close quarters.”
Johnny Kjeldsen MSc, Electromechanical System Design
Mechanics
Mechanical and hydraulic components primarily include rotating parts in the hub, the transmission system, and the yawing system.
The transmission system – including main bearings, gears, couplings, hydraulic brakes, and mechanical rotor locks – is one of the major components handled by the mechanical engineers. The hub is composed of blade bearings and the hydraulic pitch system. Lubrication systems for bearings and gears as well as cooling of all large components also constitute a large part of the work. In addition to the design and selection of components and systems, input for quality control and general follow-up with sub-suppliers require a great deal of attention.
We do not focus exclusively on individual components but consider entire systems and the connections between components. This gives us a sound understanding of the interaction between the most vital parts of the turbine. A number of tools are applied to solve tasks, including software developed in-house in response to specific requirements such as machine monitoring and data collection from the turbines. The more traditional tools used are CAD programs and FEM software.
Matlab/Simulink is preferred for the simulation of mechanical and hydraulic systems, as well as programming and data analysis. In cooling and ventilation, CFX analysis and simulation is completed with software such as EES.
7
Electrical hardware
Design of electrical components (hardware) is a diverse area of responsibility.
The tasks involved encompass a wide range of technical aspects, such as controls, power electronics, and high-voltage equipment. The main components include generators, frequency converters, and transformers. These components are part of the power circuit of the wind turbine and play an important role in the conversion of rotating mechanical energy to electrical energy, which can then be supplied to the power grid. All electrical components are functionally designed to withstand mechanical and electrical impacts, including external environmental impacts such as lightning.
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Engineers execute thorough verification of individual electrical components. Extensive measurements and tests are performed before and after installation of the turbines to validate interaction between the individual components. Work is completed through cooperation with immediate colleagues, as well as interaction across the engineering department. Close contact with subsuppliers and the project department is also necessary when specific customer requirements arise.
“The interesting thing about working with grid connection is that we not only cooperate with colleagues and across professional groups, but also work together with business partners all over Denmark and abroad. Furthermore, the technical solutions we work with can become rather advanced and complex, so you have to keep up-to-date with the latest technology.”
Michael Nørtoft Frydensbjerg MSc, Electrical Engineering
Grid connection
Design, simulation, and verification of the turbines’ grid properties are preconditions for connecting modern wind turbines to the power grid.
In order to be connected to the grid, compliance with grid connection requirements must be achieved. This is ensured through preparation of technical proposals based on simulation studies aimed at continuously enhancing grid properties and adapting them to the latest Danish and foreign requirements regarding voltage quality, active and reactive power regulation, and stability in short-circuit situations. Support is provided for the sales and project departments through static and dynamic studies which determine if wind power plants meet existing grid requirements.
Numerical computation models representing the electrical properties of a turbine in response to different types of electrical events are developed. Work primarily includes modeling within dynamic and harmonic areas. A number of different computation tools are used such as Matlab/Simulink, PSS/E and DIgSILENT.
9
Global research and development
Siemens looks for competencies among the most specialized people.
Competence centers are an integral part of the engineering department. Siemens has established a number of competence centers in Denmark, the Netherlands, the UK, Germany, China, and the US, and in universities or other research institutions with competencies in specific professional fields that are vital to Siemens Wind Power. These are typically fields in which it can be difficult
to recruit the necessary specialists to the headquarters in Brande. A location in close proximity to a university or a research institution provides Siemens Wind Power the opportunity to cooperate with external partners through research projects or PhD theses. The competence centers are constantly developing, while we also work to establish new cooperative agreements.
10
Competence centers
Denmark: Copenhagen Aerodynamics, structural dynamics, embedded software, SCADA, electrical systems, distribution grids, modeling, and regulation UK: Keele and Sheffield Keele: Frequency converters, grid requirements, and software Sheffield: Generator technology The Netherlands: Delft Offshore technology, wind turbine technology, and modeling
Germany: Aachen Gear technology, machine elements, metallurgy, and general machine technology US: Boulder and Orlando Boulder: Meteorological research, aerodynamics, structural dynamics, and operation and maintenance of wind power plants Orlando: Regional project support China: Shanghai Regional SCM support
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Testing and validation
Meteorological measurements, noise and vibration measurements, as well as measurements on turbines and turbine components are important when a design is to be validated, and when new knowledge is needed.
Every phase of working with wind turbines involves measurements throughout the sales, project, and engineering departments. One of the more visible measurements is full-scale blade testing. For this purpose several test stands are used to perform accelerated blade fatigue and extreme tests.
Structural measurements are carried out on turbines all over the world. Once a measurement has been commissioned and the equipment calibrated, it must continue to operate unmanned for up to several years at a time. This requires extremely robust equipment and software. Measuring systems are therefore developed and built in-house to meet specifications of the task at hand. Likewise, because there are no commercially available programs with the necessary flexibility, proprietary software is used for data collection, analysis, and documentation of measured data.
In addition to structural measurements, yield and noise measurements on turbines erected for sales projects are also performed. Early on in the development projects numerous lab tests are performed on key components. This allows for optimization of the product before even the first prototype is built. Testing of new sensor types is an important task in this area.
12
“There is something fascinating about developing the software that makes these enormous power plants function fully automated. This software enables you to operate turbines all over the world from a central location.”
Jesper Behrens Andersen BSc, Electrical Engineering
Software
We develop our own software for operation of Siemens wind turbines.
Software development encompasses a wide spectrum of projects dealing with embedded systems and PC systems. Embedded software development projects include development of control, regulation, and monitoring functions. The extent of projects varies between development and implementation of small changes in the control functions and development of advanced adaptive regulation systems with regards to minimization of loads, optimization of production, etc. The PC system projects include development of central data collection servers, graphic presentations of trend curves, and reports.
Windows.NET and C# constitute the development platform for PC systems. All project phases are handled by our software experts. Software is developed for a wide range of embedded hardware platforms, from 16-bit microcontrollers to x86 and Texas DSP processors. The latest technologies in real-time operating systems, software development, and hardware platforms are applied. The central monitoring system is a PC-based system, which serves as the tool for daily monitoring and operation of entire wind power plants.
The department handles a wide range of tasks, from regulation technologies via communication protocols to database reporting. The primary tool is Microsoft Visual Studio, using C#. The system’s general operating interface is a Web application encoded in asp.net using AJAX technology and a limited number of Java applets. The platforms are exclusively Microsoft operating systems, and Windows 2003 Server and Windows XP Embedded are currently being used. Matlab/Simulink is primarily used in simulation.
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“Advanced blades are up to 60 meters long and sweep an area greater than one hectare in a single turn. The design of a blade is a complex optimization task. Between specific blade design phases, we evaluate processes and the tools are honed for the next project. This is applied science where the path from idea to realization can be very short, and where innovation and creativity are key words.”
Jesper Laursen MSc, PhD, Dept. of Civil Engineering
Aerodynamics
Aerodynamics is one of the company’s core areas. Blade-related aerodynamics encompasses profile design, blade design, flow conditions in hilly terrain, and analysis of load and power curve measurements.
In the aerodynamic design of new blades, every tool is applied to achieve the perfect design – new profiles are developed, the blade shape, twist, and thickness are optimized, and the RPM, pitch angles, and tip design are adjusted to obtain efficient and noiseless operation. To a large extent we use CFD computations of profiles and the rotor, wind tunnel measurements, and customdesigned optimization tools for this task.
Work is performed in conjunction with technology development projects, load simulations, and blade development. We ensure our position at the cutting edge of aerodynamics research by participating in various Danish and international research projects, attending conferences, and publishing in scientific journals. Wind tunnel testing and fullscale testing of operational turbines are implemented.
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Blade development
Design and production of new blade types require focus on safety, quality, and cost in specifying materials and casting processes.
Sizing and design of new blade types are performed using Siemens’ unique IntegralBlade® technology. The aim of the design process is to obtain an ideal balance between optimum mechanical properties, weight, and cost. The structure is optimized for different load situations using advanced structural methods, including non-linear FE analysis (Ansys). Verification is achieved via static and dynamic testing of full-scale prototypes and field measurements. Production documentation and blade certification are important elements in the development of new blade types.
The qualification of blade materials and specification of processes used in the production units are essential tasks. Materials are developed for blade laminates in close cooperation with blade structure teams and sub-suppliers. Further development of the advanced casting concept used in production and surface treatment ensures Siemens’ technological leadership. Daily work combines experimental and theoretical tools, such as lab testing of individual materials, CFD simulation of vacuum injection, sectional casting, and
complete blade casting. The scope of design tasks ranges from components of a few grams to molding equipment of 50 tons. Part of the development of new blade types is the design and development of a variety of custom-made production tools, such as blade casting molds which generate external and internal blade geometries, and blade handling equipment used for the blade finishing processes.
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“My tasks as technical project manager span from highly technical discussions to commercial meetings and scheduling. Two workdays are never alike. During the project new challenges arise, and you can never be certain what will happen next week. Through the development of new methods and the handling of ad hoc assignments, the job as technical project manager enables me to feel the pioneering spirit that initiated the wind turbine adventure years ago.” Thomas Mousten MSc, Civil Engineering
Offshore
Offshore projects are a major business for Siemens Wind Power and demand expert knowledge.
In offshore, the focus is on contributing to existing projects, as well as creating new solutions for offshore challenges, such as installation and safe access in rough weather conditions. Participation is also required in the sales process for future projects.
Tasks vary greatly, from practical participation in the installation of wind turbines to technical discussions with customers concerning project implementation. Theoretical studies of future methods for shipping and installation are also involved. 3D-CAD and scale models of turbines and vessels are used to evaluate the feasibility of new methods.
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R&D and Technology projects
Professional and efficient completion of projects is crucial for the achievement of successful products.
New technology and advanced components result in increasingly complex development projects. Often, development projects span the entire company, placing greater requirements on project management, project management tools, and communication. An overview of the project portfolio, ongoing projects, and projects in their
final stages is maintained, in order to facilitate prioritization and achieve maximum gains. Another important aspect is to ensure effective communication between all project managers in order to create channels for shared knowledge. Projects are carried out through development, testing, and optimization.
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“In order to be a technology leader, it is necessary to be able to think innovatively and see beyond the many pressing daily tasks. The think tank is a forum in which inventiveness, innovation, and fresh thinking in the engineering department are given free rein. The participants ensure that inspiration is propagated throughout the entire engineering department in order for it to impact daily activity. The think tank is thus one of many important means for maintaining our status as a technology leader in the wind turbine industry. ”
Henrik Stiesdal Chief Technology Officer Siemens Wind Power A/S
Technology
The Technology organization manages the company’s technology development and product portfolio work. This includes the setting out of strategies for the technology development process, and the facilitation of Engineering efforts through assistance with processes, IP, etc. The overall target is to ensure that we “do the right things and do them right” when providing Siemens with the product-related basis for market leadership. The technology department has five groups: Product Portfolio Management: Provides the basis for all product-related decisions aimed at securing market leadership. This includes creating and maintaining a product strategy, ensuring that product decisions are taken throughout a product’s life cycle, and are based on relevant and up-to-date information about markets, competitors, and technologies.
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Innovation Management: Manages and reinforces innovative processes in Engineering. Work includes creating awareness of innovation as a key factor for market leadership and the management of our Think Tank. The group is also in charge of the technology project process and the technology roadmap. IPR: Provides company-wide assistance in relation to Intellectual Property Rights, which mainly pertains to assistance to Engineering regarding patents. This includes developing and maintaining a strong patent portfolio of wind power technology and monitoring competitors’ patent activities.
Advanced Technologies: Carries out initial research in relation to technologies that do not fall within the scope of the usual Engineering activities. The overall evaluation of technical solutions, scouting of turbine-relevant technologies, and specific research in key technology areas are included in this group’s responsibilities. Research Management: Coordinates research with external partners, including other Siemens partners. This includes the creation and management of research opportunities and management of the necessary agreements.
“My work offers exciting engineering challenges, and I am motivated by the fact that it contributes to the continuing development of environmentally friendly wind power. I care deeply about energy supplies and the environment, so I am proud of the solutions and results that we help produce.”
Jan Thisted Power Systems Engineer
We make a difference!
A job at Siemens allows you to help the environment.
Do you want to help shape the future of sustainable energy? Siemens Wind Power is your best career opportunity! Today, wind power makes up only a small fraction of the global energy supply. Siemens Wind Power solutions will play a critical role in meeting the world’s power consumption as demand for renewable energy increases. Siemens’ global presence spans more than 190 countries, offering numerous career opportunities around the world.
With colleagues from more than 50 nationalities in Siemens Wind Power alone, you will be working in a truly inspiring, global environment. As an engineer at Siemens Wind Power, you have the opportunity to impact the global environment. By contributing to the continuous development of reliable, cost-efficient wind turbines, you can really make a difference!
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Published by and copyright © 2010: Siemens AG Energy Sector Freyeslebenstrasse 1 91058 Erlangen, Germany Siemens Wind Power A/S Borupvej 16 7330 Brande, Denmark Phone: +45 99 42 22 22 www.siemens.com/wind Renewable Energy Division Order No. E50001-D310-A144-X-4A00 Printed in Denmark fb 2581 WS 02103.
Printed on elementary chlorine-free bleached paper. All rights reserved. Trademarks mentioned in this document are the property of Siemens AG, its affiliates, or their respective owners. Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.
www.siemens.com/energy
Engineering careers at Siemens Wind Power
Answers for energy.
Our global headquarters are located in Brande, Denmark, accessible from the Billund airport and the freeway extension between Herning and Vejle.
About us
Siemens is a leading supplier of highquality wind turbines and related services. We are the global leader in the offshore wind power market. With robust and reliable turbines and highly efficient solutions for power transmission and distribution, Siemens provides clean power along the entire energy conversion chain. Drawing on 160 years of experience and nearly 30 years as a major innovator in the wind power industry, Siemens has proven itself a trustworthy and reliable business partner. The global head office in Brande houses the main engineering department, in close proximity to nacelle production. The technology center for blade development is located at the blade factory in Aalborg, Denmark, and other factories, sales offices, and service offices are situated throughout Europe, USA, and Asia. Attractive terms of employment, pension and insurance plans, canteen arrangements, and many social activities coordinated by an active staff association make Siemens Wind Power an attractive and flexible place of work. For current job openings visit: www.siemens.com/jobswindpower or send us your application.
2
“At Siemens you can be part of the technological development of a rapidly expanding industry.”
Peder Nickelsen Director, Engineering Siemens Wind Power A/S
Siemens has played a leading role in modern wind power generation from the development of our first 22 kW turbine in 1980 to our current state-of-the-art turbines. Our visionary, enthusiastic, and professional employees ensure that we stay at the forefront of wind power technology.
Our engineering department – one of the largest R&D organizations in Denmark – forms the core of our technological leadership. We continuously support employee development through project work and supplementary training, and are always welcoming new faces to the team. This brochure will give you an insight into the various tasks performed in the Siemens Wind Power engineering department.
3
“Working with wind turbines and being at the hub of the development environment is extremely exciting. It is motivating to be part of a production company where you track projects all the way from design to handover to the customer.”
Rune Rubak MSc, Civil Engineering
Loads
Wind turbine development requires measurement of extreme loads and fatigue loads relevant to the structural design of main components.
Load calculation is a fundamental aspect of development projects, and also part of many sales projects. Work focuses on refinement of existing turbine and blade designs, development of turbine controls, and development and testing of new computation methods. In offshore projects load computations are important at an early stage in the design and sales work, thus providing opportunities to cooperate with customers and foundation designers throughout the course of the project.
Load computations must be approved by an impartial third party, presenting further challenges. Another central function of load calculations is to gain an overview of the inputs and postulates for simulations, and understand, control, and communicate results based on fundamental knowledge of dynamics and wind loads.
Work is performed individually, in groups, and in cross-divisional projects. Loads are primarily determined through dynamic time domain analyses carried out using our FEM-based aeroelastic program BHawC. Models and computations are verified with the aid of full-scale measurements on prototype turbines. The engineering department develops all of its own software tools and adapts them to the tasks at hand.
4
Construction
The construction work is divided into four groups: mechanical design, tower design, PTA, and service documentation.
Construction staff contribute significantly to development and sales projects. Responsibilities include drawings and specifications for all turbine components, participation in development projects, maintenance optimization of series-produced turbines, as well as modification or new design for sales projects. Additionally, problemsolving related to production tools, shipping and lifting equipment, turbine manuals, and spare parts catalogs is entailed in construction.
Work is group-oriented, and involves various teams within the engineering department. The duration of a project varies greatly, lasting from a few weeks to several years. 3D Inventor is the program used for design. FEM (Ansys) is used for computations and analysis. The editing and publishing tool for service documentation is FrameMaker, and the ERP system is SAP.
5
“We are highly motivated by having such a great influence on the development work. We help come up with solution proposals, develop them, and make decisions. In principle, we set our own limits to the level of responsibility we want.”
Martin Hansson MSc, Civil Engineering
Structure
Structural design of wind turbine components is an exciting challenge.
The challenge is to design the components for optimal strength while minimizing price and weight. In addition to design of components, structural work includes development of concepts for shipping the massive components from the manufacturing plant to the installation site. In both areas creativity and ingenuity are essential.
Tools used include a wide range of software such as FEM for static analyses, complete non-linear analyses, buckling analyses, contact analyses, transient and modal analyses, and in-house codes for processing large time series. Our computation methods and in-house codes allow us to design all components precisely in relation to extreme loads and fatigue loads as well as the overall dynamics of the turbine.
6
“As a mechanical engineer, it is very inspiring to work with wind turbines, because a turbine, from a mechanical point of view, has everything you could want in the machine industry. Things never get too theoretical because the production and development workshop is right next to the engineering department. So you can perform practical tests and monitor the changes in production at close quarters.”
Johnny Kjeldsen MSc, Electromechanical System Design
Mechanics
Mechanical and hydraulic components primarily include rotating parts in the hub, the transmission system, and the yawing system.
The transmission system – including main bearings, gears, couplings, hydraulic brakes, and mechanical rotor locks – is one of the major components handled by the mechanical engineers. The hub is composed of blade bearings and the hydraulic pitch system. Lubrication systems for bearings and gears as well as cooling of all large components also constitute a large part of the work. In addition to the design and selection of components and systems, input for quality control and general follow-up with sub-suppliers require a great deal of attention.
We do not focus exclusively on individual components but consider entire systems and the connections between components. This gives us a sound understanding of the interaction between the most vital parts of the turbine. A number of tools are applied to solve tasks, including software developed in-house in response to specific requirements such as machine monitoring and data collection from the turbines. The more traditional tools used are CAD programs and FEM software.
Matlab/Simulink is preferred for the simulation of mechanical and hydraulic systems, as well as programming and data analysis. In cooling and ventilation, CFX analysis and simulation is completed with software such as EES.
7
Electrical hardware
Design of electrical components (hardware) is a diverse area of responsibility.
The tasks involved encompass a wide range of technical aspects, such as controls, power electronics, and high-voltage equipment. The main components include generators, frequency converters, and transformers. These components are part of the power circuit of the wind turbine and play an important role in the conversion of rotating mechanical energy to electrical energy, which can then be supplied to the power grid. All electrical components are functionally designed to withstand mechanical and electrical impacts, including external environmental impacts such as lightning.
8
Engineers execute thorough verification of individual electrical components. Extensive measurements and tests are performed before and after installation of the turbines to validate interaction between the individual components. Work is completed through cooperation with immediate colleagues, as well as interaction across the engineering department. Close contact with subsuppliers and the project department is also necessary when specific customer requirements arise.
“The interesting thing about working with grid connection is that we not only cooperate with colleagues and across professional groups, but also work together with business partners all over Denmark and abroad. Furthermore, the technical solutions we work with can become rather advanced and complex, so you have to keep up-to-date with the latest technology.”
Michael Nørtoft Frydensbjerg MSc, Electrical Engineering
Grid connection
Design, simulation, and verification of the turbines’ grid properties are preconditions for connecting modern wind turbines to the power grid.
In order to be connected to the grid, compliance with grid connection requirements must be achieved. This is ensured through preparation of technical proposals based on simulation studies aimed at continuously enhancing grid properties and adapting them to the latest Danish and foreign requirements regarding voltage quality, active and reactive power regulation, and stability in short-circuit situations. Support is provided for the sales and project departments through static and dynamic studies which determine if wind power plants meet existing grid requirements.
Numerical computation models representing the electrical properties of a turbine in response to different types of electrical events are developed. Work primarily includes modeling within dynamic and harmonic areas. A number of different computation tools are used such as Matlab/Simulink, PSS/E and DIgSILENT.
9
Global research and development
Siemens looks for competencies among the most specialized people.
Competence centers are an integral part of the engineering department. Siemens has established a number of competence centers in Denmark, the Netherlands, the UK, Germany, China, and the US, and in universities or other research institutions with competencies in specific professional fields that are vital to Siemens Wind Power. These are typically fields in which it can be difficult
to recruit the necessary specialists to the headquarters in Brande. A location in close proximity to a university or a research institution provides Siemens Wind Power the opportunity to cooperate with external partners through research projects or PhD theses. The competence centers are constantly developing, while we also work to establish new cooperative agreements.
10
Competence centers
Denmark: Copenhagen Aerodynamics, structural dynamics, embedded software, SCADA, electrical systems, distribution grids, modeling, and regulation UK: Keele and Sheffield Keele: Frequency converters, grid requirements, and software Sheffield: Generator technology The Netherlands: Delft Offshore technology, wind turbine technology, and modeling
Germany: Aachen Gear technology, machine elements, metallurgy, and general machine technology US: Boulder and Orlando Boulder: Meteorological research, aerodynamics, structural dynamics, and operation and maintenance of wind power plants Orlando: Regional project support China: Shanghai Regional SCM support
11
Testing and validation
Meteorological measurements, noise and vibration measurements, as well as measurements on turbines and turbine components are important when a design is to be validated, and when new knowledge is needed.
Every phase of working with wind turbines involves measurements throughout the sales, project, and engineering departments. One of the more visible measurements is full-scale blade testing. For this purpose several test stands are used to perform accelerated blade fatigue and extreme tests.
Structural measurements are carried out on turbines all over the world. Once a measurement has been commissioned and the equipment calibrated, it must continue to operate unmanned for up to several years at a time. This requires extremely robust equipment and software. Measuring systems are therefore developed and built in-house to meet specifications of the task at hand. Likewise, because there are no commercially available programs with the necessary flexibility, proprietary software is used for data collection, analysis, and documentation of measured data.
In addition to structural measurements, yield and noise measurements on turbines erected for sales projects are also performed. Early on in the development projects numerous lab tests are performed on key components. This allows for optimization of the product before even the first prototype is built. Testing of new sensor types is an important task in this area.
12
“There is something fascinating about developing the software that makes these enormous power plants function fully automated. This software enables you to operate turbines all over the world from a central location.”
Jesper Behrens Andersen BSc, Electrical Engineering
Software
We develop our own software for operation of Siemens wind turbines.
Software development encompasses a wide spectrum of projects dealing with embedded systems and PC systems. Embedded software development projects include development of control, regulation, and monitoring functions. The extent of projects varies between development and implementation of small changes in the control functions and development of advanced adaptive regulation systems with regards to minimization of loads, optimization of production, etc. The PC system projects include development of central data collection servers, graphic presentations of trend curves, and reports.
Windows.NET and C# constitute the development platform for PC systems. All project phases are handled by our software experts. Software is developed for a wide range of embedded hardware platforms, from 16-bit microcontrollers to x86 and Texas DSP processors. The latest technologies in real-time operating systems, software development, and hardware platforms are applied. The central monitoring system is a PC-based system, which serves as the tool for daily monitoring and operation of entire wind power plants.
The department handles a wide range of tasks, from regulation technologies via communication protocols to database reporting. The primary tool is Microsoft Visual Studio, using C#. The system’s general operating interface is a Web application encoded in asp.net using AJAX technology and a limited number of Java applets. The platforms are exclusively Microsoft operating systems, and Windows 2003 Server and Windows XP Embedded are currently being used. Matlab/Simulink is primarily used in simulation.
13
“Advanced blades are up to 60 meters long and sweep an area greater than one hectare in a single turn. The design of a blade is a complex optimization task. Between specific blade design phases, we evaluate processes and the tools are honed for the next project. This is applied science where the path from idea to realization can be very short, and where innovation and creativity are key words.”
Jesper Laursen MSc, PhD, Dept. of Civil Engineering
Aerodynamics
Aerodynamics is one of the company’s core areas. Blade-related aerodynamics encompasses profile design, blade design, flow conditions in hilly terrain, and analysis of load and power curve measurements.
In the aerodynamic design of new blades, every tool is applied to achieve the perfect design – new profiles are developed, the blade shape, twist, and thickness are optimized, and the RPM, pitch angles, and tip design are adjusted to obtain efficient and noiseless operation. To a large extent we use CFD computations of profiles and the rotor, wind tunnel measurements, and customdesigned optimization tools for this task.
Work is performed in conjunction with technology development projects, load simulations, and blade development. We ensure our position at the cutting edge of aerodynamics research by participating in various Danish and international research projects, attending conferences, and publishing in scientific journals. Wind tunnel testing and fullscale testing of operational turbines are implemented.
14
Blade development
Design and production of new blade types require focus on safety, quality, and cost in specifying materials and casting processes.
Sizing and design of new blade types are performed using Siemens’ unique IntegralBlade® technology. The aim of the design process is to obtain an ideal balance between optimum mechanical properties, weight, and cost. The structure is optimized for different load situations using advanced structural methods, including non-linear FE analysis (Ansys). Verification is achieved via static and dynamic testing of full-scale prototypes and field measurements. Production documentation and blade certification are important elements in the development of new blade types.
The qualification of blade materials and specification of processes used in the production units are essential tasks. Materials are developed for blade laminates in close cooperation with blade structure teams and sub-suppliers. Further development of the advanced casting concept used in production and surface treatment ensures Siemens’ technological leadership. Daily work combines experimental and theoretical tools, such as lab testing of individual materials, CFD simulation of vacuum injection, sectional casting, and
complete blade casting. The scope of design tasks ranges from components of a few grams to molding equipment of 50 tons. Part of the development of new blade types is the design and development of a variety of custom-made production tools, such as blade casting molds which generate external and internal blade geometries, and blade handling equipment used for the blade finishing processes.
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“My tasks as technical project manager span from highly technical discussions to commercial meetings and scheduling. Two workdays are never alike. During the project new challenges arise, and you can never be certain what will happen next week. Through the development of new methods and the handling of ad hoc assignments, the job as technical project manager enables me to feel the pioneering spirit that initiated the wind turbine adventure years ago.” Thomas Mousten MSc, Civil Engineering
Offshore
Offshore projects are a major business for Siemens Wind Power and demand expert knowledge.
In offshore, the focus is on contributing to existing projects, as well as creating new solutions for offshore challenges, such as installation and safe access in rough weather conditions. Participation is also required in the sales process for future projects.
Tasks vary greatly, from practical participation in the installation of wind turbines to technical discussions with customers concerning project implementation. Theoretical studies of future methods for shipping and installation are also involved. 3D-CAD and scale models of turbines and vessels are used to evaluate the feasibility of new methods.
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R&D and Technology projects
Professional and efficient completion of projects is crucial for the achievement of successful products.
New technology and advanced components result in increasingly complex development projects. Often, development projects span the entire company, placing greater requirements on project management, project management tools, and communication. An overview of the project portfolio, ongoing projects, and projects in their
final stages is maintained, in order to facilitate prioritization and achieve maximum gains. Another important aspect is to ensure effective communication between all project managers in order to create channels for shared knowledge. Projects are carried out through development, testing, and optimization.
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“In order to be a technology leader, it is necessary to be able to think innovatively and see beyond the many pressing daily tasks. The think tank is a forum in which inventiveness, innovation, and fresh thinking in the engineering department are given free rein. The participants ensure that inspiration is propagated throughout the entire engineering department in order for it to impact daily activity. The think tank is thus one of many important means for maintaining our status as a technology leader in the wind turbine industry. ”
Henrik Stiesdal Chief Technology Officer Siemens Wind Power A/S
Technology
The Technology organization manages the company’s technology development and product portfolio work. This includes the setting out of strategies for the technology development process, and the facilitation of Engineering efforts through assistance with processes, IP, etc. The overall target is to ensure that we “do the right things and do them right” when providing Siemens with the product-related basis for market leadership. The technology department has five groups: Product Portfolio Management: Provides the basis for all product-related decisions aimed at securing market leadership. This includes creating and maintaining a product strategy, ensuring that product decisions are taken throughout a product’s life cycle, and are based on relevant and up-to-date information about markets, competitors, and technologies.
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Innovation Management: Manages and reinforces innovative processes in Engineering. Work includes creating awareness of innovation as a key factor for market leadership and the management of our Think Tank. The group is also in charge of the technology project process and the technology roadmap. IPR: Provides company-wide assistance in relation to Intellectual Property Rights, which mainly pertains to assistance to Engineering regarding patents. This includes developing and maintaining a strong patent portfolio of wind power technology and monitoring competitors’ patent activities.
Advanced Technologies: Carries out initial research in relation to technologies that do not fall within the scope of the usual Engineering activities. The overall evaluation of technical solutions, scouting of turbine-relevant technologies, and specific research in key technology areas are included in this group’s responsibilities. Research Management: Coordinates research with external partners, including other Siemens partners. This includes the creation and management of research opportunities and management of the necessary agreements.
“My work offers exciting engineering challenges, and I am motivated by the fact that it contributes to the continuing development of environmentally friendly wind power. I care deeply about energy supplies and the environment, so I am proud of the solutions and results that we help produce.”
Jan Thisted Power Systems Engineer
We make a difference!
A job at Siemens allows you to help the environment.
Do you want to help shape the future of sustainable energy? Siemens Wind Power is your best career opportunity! Today, wind power makes up only a small fraction of the global energy supply. Siemens Wind Power solutions will play a critical role in meeting the world’s power consumption as demand for renewable energy increases. Siemens’ global presence spans more than 190 countries, offering numerous career opportunities around the world.
With colleagues from more than 50 nationalities in Siemens Wind Power alone, you will be working in a truly inspiring, global environment. As an engineer at Siemens Wind Power, you have the opportunity to impact the global environment. By contributing to the continuous development of reliable, cost-efficient wind turbines, you can really make a difference!
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Published by and copyright © 2010: Siemens AG Energy Sector Freyeslebenstrasse 1 91058 Erlangen, Germany Siemens Wind Power A/S Borupvej 16 7330 Brande, Denmark Phone: +45 99 42 22 22 www.siemens.com/wind Renewable Energy Division Order No. E50001-D310-A144-X-4A00 Printed in Denmark fb 2581 WS 02103.
Printed on elementary chlorine-free bleached paper. All rights reserved. Trademarks mentioned in this document are the property of Siemens AG, its affiliates, or their respective owners. Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.
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