Post on 18-Aug-2015
transcript
Retrofit of control systems in wind turbines AWEA Wind Project O&M and Safety Seminar 2015, San Diego, California
03.02.2015 Rasmus Nielsen, Technical Product ManagerNiels K. Christensen, Sales Manager
[To be shared after presentation]
Retrofit of turbine controls systems
AgendaWhat to expect?
1. Our track record in wind turbine control systems
2. Why retrofit a control system?
3. Case: Bonus 1.3 MW
4. Results / lessons learned
5. Show me the money
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Retrofit of turbine controls systems
Looking backOur track record in wind turbine control systems
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1990 -> Sole supplier of control systems to Bonus/Siemens
1978We develop the world’s first control system for a modern wind turbine – a 50kW Windmatic
2012KK retrofits a V80 turbine incl. converter
2014KK develops retrofit solutions for Bonus 1.3 MW and Vestas V47 turbines incl. SCADA
TODAY we have ~20.000 control systems installed globally and 60% of all offshore turbines are equipped with a control system from KK Wind Solutions
WTC1 WTC2 WTC3 WTC6
Retrofit of turbine controls systems
Why retrofit the control system?Voice of the turbine owner/operator
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• Economic feasibility• Mechanical loads• Communication with sub systems• Communication with SCADA system
ConcernsBenefits
• Increase output• Lower O&M costs• Secure data access and quality• Enable asset management • Enable in-sourcing of service• Secure spare part availability • Enable optimization with configuration
layer and source code• Automatic/remote reset of alarms• Intelligent power reduction instead of
stopping
Retrofit of turbine controls systems
Bonus 1.3 MW caseWhat’s in the box?
Mandatory• Main controller• Grid measurement module• IO modules (Input/Output)• Pitch control module
Optional• Accelerometer• WiFi access for service• Datalogger• Service tablet
IO Module
IO Module
Accelerometer
Pitch control module
IO ModuleDatalogger
Main controller Grid measurementService tablet
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Retrofit of turbine controls systems
Bonus 1.3 MW casePitch control replacement
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Retrofit of turbine controls systems
Bonus 1.3 MW caseNacelle control replacement
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Retrofit of turbine controls systems
New O&M InterfaceImproved data access, remote control and root cause analysis tools
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• New web based service interface for local and remote operation• New web based SCADA system for park level monitoring • Customize interface e.g. with site specific service procedures• Upgrade turbine software remotely• Use extensive statistics and detailed data for analyzing problem root causes
Retrofit of turbine controls systems
ResultsImproved power curve
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0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 250
200
400
600
800
1000
1200
1400
Power Curve [kW]
Before
After
Wind Speed [m/s]
Retrofit of turbine controls systems
ResultsImproved remote control and statistics
Remote reset of known alarms provides higher availability and lowers maintenance
Improved operation statistics enables root cause analysis and lower O&M costs
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Yaw activity measured to be ~165,000 starts/year.
This is reduced around 50%, providing less yaw motor replacements
Retrofit of turbine controls systems
Assumptions:Number of turbines: 50Price per MWh: 55$Installation time: 2 days
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Show me the moneyPayback time less than 3 years
Investment $ 818,000
Availability improvements
Yaw $ 41,323
Pitch $ 75,490
Other $ 49,560
Total $ 166,373
O&M cost reduction
Yaw $ 11,390
Pitch $ 23,737
Other $ 16,030
Total $ 51,157
Power curve improvement $ 103,975 Total added revenue per year $ 321,505 Payback time in years 2.5
As well as economical feasibility, retrofit also reduces the risk of accidents due to improved safety components.
Retrofit of turbine controls systems
RecapMain conclusions
Retrofit of Bonus 1.3MW turbines show economical feasibility and payback time of less than three years
Retrofit has shown improvements in Power curve, Availability, Safety and O&M-effort
Solutions for Bonus 1.3MW and Vestas V47 are now commercial available
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Controls upgrades are substantially more profitable than other value chain elements of turbine sales or service.
Source: MAKE Consulting – Global Wind Turbine Trends 2014, page 32
Retrofit of turbine controls systems13
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