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

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Thank you for your attentionLearn more at kkwindsolutions.com