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Stan Rosinski, Electric Power Research Institute - Speaker at the marcus evans Wind Power Summit held in Dallas, TX February 25-26, 2013 delivered his presentation entitled Technology Needs for Advancing Wind Power Generation
Citation preview
Stan T. Rosinski Program Manager, Renewables
Wind Power Summit February 25, 2013
Technology Needs for Advancing Wind Power Generation
2 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Three Key Aspects of EPRI
Independent Objective, scientifically based results address reliability, efficiency, affordability, health, safety and the environment
Nonprofit Chartered to serve the public benefit
Collaborative Bring together scientists, engineers, academic researchers, industry experts
Independent
Collaborative
Nonprofit
3 © 2013 Electric Power Research Institute, Inc. All rights reserved.
EPRI’s R&D Portfolio
Environment and Renewable Energy • Air Quality • Energy and Environmental
Analysis • Land and Groundwater • Occupational Health and Safety • Renewable Energy • T&D Environmental Issues • Water and Ecosystems
Generation • Advanced Coal Plants, Carbon
Capture and Storage • Combustion Turbines • Environmental Controls • Major Component Reliability • Materials and Chemistry • Operations and Maintenance • Power Plant Water Management Nuclear
• Advanced Nuclear Technology • Chemistry, Low-Level Waste, and
Radiation Management • Equipment Reliability • Fuel Reliability • Long-Term Operations • Materials Degradation/Aging • Nondestructive Evaluation and
Material Characterization • Risk and Safety Management • Used Fuel and High-level Waste
Management
Power Delivery and Utilization • Transmission Lines and
Substations • Grid Operations and Planning • Distribution • Energy Utilization • Cross-Cutting Technologies
4 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Key Strategic Technical Issues Long-Term Operations
Smart Grid
Energy Efficiency
Near Zero Emissions
Water Resource Management
Renewable Resources and Integration
5 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Renewable Resources and Integration
Key Challenges • Generation technology:
cost and performance
• Grid reliability: Operating the system with variable resources
• Environmental impacts
Many questions remain regarding renewable costs, performance, impact and integration
6 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Drivers for Wind Research
• Reduce cost of wind (capital, LCOE), optimize performance and expand installed capacity
• Accelerate grid parity w/o subsidies • Address wind resources variability and
grid penetration issues • Innovative cost-effective wind energy
storage options • Off-shore wind deployment challenges • Minimize/mitigate environmental impact
7 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Wind R&D Roadmap
Issue R&D Area Wind Turbine Components Blade design enhancements
Improve drive train reliability Improved materials/designs for taller towers (100-175m)
Integrated Turbine Systems (large-scale; >6MW)
New large-scale systems needed
Energy Storage Integrating wind energy with on-site storage
8 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Wind R&D Roadmap
Issue R&D Area Offshore Wind Foundations
Components suited to offshore environment (blades, rotors, drive-train) Methodologies to identify/ evaluate critical risks
Wind Forecasting Improved hour-ahead and day-ahead forecasting Seconds/minutes forecasting
9 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Wind R&D Roadmap
Issue R&D Area Condition Monitoring Improved on-line monitoring, data collection/
mining and analysis Non-destructive evaluation techniques
Performance Optimization Adaptive control techniques for diverse terrains/models Enhanced reliability-centered maintenance (RCM) approaches Wind turbine database Life extension
10 © 2013 Electric Power Research Institute, Inc. All rights reserved.
EPRI Wind Energy Program
Wind Power Technology Assessment and
Development Wind Power Asset
Management Wind Environmental
Issues
Identify, evaluate and conduct targeted R&D on wind technologies with high potential to address critical industry issues
Model Development and Validation
• Ground-based inspection
• Life extension
• Curtailment for Bat Protection
11 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Ground Based Inspection of Wind Turbine Blades Drivers • Blade failure – overall reliability • Blade manufacturing improving – but defects do exist
– Bond issues (lack of, inadequate) – Delaminations, wrinkles
• Blades environmentally degrade, fatigue • Blade replacement costly
12 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Approach
• Develop an NDE and engineering tool integrating: – Advanced NDE technology for detection of flaws
• Preservice and in-service • Ground-based
– Flaw analysis processes • Effect of flaws • Remaining blade life
Proactive Wind Turbine Blade Life and Asset Management Tool
13 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Laser Shearography
• Detection of flaws in complex composite materials in aeronautical and aerospace industry (field or factory)
• Uses laser field and interferometer to detect flaws in part, under loading (heat, pressure, vacuum)
Courtesy of Laser Technology Inc.
14 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Laser Shearography Testing at National Renewable Energy Laboratory
15 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Left photo - Visual examination of lightning damage to wind turbine blade
Right photo - Laser shearogram of the same area indicating a 25 inch (635 mm) delamination extending from lightning strike.
Images Courtesy of Laser Technology Inc.
Visual Examination versus Laser Shearography Lightning Damage
16 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Infrared Thermography
• Enhance ground based inspection technology • High-speed inspection of blades during operation
– Cost effective – Large area inspection
• Infrared Thermography – Fast ‘screening’ scan – Identify areas for follow-up
inspection – Simultaneous imaging of
blade serial number Thermal Image of 15m segment of 2 MW rotating blade – No Indications Image – Courtesy of Digital Wind Systems
17 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Distance from Root: 6 meters 5 meters 3.5 meters
Laser Shearography (top) vs Thermography Imaging (bottom) Defects are Waves in the Carbon Fiber Spar Cap – HP Side (top of blade in fixture)
Images are not to scale.
Blade failed at this defect
Images – Courtesy of Digital Wind Systems
18 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Fatigue crack imaged 100 ft. from blade
Imaged Defect due to Spar Cap Fiber Wave after 2.2 Million Fatigue Cycles, Nominal Turbine Blade Operation Stress Load
Image – Courtesy of Digital Wind Systems
19 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Tower weld remains slightly warmer, heated
by sunlight during daylight.
Ground-Based Inspection Summary Wide Field Thermography of 1.6 MW Blades
Actual field tests have small field of view to image flaws
Two test types for fast survey and detailed imaging
Image – Courtesy of Digital Wind System
20 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Wind Power and Bats Issue and Challenge
• Financially important to Agriculture – Pollination – Insect control
• Important in the ecosystem – Very slow reproductive rate
(1-2 young/year) – High attrition rate of young
• Mortality rate increasing in the US/Canada – White Nose Syndrome – Expanding area
• Most mortality at wind sites occurs June through October
21 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Range of Federally Endangered Bat (and bat species proposed to be listed in 2013)
Striped – Indiana bats (Endangered) Light purple = Eastern Small-Footed (proposed for listing) Dark purple = Northern Long-Eared (proposed for listing) Gray = Little Brown Bats (proposed for listing)
Courtesy of We Energies
White-nose Fungus is driving listing consideration
22 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Options to Miminize Fatalaties
• Operation of turbines must be changed during bat migration (June-October) – Increase cut-in speed
• Turbines begin to rotate only at higher wind speeds
• Generation lost during periods of low wind
– Shut off turbines for the entire night • Generation lost every evening
– Restrict operation only during periods of bat activity (preferred)
23 © 2013 Electric Power Research Institute, Inc. All rights reserved.
ReBAT system courtesy of Normandeau Associates
Smart Curtailment Acoustic-Based Detection
24 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Automated Wind Turbine Curtailment Scope
• Acoustic monitoring of bat activity at nacelle • Post-construction mortality survey • Develop predictive bat mortality model • Develop Bat Detection Shutdown System
• Monitor 4 nacelles
25 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Automated Wind Turbine Curtailment Summary
• Reducing bat mortality through curtailments is here – Potentially widespread – Curtailing only when necessary is preferred
• Proactive approach • Minimizes generation loss
26 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
For additional information:
Stan Rosinski Program Manager, Renewables Electric Power Research Institute [email protected] 704-595-2621
Additional Information
28 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Extending Wind Turbine Life
• Reliability Challenges
• Safety Challenges
29 © 2013 Electric Power Research Institute, Inc. All rights reserved.
End of Design Life Options
Decommission upon reaching end of design life
Take measures to reduce fatigue accumulation
Run beyond design life but take measures to ensure low risk of failure Run blindly beyond design life
Lower risk Higher risk
Higher return
Lower return
Combination of proactive approaches
30 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Proactive Life Extension Methods Examples
• Operations and maintenance (O&M) strategies including modifying operations
• Mining O&M records to understand and predict component reliability • Load measurement to track fatigue accumulation or to control the
turbine better • Flight Leader Concept: selecting turbines to serve as a sample
subset of a fleet • Targeted inspections to detect incipient failures and ensure
structural integrity beyond design life • Turbine refurbishment or retrofit • Advanced controls to reduce fatigue loading
31 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Engineering/Economic Assessment Three Scenarios
• Scenario 1 – Targeted Inspections – Regular inspections to monitor risk of failure:
• Foundations - 5 year interval • Blades/selected tower welds/hubs – annually
– Continued operation • Scenario 2 – Modified Operation
– Reduce operation (turbine de-rate) during high loading events • Reduce fatigue accumulation • Less power produced (1-3% annual production)
– Operational modification assumed to start in year 1
32 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Engineering/Economic Assessment Three Scenarios
• Scenario 3 – Advanced Controls – Implement advanced controls at year 0 and at year 10 using:
• Lidar based controls (mean load reduction of 8%) • State estimation (3-7% load reduction)
– Reduced downtime and O&M costs with reduced loads – Additional O&M costs and downtime for lidar
Case Mean Load Reduction Mean Life
Lidar implemented at year 0 8% 28 years
Lidar implemented at year 10 8% 24 years
State estimation implemented at year 0 5% 25 years
State estimation implemented at year 10 5% 22 years
33 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Wind Turbine Life Extension Summary Results
Scenario NPV
(millions of dollars)
NPV Percent Difference from
Base Case IRR
IRR Percent Difference from
Base Case
Base Case $38 0% 8.1% 0%
Targeted Inspections: 25 years $82 113% 9.3% 14%
Targeted Inspections: 30 years $119 210% 10.0% 23%
Targeted Inspections: 35 years $152 294% 10.4% 28%
Operational Modifications, 9% load reduction $80 108% 9.2% 13%
Operational Modifications, 5% load reduction $105 173% 9.6% 18%
Advanced Controls, Lidar implemented at year 0 $93 143% 9.2% 13%
Advanced Controls, Lidar implemented at year 10 $63 65% 8.7% 7%
Advanced Controls, State Estimation implemented at year 0 $85 121% 9.4% 15%
Advanced Controls, State Estimation implemented at year 10 $63 64% 8.9% 9%
34 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Wind Turbine Life Extension Conclusions
• Life extension generally cost effective (your mileage may vary).
• Project-specific uncertainties will require an analysis of consumed fatigue-life prior to any life extension program.
• Best approach to life extension will be heavily site and owner specific.
• More benefit could be achieved from a combination of approaches as they are not mutually exclusive.