Reducing costs of offshore wind - Opportunities for ... · Reducing costs of offshore wind - Opportunities for condition monitoring ... Bently Nevada (GE) ... Emerson Process Management

Martin Elliott Senior Engineer [email protected]

Reducing costs of offshore wind - Opportunities for condition monitoring

2 © BVG Associates 2013


Building an Industry

Wave & Tidal Energy in the UK Pathways to Cost Reduction in Offshore Wind: Technology

Client: RenewableUK & The Crown Estate Date: June 2013

Client: RenewableUK Date: March 2013

Client: The Crown Estate Date: June 2012

State of the Industry Report: Onshore and offshore wind

UK Content Analysis of Robin Rigg offshore wind farm & O&M services Offshore Wind: Forecast of Future

Costs and Benefits Client: RenewableUK Date: October 2011

Client: E.ON Date: September 2011 & November 2012

Client: RenewableUK Date: June 2011

Offshore Wind: Opportunities for the Composites Industry

Wave & Tidal Energy in the Pentland Firth & Orkney Waters

A Guide to an Offshore Wind Farm

Client: The Crown Estate Date: June 2011

Client: The Crown Estate Date: May 2011

Client: The Crown Estate Date: January 2010

BVG Associates

Market analysis & business development •  Supply chain development •  Economic impact assessment •  Support to industrialisation

Technical innovation & engineering analysis •  Support to investment in technology •  R&D programme management •  Design and engineering services

Project implementation •  FIT project development (UK only) •  SCADA & condition monitoring •  O&M technical support

Technical education


© BVG Associates 2013 5

Condition Monitoring – Roadmap for next 15 mins


•  Wind industry – Growing up •  What IS condition monitoring? •  What it’s good and not good at •  Pathways to LCOE reduction •  Another way •  The ideal •  A few examples of innovation •  What can YOU bring to the table?

The wind industry is growing up


The wind industry is growing up

•  1984 – Onshore – 250kW / 25m dia •  Simple controls & monitoring via SCADA •  Handful of sensors •  “Agricultural” engineering

•  2004 – First “near” offshore UK wind farm – 2,000kW / 80m dia

•  Scroby Sands – Vestas V80 “Onshore” turbine •  Early drive train “Condition Monitoring System” (CMS)

•  2013 – Alstom / Areva / Samsung / Siemens / Vestas - 6,000kW / 155m dia

•  Designed for offshore •  1000+ sensors •  CMS on drive train, rotor, structure(?)

•  2023 - Far offshore – 10,000kW / 200m dia

•  Designed for reliability •  Integrated control, condition monitoring and asset management tools •  Comprehensive remote diagnostics and prognostics


What is Condition Monitoring? - Purpose

Using … •  Status monitoring = For routine reporting and operational safety •  Fault detection = finding problem (after failure = needs repair) •  Diagnostic = finding cause of problem •  Prognostic = predicting future failure To … •  Enable service crew to address problem:

•  Before failure (ie. minimising maintenance cost & lost revenue)

•  At planned time (eg low wind) •  On their first visit

•  Understand root cause of problem (may feed back to design) •  Minimise workload of engineer input looking at data from multiple sites


What is Condition Monitoring? - Data

•  Wind turbine controller •  Between 1 and 50 samples / sec [Hz] •  In excess of 1000 ‘sensors’

•  SCADA

•  Events and 10 minute average data •  Some moves to “on change” data logging

•  “Condition Monitoring System” (CMS)

•  50,000 samples / sec [Hz] •  Frequency analysis •  Drive train, and increasingly rotor

•  Structural Health Monitoring (SHM)

•  Around 5 samples per second •  Strain; Scour; Corrosion;


Condition monitoring: recent trends

1.  Market for condition monitoring systems has not grown as fast as anticipated 5 years ago

2.  All offshore wind turbine manufacturers include some level of CMS. Most are independent ‘add on’ systems – Some now integrated

3.  WTMs and others bringing experience from other sectors

4.  Technical trend towards: •  Use of more types of sensor •  Monitoring more components •  Looking wider across systems •  Analysing data from many turbines, centrally •  Use of more wind turbine design understanding and modelling


Condition monitoring: What is measured


Company System Tempera

ture

Humidity

Pressu

re

Acousti

c emiss

ion

Cleanlin

ess (

oil)

Electri

cal

StrainAcc

elero

meter

Displac

emen

t

Tacho

meter

VideoRoto

rDriv

etrain

Tower

Areva/01db-Metravib Drivetrain OneProD ü ü ü ü üBently Nevada (GE) WT-CMS Adapt.wind ü ü ü üBeran Instruments PlantProtech ü ü ü ü üBrüel & Kjær Vibro WTAS - Type 3651 ü ü ü ü ü ü ü üEickhoff E-GOMS ü ü ü üEmerson Process Management epro MMS ü ü üFAG FAG WiPro ü ü ü ü ü ü üGamesa SMP-8C ü ü üGlobal Maintenance Technologies E-Sentry System ü ü ü ü üGram & Juhl TCM® ü ü ü ü ü üHolroyd Instruments AE Systems ü ü üIGUS ITS BLADEcontrol® ü üInsensys RMS ü ü üPrüfteknik Condition Monitoring VibroWeb XP ü ü ü ü üRovsing Dynamics Winergy CDS ü ü ü üSiemens Wind Power AS FLENDER CM ü ü ü ü üSKF WindCon ü ü ü üVatron DriveMon Wind ü ü üWindSL WT-HUMS ü ü ü ü ü ü üµ-SEN Ω-Guard® ü ü ü(excludes single-sensor type systems based on acceleraometers AE, US, oil cleanliness sensing; also analytics only suppliers)

Condition monitoring: what is a CMS good & not good at

ü Bearing damage •  Detect and prognose •  Gearbox (especially HS stage), main bearing, generator bearings

ü Gear tooth damage •  Detect and prognose

ü Abnormal operation •  Gross yaw and pitch system defects

û Adding up fatigue life from day 1 & predicting date of failure

(and are unlikely ever to do so)

û Diagnosing root cause (not yet!)


LCOE – Pathways to £100/MWh [#12]


[#12] “Offshore wind cost reduction pathways: Technology work stream”, BVG Associates, June 2012 – Available from www.bvgassociates.co.uk

2013: LCOE = 140/MWh CF = 40%

FID 2020: LCOE = 100/MWh CF = 51%

LCOE – Pathways to £100/MWh – Impact of CM


LCOE – Pathways to £100/MWh – Downtime and OPEX


2011: Downtime contribution 2011: Share of £74k/MW/yr OPEX

Pathways: One developer’s roadmap [#1]


[#1] Interview with Benj Sykes of Dong Energy Wind Power – Wind&WaveCONNECT September 2013

High reliability and efficiency

Remote condition monitoring and

diagnostics

£87/MWh

Condition Monitoring: another way

•  Think differently: combine with condition-based maintenance = focus on the components that need it

•  Challenge: •  Needs more understanding of the technology •  = input from designers of WTM, structure and other BOP components


Failure-based maintenance

Time-based maintenance

Condition-based maintenance

Mai

nten

ance

Stra

tegi

es

Condition Monitoring

Condition monitoring: the ideal Turbine control

system Multiple systems

Rotor

Multiple turbines


Multiple components

Turbine Design

Knowledge

1

3

2

4

Condition Monitoring - Examples

•  Vessel Motion Monitoring §  James Fisher / Strainstall §  Widens operational window §  Mitigate against nausea §  Protect equipment and

personnel

•  Scour monitoring §  James Fisher / Strainstall §  Continuous monitoring §  Reduces diver / ROV

requirement


www.strainstall.co.uk www.strainstall.co.uk


•  Array cable monitoring §  HVPD Ltd / IPEC Ltd §  Technology transfer from

onshore power distribution §  Early warning of array cable /

joint / termination failure

•  CCTV // VOIP // Security §  Siemens Building Technology §  Installed on Greater Gabbard §  Potential technician head-cams

to aid diagnostics and recording


www.hvpd.co.uk / www.ipeceng.com/ / www.siemens.co.uk/securitysolutions


•  Holistic monitoring & prognostics §  Romax Technology §  Grown from automotive

drivetrain design history §  Monitoring / fault finding

service and software tools §  Equivalent Operating Hours

•  Holistic monitoring & prognostics §  Critical Group §  Knowledge transfer from

aerospace and other energy sectors

§  Integrate CMS / Command and Control and Asset Management


www.romaxtech.com/ www.critical-software.co.uk/

Condition Monitoring – Many more examples


•  Autonomous Unmanned Aerial Vehicles (UAV) for blade inspection

•  Oil analysis – Lab on turbine

•  RFID tagging for component inventory control

•  Equipment configuration control and e-documentation

•  Power semiconductors – Monitoring at device level

•  Decision support tools

•  Personnel tagging / tracking

•  Autonomous robotic wind turbines service technicians!

Offshore Wind – Some other funding sources

•  GROW Offshore •  Government-sponsored,

industry-led programme that is intended to stimulate the supply chain in the UK

•  Up to 10%-30% of £500k •  Match fund consultancy

support up to 50% •  Strong focus on jobs created •  Programme just starting so

“now” is a good time.

•  Offshore Renewable Energy Catapult

Looking for projects that are §  Innovative §  Technically grounded §  Supporting SMEs §  ‘Game changing’ §  Bringing value/jobs to UK


Condition Monitoring – What can YOU bring to the party?


•  Lots of opportunity for the right products and services BUT … •  European / Worldwide marketplace (not just UK) •  Need clear benefit to reduce LCOE (Increase AEP / Reduce OPEX) •  DECC website – Simple LCOE tool

•  Other funding available

•  DECC •  Offshore Renewable Energy Catapult •  GROW Offshore •  TSB

•  Help available

•  BVG Associates … or there are other consultancies!

•  Questions? •  Or let’s talk over coffee or lunch

THE END!


Condition monitoring: typical business case

•  Pay €X + €Y/year •  Avoid lost revenue of €Z •  Avoid large component replacement cost of €A

•  eg set of bearings instead of complete gearbox •  1 service van instead of 4 vans and a crane etc.

•  CMS supplier examples always look great •  Detect the problem •  Generic reliability data often ‘old’

and generic

•  Customers are enjoying benefits •  Payback average 2-8 years

(looks best for larger turbines & offshore)

•  See also DECC website for simple LCOE model


Documents

Reducing costs of offshore wind - Opportunities for ... · Reducing costs of offshore wind - Opportunities for condition monitoring ... Bently Nevada (GE) ... Emerson Process Management