Reliability of wind turbine subassemblies

We have investigated the reliability of more than 6000 modern onshore wind turbines and their subassemblies in Denmark and Germany over 11 years and particularly changes in reliability of generators, gearboxes and converters in a subset of 650 turbines in Schleswig Holstein, Germany. We first start by considering the average failure rate of turbine populations and then the average failure rates of wind turbine subassemblies. This analysis yields some surprising results about which subassemblies are the most unreliable. Then we proceed to consider the failure intensity function variation with time for wind turbines in one of these populations, using the Power Law Process, of three subassemblies; generator, gearbox and converter. This analysis shows that wind turbine gearboxes seem to be achieving reliabilities similar to gearboxes outside the wind industry. However, wind turbine generators and converters are both achieving reliabilities considerably below that of other industries but the reliability of these subassemblies improves with time. The paper also considers different wind turbine concepts. Then we conclude by proposing that offshore wind turbines should be subject to more rigorous reliability improvement measures, such as more thorough subassembly testing, to eliminate early failures. The early focus should be on converters and generators.     

Wind turbine SCADA alarm analysis for improving reliability

Previous research for detecting incipient wind turbine failures, using condition monitoring algorithms, concentrated on wind turbine Supervisory Control and Data Acquisition (SCADA) signals, such as power output, wind speed and bearing temperatures, using power‐curve and temperature relationships. However, very little research effort has been made on wind turbine SCADA alarms. When wind turbines are operating in significantly sized wind farms, these alarm triggers are overwhelming for operators or maintainers alike because of large number occurring in a 10 min SCADA period. This paper considers these alarms originating in two large populations of modern onshore wind turbines over a period of 1–2 years. First, an analysis is made on where the alarms originate. Second, a methodology for prioritizing the alarms is adopted from an oil and gas industry standard to show the seriousness of the alarm data volume. Third, two methods of alarm analysis, time‐sequence and probability‐based, are proposed and demonstrated on the data from one of the wind turbine populations, considering pitch and converter systems with known faults. The results of this work show that alarm data require relatively little storage yet provide rich condition monitoring information. Both the time‐sequence and probability‐based analysis methods have the potential to rationalize and reduce alarm data, providing valuable fault detection, diagnosis and prognosis from the conditions under which the alarms are generated. These methods should be developed and integrated into an intelligent alarm handling system for wind farms, aimed at improving wind turbine reliability to reduce downtime, increase availability and leading to a well‐organized maintenance schedule. Copyright © 2011 John Wiley & Sons, Ltd.     

Maximum generation power evaluation of variable frequency offshore wind farms when connected to a single power converter

The paper deals with the evaluation of power generated by variable and constant frequency offshore wind farms connected to a single large power converter. A methodology to analyze different wind speed scenarios and system electrical frequencies is presented and applied to a case study, where it is shown that he variable frequency wind farm concept (VF) with a single power converter obtains 92% of the total available power, obtained with individual power converters in each wind turbine (PC). The PC scheme needs multiple power converters implying drawbacks in terms of cost, maintenance and reliability. The VF scheme is also compared to a constant frequency scheme CF, and it is shown that a significant power increase of more than 20% can be obtained with VF. The case study considers a wind farm composed of four wind turbines based on synchronous generators.     

Power generation efficiency analysis of offshore wind farms connected to a SLPC (single large power converter) operated with variable frequencies considering wake effects

This paper deals with the power generation efficiency analysis of a proposed offshore wind farm topology, consisting of a SLPC (single large power converter) that simultaneously controls a group of generators. This common converter can operate at a VF (variable frequency) or at a CF (constant frequency). The results are compared with the conventional onshore wind farm scheme, where individual power converters are connected to each turbine, guaranteeing maximum power generation for the entire wind farm. A methodology to analyze different wind speed and direction scenarios, and to compute the optimal electrical frequency for each one, is presented and applied to different case studies depending on the wind farm size. In order to obtain more realistic values of wind speeds, the wake effect amongst wind turbines is considered. A wake model considering single, partial and multiple wakes inside a wind farm and taking into account different wind directions, is presented. Both wind farm topologies are analyzed by means of simulations, taking into account both wind speed variability in wind farms and the number of wind turbines. The possible resulting benefits of simplifying the MPCs (multiple power converters) of each turbine, namely saving costs, reducing losses and maintenance and increasing the reliability of the system, are analyzed, focusing on the total power extraction. The SLPC-VF scheme is also compared with a CF scheme SLPC-CF, and it is shown that a significant power increase of more than 33% can be obtained with SLPC-VF.     

Reliability of wind turbines modeled by a Poisson process with covariates,unobserved heterogeneity and seasonality

Reliability of wind turbines is analyzed with the use of an easily interpretable mathematical model based on a Poisson process, which takes into account jointly observable differences between turbines described by covariates (type of turbine, size of turbine, harshness of environment, installation date and seasonal effects) as well as unobservable differences modeled by a standard frailty approach known from survival analysis. The introduced model is applied to failure data from the WMEP database, and the fit of the model is checked. The paper demonstrates the usefulness of the model for determination of critical factors of wind turbine reliability, with potential for prediction for future installations. In particular, the model's ability to take into account unobserved heterogeneity is demonstrated. The model can easily be adapted for use with different datasets or for analysis of other repairable systems than wind turbines. Copyright © 2016 John Wiley & Sons, Ltd.     

Modelling the effects of environmental conditions on wind turbine failures

Operation and maintenance is one of the main cost drivers of modern wind farms and has become an emerging field of research over the past years. Understanding the failure behaviour of wind turbines (WTs) can significantly enhance operation and maintenance processes and is essential for developing reliability and strategic maintenance models. Previous research has shown that especially the environmental conditions, to which the turbines are exposed to, affect their reliability drastically. This paper compares several advanced modelling techniques and proposes a novel approach to model WT system and component failures based on the site‐specific weather conditions. Furthermore, to avoid common problems in failure modelling, procedures for variable selection and complexity reduction are discussed and incorporated. This is applied to a big failure database comprised of 11 wind farms and 383 turbines. The results show that the model performs very well in several situations such as modelling general WT failures as well as failures of specific components. The latter is exemplified using gearbox failures.     

A novel method for reliability and risk evaluation of wind energy conversion systems considering wind speed correlation

This paper investigates an analytical approach for the reliability modeling of doubly fed induction generator (DFIG) wind turbines. At present, to the best of the authors’ knowledge, wind speed and wind turbine generator outage have not been addressed simultaneously. In this paper, a novel methodology based on the Weibull- Markov method is proposed for evaluating the probabilistic reliability of the bulk electric power systems, including DFIG wind turbines, considering wind speed and wind turbine generator outage. The proposed model is presented in terms of appropriate wind speed modeling as well as capacity outage probability table (COPT), considering component failures of the wind turbine generators. Based on the proposed method, the COPT of the wind farm has been developed and utilized on the IEEE RBTS to estimate the well-known reliability and sensitive indices. The simulation results reveal the importance of inclusion of wind turbine generator outage as well as wind speed in the reliability assessment of the wind farms. Moreover, the proposed method reduces the complexity of using analytical methods and provides an accurate reliability model for the wind turbines. Furthermore, several case studies are considered to demonstrate the effectiveness of the proposed method in practical applications.     

Reliability analysis for wind turbines

Modern wind turbines are complex aerodynamic, mechanical and electrical machines incorporating sophisticated control systems. Wind turbines have been erected in increasing numbers in Europe, the USA and elsewhere. In Europe, Germany and Denmark have played a particularly prominent part in developing the technology, and both countries have installed large numbers of turbines. This article is concerned with understanding the historic reliability of modern wind turbines. The prime objective of the work is to extract information from existing data so that the reliability of large wind turbines can be predicted, particularly when installed offshore in the future. The article uses data collected from the Windstats survey to analyse the reliability of wind turbine components from historic German and Danish data. Windstats data have characteristics common to practical reliability surveys; for example, the number of failures is collected for each interval but the number of turbines varies in each interval. In this article, the authors use reliability analysis methods which are not only applicable to wind turbines but relate to any repairable system. Particular care is taken to compare results from the two populations to consider the validity of the data. The main purpose of the article is to discuss the practical methods of predicting large‐wind‐turbine reliability using grouped survey data from Windstats and to show how turbine design, turbine configuration, time, weather and possibly maintenance can affect the extracted results. Copyright © 2006 John Wiley &Sons, Ltd.     

Qualitative performance assessment of semiconductor switching device,converter and generator candidates for 10 MW offshore wind turbine generators

This paper investigates the possibilities of viable power electronics converters, semiconductor switching devices and electric machines for 10 MW variable‐speed wind turbine generators. The maximum rated power of existing wind turbine configurations is in the range of 6 MW. The proposed alternatives are compared against several technical and economical factors, and their advantages over the present wind turbines are highlighted. A comprehensive performance comparison of modern power semiconductor devices, their electrical characteristics and the key differentiators among them are presented. The power electronics converters considered include all commercially available multilevel voltage source and current source converters as well as the opportunities offered by power electronics building block‐based design. The factors used for the comparison include the converter power range, capacitor voltage balancing, common mode voltage and current, electromagnetic interference emissions, fault ride‐through capability, reliability, footprint, harmonic performance, efficiency and losses, component count, risk of torsional vibration by the harmonics and inter‐harmonics, complexity, ease of back‐to‐back operation and filtering requirements. For the electric machines, this study concentrates on high‐temperature superconducting machines, multi‐phase induction machines and permanent magnet synchronous machines. These machines are compared against existing wind generator technologies in terms of their power range, torque density, efficiency, fault ride‐through capability, reliability, footprint, harmonic performance, ease of fault detection, excitation control, noise and vibration signature, oscillation damping, gearbox requirement, cost and the size of the associated converter. Copyright © 2010 John Wiley & Sons, Ltd.     

Dynamic modelling and control of fully rated converter wind turbines

Today, many countries are integrating large amount of wind energy into the grid and many more are expected to follow. The expected increase of wind energy integration is therefore a concern particularly to transmission grid operators. Based on the past experience, some of the relevant concerns when connecting significant amount of wind energy into the existing grid are: fault ride through requirement to keep wind turbines on the grid during faults and wind turbines have to provide ancillary services like voltage and frequency control with particular regard to island operation.While there are still a number of wind turbines based on fixed speed induction generators (FSIG) currently running, majority of wind turbines that are planned to be erected are of variable speed configurations. The reason for this is that FSIG are not capable of addressing the concern mentioned above. Thus, existing researches in wind turbines are now widely directed into variable speed configurations. This is because apart from optimum energy capture and reduction of mechanical stress, preference of these types is also due to the fact that it can support the network such as its reactive power and frequency regulation. Variable wind turbines are doubly fed induction generator wind turbines and full converters wind turbines which are based on synchronous or induction generators.This paper describes the steady state and dynamic models and control strategies of wind turbine generators. The dynamic models are presented in the dq frame of reference. Different control strategies in the generator side converter and in the grid side converter for fault ride through requirement and active power/frequency and reactive/voltage control are presented for variable speed wind turbines.     

Reliability analysis of grid connected small wind turbine power electronics

Grid connection of small permanent magnet generator (PMG) based wind turbines requires a power conditioning system comprising a bridge rectifier, a dc–dc converter and a grid-tie inverter. This work presents a reliability analysis and an identification of the least reliable component of the power conditioning system of such grid connection arrangements. Reliability of the configuration is analyzed for the worst case scenario of maximum conversion losses at a particular wind speed. The analysis reveals that the reliability of the power conditioning system of such PMG based wind turbines is fairly low and it reduces to 84% of initial value within one year. The investigation is further enhanced by identifying the least reliable component within the power conditioning system and found that the inverter has the dominant effect on the system reliability, while the dc–dc converter has the least significant effect. The reliability analysis demonstrates that a permanent magnet generator based wind energy conversion system is not the best option from the point of view of power conditioning system reliability. The analysis also reveals that new research is required to determine a robust power electronics configuration for small wind turbine conversion systems.     

A Bayesian reliability analysis exploring the effect of scheduled maintenance on wind turbine time to failure

This article presents a Bayesian reliability modelling approach for wind turbines that incorporates the effect of time-dependent variables. Namely, the technique is used to explore the effect of annual services on wind turbine failure intensity through time for turbines within a currently operational wind farm. In the operator's experience, turbines seemed to fail more frequently after scheduled maintenance was performed; however, this is an unexplored effect in the literature. Additionally, the effects of seasonality, year of operation and position in the array on failure intensity are explored. These features were included in a Cox-like model formulation which allows for time-dependent covariates. Inference was performed via Bayes rule. Results show a spike in failure intensity reaching 1.57 times the baseline in the six days directly proceeding annual servicing, after which failure intensity is reduced compared to baseline. Also observed is a significant year-on-year reduction of failure intensity since the introduction of the site's data management system in 2018, a clear preference for modelling time to failure via a Weibull distribution and a dependence on location in the array with respect to the prominent wind direction. Results also show the benefit of employing a Bayesian regime, which provides easily interpretable uncertainty quantification.     

Load flow analysis for variable speed offshore wind farms

A serial AC?DC integrated load flow algorithm for variable speed offshore wind farms is proposed. It divides the electrical system of a wind farm into several local networks, and different load flow methods are used for these local networks sequentially. This method is fast, more accurate, and many factors such as the different wind farm configurations, the control of wind turbines and the power losses of pulse width modulation converters are considered. The DC/DC converter model is proposed and integrated into load flow algorithm by modifying the Jacobian matrix. Two iterative methods are proposed and integrated into the load flow algorithm: one takes into account the control strategy of converters and the other considers the power losses of converters. In addition, different types of variable speed wind turbine systems with different control methods are investigated. Finally, the method is demonstrated using an 80-MW offshore wind farm.     

Flicker Mitigation by Active Power Control of Variable-Speed Wind Turbines With Full-Scale Back-to-Back Power Converters

Grid-connected wind turbines are fluctuating power sources that may produce flicker during continuous operation. This paper presents a simulation model of a megawatt-level variable-speed wind turbine with a full-scale back-to-back power converter developed in the simulation tool of PSCAD/EMTDC. Flicker emission of this system is investigated. Reactive power compensation is mostly adopted for flicker mitigation. However, the flicker mitigation technique shows its limits, when the grid impedance angle is low in some distribution networks. A new method of flicker mitigation by controlling active power is proposed. It smoothes the 3p active power oscillations from wind shear and tower shadow effects of the wind turbine by varying the dc-link voltage of the full-scale converter. Simulation results show that damping the 3p active power oscillation by using the flicker mitigation controller is an effective means for flicker mitigation of variable-speed wind turbines with full-scale back-to-back power converters during continuous operation.      

Fault ride-through capability of DFIG wind turbines

This paper concentrates on the fault ride-through capability of doubly fed induction generator (DFIG) wind turbines. The main attention in the paper is, therefore, drawn to the control of the DFIG wind turbine and of its power converter and to the ability to protect itself without disconnection during grid faults. The paper provides also an overview on the interaction between variable-speed DFIG wind turbines and the power system subjected to disturbances, such as short circuit faults. The dynamic model of DFIG wind turbine includes models for both mechanical components as well as for all electrical components, controllers and for the protection device of DFIG necessary during grid faults. The viewpoint of the paper is to carry out different simulations to provide insight and understanding of the grid fault impact on both DFIG wind turbines and on the power system itself. The dynamic behaviour of DFIG wind turbines during grid faults is simulated and assessed by using a transmission power system generic model developed and delivered by the Danish Transmission System Operator Energinet.dk in the power system simulation toolbox PowerFactory DIgSILENT. The data for the wind turbines are not linked to a specific manufacturer, but are representative for the turbine and generator type used in variable-speed DFIG wind turbines with pitch control.     

Wind turbines equipped with fractional‐order controllers: Stress on the mechanical drive train due to a converter control malfunction

This paper is on variable‐speed wind turbines with permanent magnet synchronous generator (PMSG). Three different drive train mass models and three different topologies for the power‐electronic converters are considered. The three different topologies considered are respectively a matrix, a two‐level and a multilevel converter. A novel control strategy, based on fractional‐order controllers, is proposed for the wind turbines. Simulation results are presented to illustrate the behaviour of the wind turbines during a converter control malfunction, considering the fractional‐order controllers. Finally, conclusions are duly drawn. Copyright © 2010 John Wiley & Sons, Ltd.     

Failure rate,repair time and unscheduled O&M cost analysis of offshore wind turbines

Determining and understanding offshore wind turbine failure rates and resource requirement for repair are vital for modelling and reducing O&M costs and in turn reducing the cost of energy. While few offshore failure rates have been published in the past even less details on resource requirement for repair exist in the public domain. Based on ~350 offshore wind turbines throughout Europe this paper provides failure rates for the overall wind turbine and its sub‐assemblies. It also provides failure rates by year of operation, cost category and failure modes for the components/sub‐assemblies that are the highest contributor to the overall failure rate. Repair times, average repair costs and average number of technicians required for repair are also detailed in this paper. An onshore to offshore failure rate comparison is carried out for generators and converters based on this analysis and an analysis carried out in a past publication. The results of this paper will contribute to offshore wind O&M cost and resource modelling and aid in better decision making for O&M planners and managers. Copyright © 2015 John Wiley & Sons, Ltd.     

Wind turbine reliability data review and impacts on levelised cost of energy

Reliability is critical to the design, operation, maintenance, and performance assessment and improvement of wind turbines (WTs). This paper systematically reviews publicly available reliability data for both onshore and offshore WTs and investigates the impacts of reliability on the cost of energy. WT failure rates and downtimes, broken down by subassembly, are collated from 18 publicly available databases including over 18 000 WTs, corresponding to over 90 000 turbine‐years. The data are classified based on the types of data collected (failure rate and stop rate) and by onshore and offshore populations. A comprehensive analysis is performed to investigate WT subassembly reliability data variations, identify critical subassemblies, compare onshore and offshore WT reliability, and understand possible sources of uncertainty. Large variations in both failure rates and downtimes are observed, and the skew in failure rate distribution implies that large databases with low failure rates, despite their diverse populations, are less uncertain than more targeted surveys, which are easily skewed by WT type failures. A model is presented to evaluate the levelised cost of energy as a function of WT failure rates and downtimes. A numerical study proves a strong and nonlinear relationship between WT reliability and operation and maintenance expenditure as well as annual energy production. Together with the cost analysis model, the findings can help WT operators identify the optimal degree of reliability improvement to minimise the levelised cost of energy.     

Wind turbine downtime and its importance for offshore deployment

While the performance and the efficiency of wind turbines and their energy yields have been improved with time, their reliability still needs improvement, particularly when considering their deployment offshore. IWES has been gathering operational experience from wind turbines since 1989, being involved in different projects dealing with the topic of availability and reliability. This paper draws statistical data from Germany's ‘250 MW Wind’ programme, evaluated by IWES. The prime objective of the survey was to extract information about the reliability characteristics of wind turbines. The main purpose of this paper is to discuss the frequency of failures and duration of downtimes for different wind turbine subassemblies based on existing onshore experience and point out the likely outcomes when turbines are deployed offshore. Copyright © 2010 John Wiley & Sons, Ltd.     

Aggregated dynamic model for wind farms with doubly fed induction generator wind turbines

As a result of increasing wind farms penetration in power systems, the wind farms begin to influence power system, and thus the modelling of wind farms has become an interesting research topic. Nowadays, doubly fed induction generator based on wind turbine is the most widely used technology for wind farms due to its main advantages such as high-energy efficiency and controllability, and improved power quality. When the impact of a wind farm on power systems is studied, the behavior of the wind farm at the point common coupling to grid can be represented by an equivalent model derived from the aggregation of wind turbines into an equivalent wind turbine, instead of the complete model including the modelling of all the wind turbines. In this paper, a new equivalent model of wind farms with doubly fed induction generator wind turbines is proposed to represent the collective response of the wind farm by one single equivalent wind turbine, even although the aggregated wind turbines operate receiving different incoming winds. The effectiveness of the equivalent model to represent the collective response of the wind farm is demonstrated by comparing the simulation results of equivalent and complete models both during normal operation and grid disturbances.