Operation of Wind Turbines. Which problem areas should be focused. Experiences from Europe. by Jan Behrendt Ibsø
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1 Operation of Wind Turbines Which problem areas should be focused Experiences from Europe by Jan Behrendt Ibsø
2 Jan Behrendt Ibsø : INTRODUCTION Master degree in Civil Engineering 1991, DTU Design of Concrete Structures Ph.D. in Structural Engineering 1994, DTU Offshore Structures Fatigue 2 years in COWI Bridge Department - Design of Larger Bridges 9 years in DNV Farm Projects Certification of Wind Turbines- and Offshore Wind 3 years in SGS Heading SGS Global Wind Energy Global Director, SGS Renewable Energy Member of IEC TC88 Wind Turbines and ISO TC67 Offshore Structures Committees
3 Size of WTGs Scaling up in large Magnitude!
4 Wind Turbines and Wind Farms Quality Issues
5 Main Causes of damages on Wind Turbines and Foundations Poor material quality Wrong choice of materials Specifications not followed Manufacturing faults Improper mounting / fastening Improper Service and Maintenance Unforeseen Loads / Site Specific Loads Wear Lightening / overvoltage
6 Overview Calculated life time/ Experience with life time Wind turbine development during time Failures of critical components causing most downtime: Blades Gearboxes Main bearing Service and maintenance Wind turbines of the future
7 Life time 20 years calculated life time. Does the wind turbines last for 20 years? Many break downs There has never been sold a fully finish developed wind turbine. Retrofit programs Very rapid development so far Follow or you are out
8 Development during time kg/kw time
9 Failures Experience: Failures have occurred on all components Same problems offshore and onshore Additional cause of problems offshore High maximum wind speeds Wet and salty environment Manufacturers have not really implemented experience from other industries Wind turbine components today are very specialized
10 Failures on blades Failure in manufacturing
11 Failures on blades Large repairs near root
12 Failures on blades Cracks in trailing edge
13 Failures on blades Longitudinal crack in trailing edge due to vibrations
14 Failures on blades Repair of crack in trailing edge
15 Failures on blades Scaling of topcoat due to air trapped in the manufacturing process
16 Failures on blades Damage from lightening stroke
17 Failures on blades Single failure Complete damage of blade
18 Access for blade inspection Binoculars from the nacelle Telescope on tripod from ground (not offshore) Rope climbing Mobile work platform (not off-shore) Façade hoist Cost Quality Cheap Low Expensive High
19 Access for blade inspection
20 Methods for blade inspection Outside surface defects: Visual inspection Structural defects: Knocking Ultra sound (by portable equipment or alternatively by whole blade automatic scanner) Thermography
21 Failures in gearboxes Severe wear in a bearing
22 Failures in gearboxes Worn out planet bearing
23 Failures in gearboxes Wear particles on magnet
24 Failures in gearboxes Grinding temper on gear wheel
25 Failures in gearboxes Broken tooth on gear wheel
26 Failures in gearboxes ALL manufacturers have experienced break downs Nearly all failures are wear in bearings Large effort to find reason for failures, but without result The industry lack knowledge of loads in gearboxes Failures in gearboxes will occur in the future Not all retrofit solutions have solved the problems
27 Methods for inspection of gearboxes Visual inspection Visual inspection by endoscope Oil analysis Magnet in oil Examination of used filters Online particle counting Vibration analysis
28 Gearbox repair New gearbox + Best solution - Most expensive Gearbox renovated by manufacturer + Upgrades introduced - Expensive Local repair + Cheap - Out time production loss + Delivery time on spare gearboxes
29 Service and maintenance Manufacturer + Warranty + Has the best knowledge of the wind turbine +/- Large organization - independence in service control and maintenance Independent service company + Cheap + Individual solutions +/- Spare parts
30 Wind turbines in the future? Gearbox or not? Size?
31 The highest wind turbine in the world
32 SGS Wind Energy Services Competence Centre Raboisen 28 D Hamburg Germany t f internet: wind@sgs.com
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