Wind turbine prognostics

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Early small scale onshore Wind Turbines Barn wind turbines 0504.jpg
Early small scale onshore Wind Turbines

The growing demand for renewable energy has resulted in global adoption and rapid expansion of wind turbine technology. Wind Turbines are typically designed to reach a 20-year life, [1] however, due to the complex loading and environment in which they operate wind turbines rarely operate to that age without significant repairs and extensive maintenance during that period. [2] In order to improve the management of wind farms there is an increasing move towards preventative maintenance as opposed to scheduled and reactive maintenance to reduce downtime and lost production. This is achieved through the use of prognostic monitoring/management systems.

Contents

Typical Wind Turbine architecture consists of a variety of complex systems such as multi stage planetary gear boxes, hydraulic systems and a variety of other electro-mechanical drives. Due to the scale of some mechanical systems and the remoteness of some sites, wind turbine repairs can be prohibitively expensive and difficult to co-ordinate resulting in long periods of downtime and lost production.

As typical wind turbine capacity is expected to reach over 15MW is coming years [3] combined with the inaccessibility of Offshore wind farms, the use prognostic method is expected to become even more prevalent within the industry.

Modern Large Scale Offshore Wind Farm Barrow Offshore wind turbines NR.jpg
Modern Large Scale Offshore Wind Farm

Wind Turbine prognostics is also referred to as Asset Health Management, Condition Monitoring or Condition Management.

History

Early small-scale wind turbines were relatively simple and typically fitted with minimal instrumentation required to control the turbine. There was little design focus on ensuring long-term operation for the relatively infantile technology. The main faults resulting in turbine downtime are typically drive train or pitch system related. [4]

Wind Turbine Gearbox Replacement Gearbox , Rotor Shaft and Disk Brake Assembly for Turbine No 3 - geograph.org.uk - 758164.jpg
Wind Turbine Gearbox Replacement

There has been rapid development of wind turbine technology. As turbines have grown in capacity, complexity and cost, there have been significant improvements in the sophistication of instrumentation installed on wind turbines which has enabled more effective prognostic systems on newer wind turbines. In response, there has been a growing trend of retro-fitting similar systems on existing wind turbines in order to manage aging assets effectively.

Prognostic methods that enable preventative maintenance have been common place in some industries for decades such as Aerospace and other industrial applications. As the cost of repairing wind turbines has increased as designs have grown more complex it is expected that the Wind Turbine industry will adopt a number of prognostic methods and economic models from these industries such a power-by-the-hour approach to ensure availability. [5]

Data Capture

The methods for wind turbine prognostics can broadly be grouped into two categories:

Most wind turbines are fitted with a range of instrumentation by the manufacturer. However this is typically limited to parameters required for turbine operation, environmental conditions and drive train temperatures. [6] This SCADA based turbine prognostics approach is the most economical approach for more rudimentary wind turbine designs.

For more complex designs, with complex drive-train and lubrication systems, a number of studies have demonstrated the value of Vibration monitoring and Oil monitoring prognostic systems. [7] These are now widely commercially available.

Data Analysis

Once data is collected by on board data acquisition systems, this is typically processed and communicated to ground based or cloud based data storage system.

Raw parameters and derived health indicators are typically trended over time. Due to the nature of drive-train faults, these are typically analysed in the frequency domain in order to diagnose faults. [8]

GHE can be generated from a wind turbine SCADA (Supervisory Control and Data Acquisition) system, by interpreting turbine performance as its capability to generate power under dynamic environmental conditions. Wind speed, wind direction, pitch angle and othera parameters are first selected as input. Then two key parameters in characterizing wind power generation, wind speed and actual power output, collected while turbine is known to work under nominal healthy condition are used to establish a baseline model. When real-time data arrives, same parameters are used to model current performance. GHE is obtained by computing the distance between the new data and its baseline model.

By trending the GHE over time, performance prediction can be made when unit revenue will drop below a predetermined break-even threshold. Maintenance should be triggered and directed to components with low LDE values. LDE is computed based on measurements from condition monitoring system (CMS) and SCADA, and is used to locate and diagnose incipient failure at component level.

Machine learning is also used by collecting and analyzing massive amounts of data such as vibration, temperature, power and others from thousands of wind turbines several times per second to predict and prevent failures. [9]

See also

Related Research Articles

<span class="mw-page-title-main">Telemetry</span> Data and measurements transferred from a remote location to receiving equipment for monitoring

Telemetry is the in situ collection of measurements or other data at remote points and their automatic transmission to receiving equipment (telecommunication) for monitoring. The word is derived from the Greek roots tele, 'remote', and metron, 'measure'. Systems that need external instructions and data to operate require the counterpart of telemetry: telecommand.

Instrumentation is a collective term for measuring instruments, used for indicating, measuring and recording physical quantities. It is also a field of study about the art and science about making measurement instruments, involving the related areas of metrology, automation, and control theory. The term has its origins in the art and science of scientific instrument-making.

<span class="mw-page-title-main">Maintenance</span> Maintaining a device in working condition

The technical meaning of maintenance involves functional checks, servicing, repairing or replacing of necessary devices, equipment, machinery, building infrastructure, and supporting utilities in industrial, business, and residential installations. Over time, this has come to include multiple wordings that describe various cost-effective practices to keep equipment operational; these activities occur either before or after a failure.

<span class="mw-page-title-main">Remote terminal unit</span> Computer peripheral to collect telemetry data

A remote terminal unit (RTU) is a microprocessor-controlled electronic device that interfaces objects in the physical world to a distributed control system or SCADA system by transmitting telemetry data to a master system, and by using messages from the master supervisory system to control connected objects. Other terms that may be used for RTU are remote telemetry unit and remote telecontrol unit.

<span class="mw-page-title-main">FADEC</span> Computer used for engine control in aerospace engineering

A full authority digital engine (or electronics) control (FADEC) is a system consisting of a digital computer, called an "electronic engine controller" (EEC) or "engine control unit" (ECU), and its related accessories that control all aspects of aircraft engine performance. FADECs have been produced for both piston engines and jet engines.

Prognostics is an engineering discipline focused on predicting the time at which a system or a component will no longer perform its intended function. This lack of performance is most often a failure beyond which the system can no longer be used to meet desired performance. The predicted time then becomes the remaining useful life (RUL), which is an important concept in decision making for contingency mitigation. Prognostics predicts the future performance of a component by assessing the extent of deviation or degradation of a system from its expected normal operating conditions. The science of prognostics is based on the analysis of failure modes, detection of early signs of wear and aging, and fault conditions. An effective prognostics solution is implemented when there is sound knowledge of the failure mechanisms that are likely to cause the degradations leading to eventual failures in the system. It is therefore necessary to have initial information on the possible failures in a product. Such knowledge is important to identify the system parameters that are to be monitored. Potential uses for prognostics is in condition-based maintenance. The discipline that links studies of failure mechanisms to system lifecycle management is often referred to as prognostics and health management (PHM), sometimes also system health management (SHM) or—in transportation applications—vehicle health management (VHM) or engine health management (EHM). Technical approaches to building models in prognostics can be categorized broadly into data-driven approaches, model-based approaches, and hybrid approaches.

Reliability, availability and serviceability (RAS), also known as reliability, availability, and maintainability (RAM), is a computer hardware engineering term involving reliability engineering, high availability, and serviceability design. The phrase was originally used by International Business Machines (IBM) as a term to describe the robustness of their mainframe computers.

Condition monitoring is the process of monitoring a parameter of condition in machinery, in order to identify a significant change which is indicative of a developing fault. It is a major component of predictive maintenance. The use of condition monitoring allows maintenance to be scheduled, or other actions to be taken to prevent consequential damages and avoid its consequences. Condition monitoring has a unique benefit in that conditions that would shorten normal lifespan can be addressed before they develop into a major failure. Condition monitoring techniques are normally used on rotating equipment, auxiliary systems and other machinery like belt-driven equipment,, while periodic inspection using non-destructive testing (NDT) techniques and fit for service (FFS) evaluation are used for static plant equipment such as steam boilers, piping and heat exchangers.

<span class="mw-page-title-main">Predictive maintenance</span> Method to predict when equipment should be maintained

Predictive maintenance techniques are designed to help determine the condition of in-service equipment in order to estimate when maintenance should be performed. This approach promises cost savings over routine or time-based preventive maintenance, because tasks are performed only when warranted. Thus, it is regarded as condition-based maintenance carried out as suggested by estimations of the degradation state of an item.

High availability (HA) is a characteristic of a system that aims to ensure an agreed level of operational performance, usually uptime, for a higher than normal period.

Machine to machine (M2M) is direct communication between devices using any communications channel, including wired and wireless. Machine to machine communication can include industrial instrumentation, enabling a sensor or meter to communicate the information it records to application software that can use it. Such communication was originally accomplished by having a remote network of machines relay information back to a central hub for analysis, which would then be rerouted into a system like a personal computer.

A blade inspection method is the practice of monitoring the condition of a blade, such as a helicopter's rotor blade, for deterioration or damage. A common area of focus in the aviation industry has been the detection of cracking, which is commonly associated with fatigue. Automated blade condition monitoring technology has been developed for helicopters and has seen widespread adoption. The technique is routinely mandated by airworthiness authorities for engine inspections. Another commercial sector where such monitoring has become important is electricity generation, particularly on wind farms.

<span class="mw-page-title-main">Stand-alone power system</span>

A stand-alone power system, also known as remote area power supply (RAPS), is an off-the-grid electricity system for locations that are not fitted with an electricity distribution system. Typical SAPS include one or more methods of electricity generation, energy storage, and regulation.

Pipeline leak detection is used to determine if and in some cases where a leak has occurred in systems which contain liquids and gases. Methods of detection include hydrostatic testing, infrared, and laser technology after pipeline erection and leak detection during service.

Fault detection, isolation, and recovery (FDIR) is a subfield of control engineering which concerns itself with monitoring a system, identifying when a fault has occurred, and pinpointing the type of fault and its location. Two approaches can be distinguished: A direct pattern recognition of sensor readings that indicate a fault and an analysis of the discrepancy between the sensor readings and expected values, derived from some model. In the latter case, it is typical that a fault is said to be detected if the discrepancy or residual goes above a certain threshold. It is then the task of fault isolation to categorize the type of fault and its location in the machinery. Fault detection and isolation (FDI) techniques can be broadly classified into two categories. These include model-based FDI and signal processing based FDI.

Integrated vehicle health management (IVHM) or integrated system health management (ISHM) is the unified capability of systems to assess the current or future state of the member system health and integrate that picture of system health within a framework of available resources and operational demand.

<span class="mw-page-title-main">Stack light</span>

Stack lights are commonly used on equipment in industrial manufacturing and process control environments to provide visual and audible indicators of a machine's status to machine operators, technicians, production managers and factory personnel. They are a form of andon: a manufacturing system that identifies errors as they happen.

Dynamic line rating (DLR), also known as real-time thermal rating (RTTR), is an electric power transmission operation philosophy aiming at maximizing load, when environmental conditions allow it, without compromising safety. Research, prototyping and pilot projects were initiated in the 1990s, but the emergence of the "smart grid" stimulated electric utilities, scientists and vendors to develop comprehensive and sustainable solutions.

Eleni Chatzi is a Greek civil engineer, researcher, and an associate professor and Chair of Structural Mechanics and Monitoring at the Department of Civil, Environmental and Geomatic Engineering of the Swiss Federal Institute of Technology in Zurich.

References

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  3. "Next-Generation Wind Technology". Energy.gov. Retrieved 2020-02-19.
  4. "Wind Turbine Failures Encyclopedia". ONYX InSight. Retrieved 2020-02-19.
  5. "Reducing complexity in Wind Turbine Maintenance". ONYX InSight. 2019-06-24.
  6. ORE Catapult (UK). "Wind Turbine Condition Monitoring Methods" (PDF). ORE Catapult.
  7. García Márquez, Fausto Pedro; Tobias, Andrew Mark; Pinar Pérez, Jesús María; Papaelias, Mayorkinos (2012-10-01). "Condition monitoring of wind turbines: Techniques and methods". Renewable Energy. 46: 169–178. doi:10.1016/j.renene.2012.03.003. ISSN   0960-1481.
  8. "Machinery Diagnostics". ONYX InSight. Retrieved 2020-02-19.
  9. "Neurale netværk kan forudsige, hvornår møllens tandhjul knækker". Version2/Ingeniøren . 2016-11-19. Retrieved 19 November 2016.