Technology Needs for Advancing Wind Power Generation - Stan Rosinski, Electric Power Research Institute

Technology Needs for Advancing
Wind Power Generation

Stan T. Rosinski
Program Manager, Renewables
Wind Power Summit
February 25, 2013

Three Key Aspects of EPRI

Independent
Objective, scientifically based
results address reliability,
Independent
efficiency, affordability, health,
safety and the environment
Nonprofit Nonprofit
Chartered to serve the public
benefit
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Collaborative
Bring together scientists,
engineers, academic
researchers, industry experts

© 2013 Electric Power Research Institute, Inc. All rights reserved. 2

EPRI’s R&D Portfolio
Power Delivery and Utilization Generation
• Transmission Lines and • Advanced Coal Plants, Carbon
Substations Capture and Storage
• Grid Operations and Planning • Combustion Turbines
• Distribution • Environmental Controls
• Energy Utilization • Major Component Reliability
• Cross-Cutting Technologies • Materials and Chemistry
• Operations and Maintenance
Nuclear • Power Plant Water Management
• Advanced Nuclear Technology
• Chemistry, Low-Level Waste, and Environment and
Radiation Management Renewable Energy
• Equipment Reliability • Air Quality
• Fuel Reliability • Energy and Environmental
• Long-Term Operations Analysis
• Materials Degradation/Aging • Land and Groundwater
• Nondestructive Evaluation and • Occupational Health and Safety
Material Characterization • Renewable Energy
• Risk and Safety Management • T&D Environmental Issues
• Used Fuel and High-level Waste • Water and Ecosystems
Management


Key Strategic Technical Issues
Smart Energy Long-Term
Grid Efficiency Operations

Renewable Resources Near Zero Water Resource
and Integration Emissions Management


Renewable Resources and Integration

Many questions remain regarding renewable costs,
performance, impact and integration

Key Challenges
• Generation technology:
cost and performance
• Grid reliability:
Operating the system with
variable resources
• Environmental impacts


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


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 New large-scale systems needed
(large-scale; >6MW)
Energy Storage Integrating wind energy with on-site storage


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


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


EPRI Wind Energy Program

Identify, evaluate and conduct targeted R&D on wind technologies with
high potential to address critical industry issues

Wind Power Technology Model Development
Wind Power Asset Wind Environmental
Assessment and and Validation
Management Issues
Development

• Ground-based • Curtailment for
inspection Bat Protection
• Life extension


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


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


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.

Laser Shearography
Testing at National Renewable Energy Laboratory


Visual Examination versus Laser Shearography
Lightning Damage

Images Courtesy of Laser Technology Inc.

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.


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


Laser Shearography (top) vs Thermography Imaging (bottom)
Defects are Waves in the Carbon Fiber Spar Cap – HP Side (top of blade in fixture)
Distance from Root: 6 meters 5 meters 3.5 meters

Blade failed at this defect

Images – Courtesy of Digital Wind Systems Images are not to scale.

Imaged Defect due to Spar Cap Fiber Wave after 2.2 Million Fatigue
Cycles, Nominal Turbine Blade Operation Stress Load
Fatigue crack imaged 100 ft. from blade

Image – Courtesy of Digital Wind Systems


Ground-Based Inspection Summary
Wide Field Thermography of 1.6 MW Blades

Two test types for fast
survey and detailed imaging

Tower weld
remains slightly
warmer, heated
by sunlight
during daylight.

Actual field tests have small
field of view to image flaws

Image – Courtesy of Digital Wind System

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


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)

White-nose Fungus is
driving listing consideration

Courtesy of We Energies


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)


Smart Curtailment
Acoustic-Based Detection

ReBAT system courtesy of
Normandeau Associates


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


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


Together…Shaping the Future of Electricity

For additional information:

Stan Rosinski
Program Manager, Renewables
Electric Power Research Institute
srosinski@epri.com
704-595-2621


Extending Wind Turbine Life

• Reliability
Challenges
• Safety
Challenges


End of Design Life Options

Combination of proactive
approaches

Run beyond design life but take

Higher return
measures to ensure low risk of failure Run blindly beyond design life

Take measures to reduce fatigue
accumulation

Lower risk Higher risk

Lower return

Decommission upon reaching
end of design life


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


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


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


Wind Turbine Life Extension
Summary Results
NPV NPV Percent IRR Percent
Scenario (millions of Difference from IRR Difference from
dollars) Base Case Base Case

Base Case $38 0% 8.1% 0%

Targeted Inspections: 25 years $82 113% 9.3% 14%



Operational Modifications, 9% load
$80 108% 9.2% 13%
reduction
Operational Modifications, 5% load
$105 173% 9.6% 18%
reduction

Advanced Controls, Lidar implemented
$93 143% 9.2% 13%
at year 0

Advanced Controls, Lidar implemented
$63 65% 8.7% 7%
at year 10

Advanced Controls, State Estimation
$85 121% 9.4% 15%
implemented at year 0

Advanced Controls, State Estimation
$63 64% 8.9% 9%
implemented at year 10


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.


Technology Needs for Advancing Wind Power Generation - Stan Rosinski, Electric Power Research Institute

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