Future Onshore Wind Energy Technology

2017 2018 2019 2020+

Future Onshore

Wind Technologies

Industry

Impact

&

Adoption

Time-frame

©2017 Totaro & Associates, All Rights Reserved

Site Specific Design

Hybrid Materials - Towers

Hybrid Materials - Blades

Yaw System - Sliding BearingComputational Component Validation Testing

Wake Effect Power Optimization

Neural Network / AI Controls

Passive Flexible Trailing Edge

Condition Based / Predictive Maintenance Program

Wireless SCADA / Power Plant Control

Fibre Optic Controller Architecture

UAV / Remote Inspection

Pre-cast Foundation

Electrical System Condition Monitoring

Model Predictive Control High Voltage Converter

Carbon Nanotube Ice Protection Coatings

AR / VR for Field Techs

Segmented Blades

Spares Inventory Mgmt. with Damage / RUL data

State Machine “App Store”

Max Revenue Power Delivery

Asset Performance Profiles (Reverse Engineering / Sensors)

Lifting Fixtures with Variable Orientation

Field Fixtures for Segmented Components

Integrated Power Plant Controls – RE & Storage

Ancillary Services

HTS Cables

Integrated Service Lift / Platform

Component 3D Printing / Materials

Future Onshore Wind Technologies

#30 Joint Transport Lifting Fixtures

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What is it?

Tower, blade or nacelle

transportation fixtures which

double as lifting fixtures

Why is it Important?

• Reduction of CapEx cost for

separate assemblies

• Improvement in safety - no

transport vehicle unmounting

and fixture disassembly

required

• Reduction in construction

cycle time (drive up and pick)


#29 Ancillary Services Support

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What is it?

Providing reactive power, managing

reserve power, reducing

congestion, storage integration


• Long talked about, now

becoming standard offering

• Improved grid stability enhances

wind park up-time

• Enables renewables to displace

conventional power while

behaving with the same grid

mgmt characteristics


#28 Carbon Nano-tube Coatings

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What is it?

Blade coatings for ice protection or

erosion prevention comprising carbon

nano-tubes


• Erosion resistance - material strength

significantly higher than conventional

tapes or coatings

• Efficiency improvement - allows for

smaller heating element in ice

protection systems (also negates the

need for hot air blowing systems)

• Limited impact from lightning strikes


#27 Wireless SCADA, Yaw, & Pitch

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What is it?

Wireless interconnection

of pitch & yaw controller

with turbine controller,

as well as SCADA &

remote monitoring


• Eliminates cables and

some communications

slip rings in the

turbines

• Challenge is connection fidelity, but the Wi-Fi technology used in

Formula 1 racing to connect cars to remote monitoring sites

proves the technology exists to enable this capability now


#26 Fiber Optic Turbine Controller

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What is it?

Interconnection of control

systems to sub-systems, such

as safety system, pitch, yaw &

converter with fiber optic cables


• For those who opt to avoid Wi-

Fi connectivity, fiber optic

connections have become

cheaper & viable for comms

• Increases response time for

pitch or yaw systems,

especially in EFF

• Patent on the subject was prematurely abandoned, making the

technology royalty-free for the industry


#25 Sliding Bearing Yaw System

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What is it?

A plain bearing for the yaw

system with no yaw motors, only

pitch control for yaw positioning


• Elimination of yaw motors in

favor of yaw control through

cyclic or individual blade pitch

control (i.e. rotor inertia)

• Simple sliding bearing would

reduce cost vs. geared bearing

• Reduced maintenance interval

• Lubrication system can maintain fluid film, substantially increasing

yaw bearing life


#24 Flexible Trailing Edge Blade

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What is it?

A variable profile blade which

allows the trailing edge to

flex in order to create a blunt

end during slower flows in

order to maximize lift, and

straighten during faster flows

in order to minimize drag


• Additional AEP of 5 - 7% is possible using this technology

• Design can be active or passive, the latter requiring very little

power, which maximizes efficiency of AEP gains

• Fixed flaps also possible, but hydraulic system or piezoelectric

actuators undesirable


#23 Field Assembly Fixtures

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What is it?

Field assembly fixtures for

nacelle, drivetrain, segmented

towers, multi-piece blades


• Push towards 4 - 5MW onshore necessitates

components with compact design or

segmentation. On-site component sub-

assembly will be mandatory and fixtures to

expedite construction will be important.


#22 Pre-Cast Foundations

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What is it?

Factory manufactured pre-cast

concrete segments;

transported to site on flatbed,

then bolted together & installed


• Improves quality and reduces

defects through factory

controlled manufacturing

process

• Can reduce construction

cycle time

• Allows for site-specific

‘tuning’ of concrete mixture


#21 High Voltage Converter

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What is it?

High voltage output from

active rectifier directly

connected to generator


• Lowers CapEx costs by

minimizing switchgear

and eliminating step-

up/down transformers

• Enables ‘direct to DC’

(HVDC integration)

• Improves efficiency


#20 Electrical System CMS

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What is it?

Condition monitoring systems for

electrical system and generator

components; monitoring temperatures,

faults, component wear, and efficiency


• As with any CMS, this provides visibility

to information on operation & function

of key systems

• Can provide prediction of nuisance

faults which plague electrical

components; model predictive control

• Useful for developing operational

envelope (RUL) of wind turbines / parks


#19 Segmented Blades

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What is it?

Wind turbine blade with at

least one joint that can be

bolted, bonded or

otherwise affixed together


• 1st gen technology

already in LRP makes

way for 2nd gen

• Provides access to

lower wind sites in

complex terrain

• Overcomes transport

hurdles


#18 Joint Service Lift / Platform

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What is it?

A service platform which can

be hoisted the entire height

of the tower, acting as

platform and service lift


• Enhances field tech safety

• Doubles as internal service

crane for up-tower

components (pitch motors,

electrical cabinets)

• Reduces total tower cost

by eliminating sectional

welds for support platforms


#17 HTS Cables

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What is it?

Using high

temperature super-

conducting wire for

electrical cabling


• Improves

efficiency – low

current drop-off

• Minimal eddy

currents

• Easier HVDC

transmission

integration


#16 Hybrid Material Towers

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What is it?

Tubular towers made from composite,

metal matrix composite or other

materials wrapped in a structural fabric


• Existing CapEx infrastructure is

geared towards tubular towers (mfg

tooling, transport fixtures, cranes)

• Designs allow for existing

infrastructure to be leveraged while

maintaining tower base diameter

within transport limits and tower

within loads envelope


#15 Spares Inventory Mgmt / RUL

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What is it?

Using remaining useful life (RUL)

calculation from CMS, SCADA &/or

models to determine optimal

service interval & identify gaps in

spares inventory


• Anticipatory turbine controls to

extend operation to a scheduled

maintenance window

• Ensures minimum offline time

for scheduled maintenance

• Eliminates unplanned

maintenance with no spares


#14 Model Predictive Control

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What is it?

Multi-variable turbine control

scheme based on comparison

of performance to optimal

limits in digital turbine model


• Enables ‘real-time’ energy

output optimization based

on reaction to operational

conditions and dynamic

limit values of turbine

performance

• Also an enabler for max

revenue based control


#13 VR / AR for Field Techs

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What is it?

Virtual reality /

augmented reality

devices to assist field

technicians with

installation &/or repairs


• Gain remote expertise

while minimizing cost

• Reduce faulty component compatibility issues and mitigate

outdated repair procedures

• Improve worker safety – monitoring and oversight

• Improve worker efficiency – provide step by step instructions


#12 UAV / Drone Inspection

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What is it?

Remote inspection of wind turbine

components using a UAV / drone

outfitted with optical camera &/or

sensors


• Reduces inspection cycle time;

could allow for increased inspection

frequency

• Use of sensors improves inspection

quality beyond visual range

• Improves inspection consistency

• Improves worker safety


#11 Condition Based Maintenance

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What is it?

Using CMS, SCADA data, and modelling

analysis of component and system

damage accumulation to predict a

revenue optimal service interval


• Enables anticipatory turbine control

to extend operation to a scheduled

maintenance window

• Ensures offline time for scheduled

maintenance is minimized, with as

little revenue impact as possible

• Mitigates unplanned maintenance


#10 Additive Mfg / 3D Printing

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What is it?

Fabrication of a 3D object through

laying down successive layers of

liquid, powder, metal or other material

based on a computer generated design

• Blades can integrate multiple materials to maximize strength and

minimize weight with virtually no structural defects

• Nacelles can be made in more complex and aesthetically pleasing

shapes to accommodate on-board cranes or cooling systems

• Tubular towers could be made from metal matrix composites

which would allow for diameters to stay within transport limits


• Manufacturing quality defects are minimal


#9 Wake Effect Power Optimizer

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What is it?

Turbine power rating

control based on impact of

wake effects from upwind

turbines


• Optimal power during

wake interference event

determined by computer

algorithm(s)

• Minimize component

damage on downwind

turbines


#8 Neural Network / AI Controls

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What is it?

System level control based

on machine learning

algorithms &/or artificial

intelligence


• Automated / semi-

automated turbine and

wind park control

• Computer determined

max revenue wind turbine

/ park power output

• Determines NPV of power delivery vs. turbine component damage

accumulation (de-rate / up-rate impact analysis on park revenue)

• Calculates whether to “bank” power in energy storage vs. deliver

to grid based on prevailing market conditions

• Supplements power delivery to meet PPA guarantee via turbine

up-rate or energy storage when other turbines require a

component life preserving de-rate


#7 Max Revenue Power Delivery

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What is it?

Simulation and control system which

calculates the optimal amount of

power delivery for a given time

interval based on prevailing wind

conditions and market conditions



#6 Site Specific Design

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What is it?

Turbine product family with

a common electrical

system and drivetrain, plus:

• Multiple power ratings

• Multiple rotor diameters

• Multiple hub heights


• Max power for wind

conditions at each

turbine pad

• Enables global sales vs

regional sales


#5 Hybrid Material Blades

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What is it?

Blade comprised of multiple

materials throughout length.

Design options include:

• HM Glass Root, E Glass Outboard

• Carbon Root, Glass Outboard


• Manufacturing quality defects are minimal

• Strength is maintained with minimal weight and cost impact

• Fundamental technology for 10MW+ offshore & 4 – 5MW+ onshore

• Opportunity to combine technology with segmented blades

• Carbon Root, Structural Fabric Outboard

• Metal Matrix Composite Root, Glass or Structural Fabric Outboard


#4 Asset Performance Profiles

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What is it?

Definition of a turbine or wind

park dynamic operational

envelope based on CMS, SCADA

data, &/or modelling


• Digitalization of wind assets

• Enabler for Asset Performance &/or

Asset Health digital services

companies

• Ability to reverse engineer turbine /

park operational profile to analyze

potential for retrofit upgrades


#3 Unified Power Plant Controls

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What is it?

Power plant control system

which integrates and

balances wind, solar and

energy storage; distributed

generator mode or grid

integration mode capability


• Provides centralized control of integrated assets – market moving

towards system integration

• Supports expansion of distributed generation market

• Enables energy output balancing and market price optimization


#2 Computational Component Test

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What is it?

Using physics based

models to predict

component fatigue life


• Improves accuracy of

digital models of turbine

components

• Complimentary to turbine

certification process

• Enabler for Additive

Manufacturing / 3D

printing processes

Available Apps


#1 Digital Services App Store

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Vestas Wind Systems V112 3.0MW

Add Feature

Developed by:

Add Feature

Developed by:

Add Feature

Developed by:

Add Feature

Developed by:

Add Feature

Developed by:

Add Feature

Developed by:

Condition Based

MaintenanceThis app allows asset owners

to…

Turbine Re-rating

ControlThis app allows asset owners

to…

Wake Mitigation

ControlThis app allows asset owners

to…

Life Extension

CalculatorThis app allows asset owners

to…

Revenue

OptimizerThis app allows asset owners

to…

Spares Inventory

ManagerThis app allows asset owners

to…

Feature Unavailable

Based on Selected

Turbine Make / Model

Feature Unavailable

Based on Selected


Feature Unavailable

Based on Selected


Feature Unavailable

Based on Selected


What is it?

Selection method for asset

performance and asset health

digital services offerings


• Digitally delivered services

will be ~US$4.5B in annual

revenue for wind by 2030

• ‘One Stop Shopping’ for

Asset Performance &/or

Asset Health Capabilities

• Mechanism to determine

optimal capabilities for

specific turbine models

Select Turbine Make Select Turbine Model

Future Onshore Wind Energy Technology

Engineering

Transcript of Future Onshore Wind Energy Technology