Seminar Offshore Wind Energy Greenbridge Oostende – 04/06/2015

The importance of test and monitoring solutions

to increase resilience and mitigate risk for offshore wind turbine systems

Pieter Jan Jordaens

Business development & Innovation – Sirris, department OWI-Lab

pieterjan.jordaens@owi-lab.be / www.owi-lab.be

Content of this presentation

1) Introduction Sirris & OWI-Lab

2) Short review on offshore wind energy - Drivers

- Technological Evolution

- Market trends

- Challenges

3) Reliability issues

4) Risk mitigation pathways

5) Test & monitoring examples

Sirris – collective technology centre

Non-profit Belgian technology centre

Mission: to support companies with implementing technology innovations

160 engineers and scientists

Multidisciplinary R&D and innovation projects Mainly for Belgian companies (SME & Large)

Also shared R&D projects with EU companies

High tech R&D infrastructure

Sirris – collective technology centre

Department OWI-Lab

Open R&D&I

Platform

Research test &

monitoring

infrastructure

Collaborative R&D &

Innovation projects

Industry Academic institutes

http://www.owi-lab.be/content/climate-chamber-testing

OWI-Lab Offering: Structural Health Monitoring

Foundations

OHVS structures

Thermal camera monitoring

Condition Monitoring (CMS)

Performance Monitoring

Design Verification Measurements

Vibration measurements

http://www.owi-lab.be/content/services

2

2

2

Why OWI-Lab and need for R&D?

Content of this presentation

1) Introduction Sirris & OWI-Lab

2) Short review on offshore wind energy - Drivers

- Technological Evolution

- Market trends

- Challenges

3) Reliability issues

4) Risk mitigation pathways

5) Test & monitoring examples

2.488 = Number of offshore wind turbines in Europe at the end of 2014

8.759 GW = The amount of offshore wind power installed globally at the end of 2014

More than 91% (8,045 MW) of all offshore wind installations can be found in European waters

Overview technology progress & key trends: Two main drivers in wind turbine technology to date

1 2

36 8 3 10

Size & MW evolution

Source: OWI-Lab - overview 2014

Siemens 6MW blade: 75m vs. A380 wing span

73,5m

V52-850kW

Hub height 54m

100m

83,5m

80m

Two main drivers in wind turbine technology to date

100€/MWh (Target Dong Energy)

Drivers for wind energy R&D

100€/MWh (Target Dong Energy)

Drivers for wind energy R&D

LCOE Offshore Wind Energy

Timeline LCOE OFFSHORE

LCOE 2012 ± 173€/MWh – 185€/MWh (2 x onshore)

LCOE 2020 (forecast) ± 100€/MWh – 123.5€/MWh

LCOE 2030 (forecast) ± 86€/MWh – 99€/MWh

Grid parity reached for average wind farm * After 2020

* Depending on oil & gas prices; siting; CO2 tax,…

Sources : The Crown Estate, Bloomberg New Energy Finance

“Offshore wind power is an industry

15 years behind onshore in terms of maturity”

innovation needed !

Cost history - CAPEX €/MW installed

Near-shore wind turbine (1,8km)

450kW / OEM: Bonus

LCOE Offshore Wind Energy

OFFSHORE CAPEX

Source: ZF Wind Power Antwerp NV

Inauguratin climate chamber

OFFSHORE OPEX

OFFSHORE 25% - 30% of LCOE 44.8€/MWh – 53.7€/MWh (gem.)

ONSHORE:

1980: 50€/MWh ≈ offshore now

2011: 11€/MWh

Source: ECN, O&M Workshop Oostende

Bloomberg New Energy Finanance

Overview technology progress & key trends

Good practices to lower LCOE “Reduce the cost of installation”

Good practices to lower LCOE “Reduce weight; Increase capacity”

Vs.

250MW

Good practices to lower LCOE “Higher reliability & improved O&M”

Advanced testing & test methodologies

Advanced O&M tools & improved monitoring tools

Good practices to lower LCOE “Higher reliability & improved O&M”

LPF definition: Percentage of MWh loss

during downtime out of total Possible

Production

Overview technology progress & key trends: Past growth & future prediction

Consolidation

…

Overview technology progress & key trends

- Business normalization

- New markets

- Cold climate

- Hot / Tropical climate

- …

Overview technology progress & key trends

Risky business – “only the strong survive”

Overview technology progress & key trends: Challenges for offshore wind

Do we understand the real loads in these

harsh environments where offshore wind turbines

are installed?

Vibration levels, Temperatures (cold & warm) , Humidity,

Electromagnetic noise,…

Offshore wind Offshore Oil & Gas

Overview technology progress & key trends: Challenges for offshore wind

A wind turbine is a very dynamic system,

and it’s dynamics are depending on

environmental loads in combination with

it’s operational status

Tacoma Narrows Bridge 1940 Wind induced vibrations

Overview technology progress & key trends: Challenges for offshore wind

New markets? Baltic Sea and Arctic Offshore

Wind farms pose even bigger technical challenges

Brittle fracture: Liberty ships 1943 - Cold North Sea Water 1943: #20

1944: #120

Robustness optimization

Source: Vestas

Lessons from automotive testing

Content of this presentation

1) Introduction Sirris & OWI-Lab

2) Short review on offshore wind energy - Drivers

- Technological Evolution

- Market trends

- Challenges

3) Reliability issues

4) Risk mitigation pathways

5) Test & monitoring examples

‘Small defects & damages’

Reliability issues: offshore wind is not immune for faults & errors

‘Small defects & damages’

‘Failure of large components’

Corrosion Tower failure

Suction bucket foundation failure - buckling Blade failure

Failure rate per component (1)

Source: ReliaWind

2008-2011

Downtime rate per component (1)

Source: ReliaWind

2008-2011

Failure rate per component (2)

Down-time rate per component (2)

Electrical & Mechanical failure causes

Summary of Reliawind – Critical Subassemblies & Highest Failure Modes

Case study Teesside Offshore Wind Farm – January 2014

Case study Teesside Offshore Wind Farm – January 2014

Message with regard to this topic of wind turbine failures & reliability issues

Take wind turbine failures in perspective

It takes time to reach a mature technology

Brothers Wright – First flight 1903

Airbus – First flight - 2005

102 years of development

1991 First offshore wind farm (nearshore) 450 kW turbines 4.95MW farm

22 years of development

2013 One of the latest offshore wind farms 6.5 MW turbines 325MW farm

How to increase resilience and

mitigate the Risk?

Risk mitigation pathways

Increasing Reliability and reducing Operation Costs

1 2

Specification

for the right environment

Increasing Reliability and reducing Operation Costs

Testing according the V-cycle

Different test rig concepts & test procedures

1 1

2

2 3 3

Example 1: end-of-line test

Example 2: end-of-line test

Example 3: Development test (climatic test multi-MW gearbox

Link aerospace testing

Example 4 : Development test RWTH Aachen

Content of this presentation

1) Introduction Sirris & OWI-Lab

2) Short review on offshore wind energy - Drivers

- Technological Evolution

- Market trends

- Challenges

3) Reliability issues

4) Risk mitigation pathways

5) Test & monitoring examples

Increasing Reliability and reducing Operation Costs

1 2

Specification

for the right environment

Maintenance approaches in general

1. Reactive or corrective maintenance (run to failure)

2. Preventive maintenance (time based)

3. Predictive maintenance

(condition based - CMS)

Trend for offshore wind O&M

New project @ OWI-Lab:

Offshore Wind Operations

& Maintenance Excellence

The dream… “See the bullet coming approach”

Count down approach with respect to lifetime & lifetime consumption - a combination of using real time data with advanced simulation models

Expected lifetime based

on loading history: 11 years

Exceptional values

measured on: 05-12-14

The dream… “See the bullet coming approach”

Count down approach with respect to lifetime & lifetime consumption - a combination of using real time data with advanced simulation models

Next critical repair:

Before 4 months

Target repair: Hspeed shaft

The aim of Prediction Maintenance

Avoiding costly failures in advance

Plan maintenance with minimum lost production

Predictive maintenance Real time monitoring

Of different components

CMS drivetrain

CMS electrical

SHM

Icing

…

Identify deviations

in performance

CMS drivetrain

CMS electrical

SHM

Icing

…

+ decision support

tools

Optimal maintenance

planning based on

weather forecasts

to minimize lost

production

Data & events

are used to improve

prediction models

(Simulation & real time coupled)

Business case EXAMPLE HVDP

Trends – Additional Instrumentation

Learning from other industries

Learning from other industries: SHM @ OWI-Lab R&D

Check out: https://www.youtube.com/watch?v=nLY2mLlka-s

Synergies in approach & technology

In-the-field tests to evaluate structural performance of an offshore wind turbine

Benchmark other industry:in-flight flutter test to evaluate structural performance Check out: https://www.youtube.com/watch?v=nLY2mLlka-s

http://www.24sea.eu/

Finisher: BIG DATA TREND

Predictive analytics for the power industry:

‘A cemetery of data, or a goldmine of opportunities?

www.owi-lab.be Projects VIS O&M Excellence http://www.owi-lab.be/content/vis-project-owome-offshore-wind-operations-maintenance-excellence

Offshore Wind Operations

&

Maintenance Excellence

Thank you for your attention!

Contact: pieterjan.jordaens@owi-lab.be

pieterjan.jordaens@sirris.be

+32 491345382

www.sirris.be

Group: Offshore Wind Infrastructure

Application Lab (OWI-Lab)

@OWI_lab

www.owi-lab.be/