Planned maintenance (scheduled) Unplanned maintenance (unscheduled) ENERGIVÄRLDEN-TEMA VIND, STOCKHOLM, 29 MAJ, 2018 Digital electrical drivetrain Example of innovation case Teijo Kärnä, Industry segment manager wind
PITCH SYSTEM FREQUENCY CONVERTER GENERATOR ASSEMBLY YAW SYSTEM GEARBOX ASSEMBLY SENSORS COMMUNICATION SYSTEM MV SWITCHGEAR LV SWITCHGEAR SAFETY CHAIN BLADES TRANSFORMER HUB TOWER CONTROLLER H/W OTHERS PITCH SYSTEM FREQUENCY CONVERTER GENERATOR ASSEMBLY YAW SYSTEM GEARBOX ASSEMBLY SENSORS COMMUNICATION SYSTEM MV SWITCHGEAR LV SWITCHGEAR SAFETY CHAIN BLADES TRANSFORMER HUB TOWER CONTROLLER H/W OTHERS Electrical drivetrain a multidisciplinary system But what happens inside the components? Electrical 40% 35% 30% 25% 20% 15% 10% 5% 0% Mechanical Contribution to Total Failure Rate % [failures/turbine/year] Contribution to Average Time lost % [hours/year] Fault ridethrough Variable voltage Variable frequency Demand & support Stochastic wind Variable speed Variable power Grid support Converter generator frequency torque management P/Q management harmonics and flicker LVRT/HVRT EMC/EMI CM voltages & currents peak voltages & du/dt switching frequency grid resonances short-circuit currents PLC Switchgear frequent ON/OFF switching overloads over- and under-voltages harmonics transient voltages grid resonances unbalanced loads Transformer unbalanced load harmonics transient over-voltages grid resonances short-circuit withstanding Generator speed vs. torque characteristics bearing currents & shaft voltages voltage stress & harmonics insulation class (F & H) natural mode frequencies mechanical vibrations torque ripple & torsion torque slip-ring & rotor design magnets & demagnetisation noise May 31, 2018 Slide 2
How to improve performance of electrical drivetrain Back to basics: combine components and knowhow Q/A during development process What to measure? Needs, must-haves, nice-to-haves. Need of additional sensors? How and who to analyze? Cost versus advantage Real condition of old assets? Big data? Can 10 min average data be used to analyze millisecond phenomena's? Cyber security. How to ensure?. No need for additional sensors Utilize converter as the brain of the system Sensors, data collection/transmission not a real issue Existing big data only as support We have almost all we need: speed, current, voltage frequency, temperatures, torque.. AND we have the domain knowledge. May 31, 2018 Slide 3
Pilot case Site survey and 12 turbines connected to ABB Ability Learnings so far Owner had no KPI for turbine maintenance, except for spare prices and consumption Asset health differ even with the turbines of same site and age Different behavior between turbines Maintenance information missing Components not maintained accessible to component suppliers recommendations Other component faults and trips recorded as converter faults Components not operated accessible to original specification Electrical drivetrain not running optimal as subsystem Fault and wear out in main breaker could be identified from converter data Pilot installation has generated lot of new ideas for new offering by combining domain knowledge and correct measuring data Opening huge amount of opportunities for further developments Surprising? May 31, 2018 Slide 4
Step one two three Get connected monitor the essentials be prepared Remote assistance (remote) 24/7/365 remote assistance upon request decisions and solving problems quickly condition monitoring services reported solutions for failure cases Condition monitoring (remote) Predictive maintenance (remote) monitor overall condition of your fleet data visualization (trend fleet comparison, scatter plot comparison, histogram comparison) signals and parameter exports configurable E-mail alerts and automated reports periodical ABB expert analysis 24/7 access to portal analysis on wear-out and aging factors analysis on usage according to the specification optimized maintenance schedules reduced downtime enhanced overall performance periodical service notifications: availability, faults and warnings, condition indexes, remaining lifetime May 31, 2018 Slide 5
Digitalization of wind sector Holistic solution based on our extensive experience and expertize in the sector Value creation Operations Optimization Performance Automation Yield Revenue streams Trading strategy Investment strategy Analytics Performance Health index Prognostics & forecasting Maintenance Recommendations Suppliers Spare parts Workforce Data management ABB Ability Asset digitization Blade Gearbox Generator Converter LV circuit breaker Transformer MV circuit breaker Substation May 31, 2018 Slide 6