WindCORE Control Center for Wind Farms Miguel Angel Chimeno Iberdrola Ingenieria y Construccion

WindCORE Control Center for Wind Farms

Miguel Angel Chimeno

Iberdrola Ingenieria y Construccion

Copyright © 2006 OSIsoft, Inc. Company Confidential. All rights reserved. 2

Table of Contents1. IBERDROLA

2. IBERINCO

3. Wind Energy introduction

4. WindCORE definition

5. WindCORE objectives

6. WindCORE Energy control functions

7. WindCORE Technical characteristics

8. System Structure

9. System Functions

10. Other System Functions

11. WindCORE Architecture

12. Customer case: PI Subsystem

13. WindCORE typical PI Subsystem

14. WindCORE Benefits

15. Payout calculation


IBERDROLA

Sound position on the Spanish market and international presence in more than 20 countries; mainly Mexico and Brazil

Sound position on the Spanish market and international presence in more than 20 countries; mainly Mexico and Brazil

IBERDROLA Merger of Hidroeléctrica Española - Iberduero (1991)IBERDROLA Merger of Hidroeléctrica Española - Iberduero (1991)

IBERDROLA is the world leader in Wind Energy, and is one of the largest industrial corporations in Europe by market capitalization, sales and profits

IBERDROLA is the world leader in Wind Energy, and is one of the largest industrial corporations in Europe by market capitalization, sales and profits

Global gas and electricity operator through profitable growth strategy and creation of value for clients and investors

Global gas and electricity operator through profitable growth strategy and creation of value for clients and investors


Evolution of installed capacity and objective (MW)

Iberdrola at the renewable business• Iberdrola is one of the world´s leading operators in renewable

energies with 3,810 MW (3,494 wind) and with a target of 6,200 MW for 2008

Capacity breakdown (MW), Dec 2005

x 12,2

6.200

3.810

3.200

1.414

507

2000 …

2002 …

2004

…

200

5 (1

)

…20

08E (2

)

(1) Includes stakes in Rokas Group

(2) Latest forecast

91% 9% 100%

3,8103,494 316

Wind Minihydro TOTAL

5.000 MW national

1.200 of international development


* Dec. 2005

Iberdrola: World leader in installed capacity in wind

MW

3,494

3,193

1,694

Renewable energies


IBERINCO• Founded in 1995 IBERINCO

incorporating all engineering and construction activities within the IBERDROLA group

• Turnover 475 M€ in 2005• Wide international experience with

projects in more than 30 countries• IBERINCO develops projects of:

– Power plants (Thermal, Nuclear Hydraulic and Renewable Energy Plants)

– Electricity distribution networks (Substations, Lines)

– Communication and control systems for utilities


Wind Turbine typical components

16 17

11

12 13 14 18 19 20

1 2 3 4 105 7 8

15

6 9

1. Blade2. Hub controller

3. Blade bearing

4. Main carrier

5. Composite disk coupling6. Main disc brake

7. Oil cooler

8. Yaw gears

9. Generator10. Polipasto

11. Anemometer and wind vane

12. Pitch actuator13. Machine foundation

14. Tower

15. Bearing controllers

16. Shock absorbers

17. Turning crown

18. Turning differential

19. Electrical control20. Hydraulic group


WindCORE definition• A control centre for wind farms that allows remote

supervision, control, and data acquisition 24 / 7 for Operation and Maintenance

• Able to communicate with other energy management centres

• Implemented energy control functions to satisfy the grid operation requirements as of the TSO (Transmission Operator System)

• Easily scalable by means of aggregation. Although presently the WindCORE developed for Iberdrola is managing almost 140 wind farms (4000 wind turbines) worldwide, these figures could be no limits exceeded.


WindCORE Objectives• Cost reduction in O&M

– By centralizing operation, resource optimization is achieved with a significant reduction of local staff

• Reduction of unavailability costs– Continuous monitoring and remote

operation of wind farms– Remote pre-diagnosis and activation of

local maintenance squads for the solution of failures

• Implementation of energy control functions

– To meet new grid operation requirements based on high penetration rate of wind energy…

• Centralized way to communicate with other energy management centres


WindCORE : Technical Characteristics

• Capacity to optimally manage a great quantity of information.

• Multimedia alarm management.

• Flexible and centralised configuration.

• Object oriented technology.

• TCP/IP communications.

• Communication protocol by exception.

• Capacity for application development and integration.


System Functions

• WEB Server

• User Interface


System Functions

• Dynamic Configuration Tool

• User Management


System Functions

• Alarm Warnings and Events

• Advanced Alarm Manager (Multimedia and Squad Manager)


System Functions

• Historic Data Storage

• Historic Reports

• Calculation

• Reports


Iberinco HISTORICAL SCADA + PI System

ColourW/B

Ethernet Network (1000 Mbps)-TCP/IP

SCADA#1HDB#2

OPERATION CONSOLE #1

Corporate Network

ROUTER

GIS MAINTENANCE FAILURES.OTHERS

Ethernet-TCP/IP

INTRANET

INTERNET

FIREWALLCORPORATE INTEGRATION

SCADA #2HDB #1

ROUTER #2

WAN

ROUTER #1

...

SIPCO

WIND FARM

99999999ROUTER

OPERATION CONSOLE #2ENGINEERING

WORKSTATION

SMSe-mail

FaxPhone

Multimedia Alarms

Manager

CommunicationsFront-End #1

Communications Front-End #2

Web server

Communications Front-End #7

...

WindCORE Architecture


Customer case: PI Subsystem1. Reference: Iberdrola Renewable Energy Operation

Centre

- Currently it operates almost 140 Wind Farms (including those outside Spain), i.e. 4,000 turbines, i.e. over 1,200,000 acquired data

- The 250,000 most significant data points are processed by the PI Subsystem (included an extension to be executed in the short term)


Customer case: PI Subsystem1. Reference: Iberdrola Renewable Energy Operation Centre

- Major parameters of:• Wind Farms (state, pitch angle, main shaft speed, oil temperatures…)

• Electrical Substations (active and reactive power, voltage…)

• And Meteorological data from each wind turbine (temperatures, barometric

pressures, wind speed…) are being acquired by the PI Enterprise

server, stored in the Historian subsystem,

and Rt info is being used in trend displays,

Production curves of Wind Farms…

- PI data information being used for the

availabilities calculations in a maintenance

system based on SAP

- Mini-hydraulic stations


Iberdrola is applying its own professional production management model to wind energy using the CORE data

Maximize economic performance of every wind farm during the

extension of its lifetime

Starting point

Production Management Model

Main goal Iberdrola’s 100 years

utility culture Wide O&M expertise:

Hydroelectric Gas combine cycles Nuclear Renewables Fuel oil Coal Cogeneration

• Iberdrola doesn’t develop a wind farm to sell it

• Iberdrola develops to create value

Systems and procedures

Strategy

Organization & functions

“Dominate technology and key

management factors”


DOMINA project: Development of a Production and Maintenance Management System

Objective 1:

Maximize economic

performance of wind

farms

ASSET MANAGEMENT

MAINTENANCE MANAGEMENT

OPERATING EXPERIENCE FEEDBACK

PRODUCTION MANAGEMENT

• Collection of every asset information in an homogeneous way

• Control of changes in the asset

• Analysis of incidents and identification of root causes

• Definition of WTG design modifications to increase its reliability

• Quantification of unproduced energy

• Identification of the main causes of unproduced energy

Dominate technology

Objective 2:

• Supervision of maintenance process• Review and improvement of tasks• Achievement of an efficient maintenance cost


Communications and hardware simplified architecture

WAN

...WIND FARM A

99999999ROUTER

Local Control System

Corporate Network Access System

...WIND FARM B

99999999ROUTER

Local Control System

Corporate Network Access System

INTRANET

INTERNET

FIREWALLProduction ManagementServer

SAPMaintenance ManagementServer

CORPORATE NETWORK

ROUTER ROUTER

DOMINA SYSTEM

Retro projection screen

CENTRAL OPERATION CENTER NETWORK

ROUTER ROUTER

SCADA #1HDB #2

SCADA #2HDB #1

IBERDROLA RENEWABLE ENERGY O&M CENTER

iBerinco Historical SCADA + PI System


DOMINA: Production management

Causes of unavailability

• O&M people at wind farms characterize every single stop occurred, naming causes of unavailability

• Iberdrola’s own methodology to obtain production reference for every WTG every day

• Automatically DOMINA obtains working parameters: unproduced energy, time intervals, frequencies

• Parameters turn into indicators that are used to control and manage productionUnproduced Energy• Gap identification for

particular time

intervals• Due to

unavailabilities

Pro

du

ctio

n r

efe

ren

ce

Rea

l p

rod

uc

tio

n

Unavailability 1

Unavailability 2

Unavailability 3

Unavailability 4

Unavailability 5

Maintenance

OperationTime intervals

Working parametersWorking parameters

Production indicators

Operation indicators

Maintenance indicators

Production indicators

Operation indicators

Maintenance indicators

Frequencies


Customer case: PI Subsystem2. Reference: Eólica CESA Renewable Energy Operation Centre

- Currently it operates 18 Wind Farms in Spain, i.e. 476 turbines, i.e. over 155,000 acquired data.

- 20,000 data are processed by the PI Subsystem

- An extension is planned according to the new situation (growth up to 30 WF)

3. In addition, Iberdrola has other successfully References with the PI System:

- The Monitoring, Diagnosis and Simulation Centre (CMDS) for

Iberdrola's world-wide combined cycle facilities - On-site supervision of the Iberdrola´s Combined Cycle power plants


WindCORE PI Subsystem• Currently WindCORE is the solution for:

– This new process. It´s not known in detail what information it will be necessary for either Operation and Explotaition, and what will be the real needs of the users

– The huge amount of information (between 200 and 500 data points per Turbine). Now there are around 1 million data points from the Iberdrola Wind Farms.

• The PI subsystem integrated in the WindCORE is able to solve:– An Historian to store for years all the requested variables in real time, without

previous averages or aggregations– The averages, ranges , calculations, acumulated data, etc. with whatever time

rate. This means; Whatever I want, Whenever I want, and immediately.– Web based information of whatever variable on time without cost expensive

specific applications and customizables by the own user.– A complete environment to optimise the maintenance and exploitation:

calculations from whatver interface (DataLink, ACE, etc.), real time reports, statistical analyses, etc.


WindCORE Benefits

• 1% estimated increase in Operation and Maintenance cost reduction (availability)

• O&M resources optimization

• Trading operations optimized through very precise production forecast

• Remote assistance

• Fault/lost energy calculations for economy dispatching


Payout Calculation

•Cost Assumptions: Number of Wind Farms

Benefit ReceivedMW Capacity Factor Availability MWh Production

2000 27,5% 97% 46734602000 27,5% 98% 4721640

48180 MWh Gain from Availability Improvement80,00$ Feed In Tariff USD/MWh

3.854.400,00$

Cost Model for WindCOREYear 1 Year 2 Year 3 Year 4 Year 5

Total cost 2.100.000$ 600.000$ 600.000$ 600.000$ 600.000$ (infrastructure, system, labor, utilities, rent…)

Net Present Value of Cost $3.638.108Benefit 3.854.400$ 3.854.400,00$ 3.854.400,00$ 3.854.400,00$ 3.854.400,00$

Net Present Value of Benefit $14.611.209Payout per Dollar Spent 4,02$

Documents

WindCORE Control Center for Wind Farms Miguel Angel Chimeno Iberdrola Ingenieria y Construccion