WindCORE Control Center for Wind Farms
Miguel Angel Chimeno
Iberdrola Ingenieria y Construccion
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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
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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
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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
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* Dec. 2005
Iberdrola: World leader in installed capacity in wind
MW
3,494
3,193
1,694
Renewable energies
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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
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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
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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.
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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
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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.
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System Functions
• WEB Server
• User Interface
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System Functions
• Dynamic Configuration Tool
• User Management
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System Functions
• Alarm Warnings and Events
• Advanced Alarm Manager (Multimedia and Squad Manager)
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System Functions
• Historic Data Storage
• Historic Reports
• Calculation
• Reports
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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
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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)
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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
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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”
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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
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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
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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
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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
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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.
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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
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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 $14.611.209Payout per Dollar Spent 4,02$