Wind OM Robichaud Senior Engineer WINDExchange NREL DOE
Wind O&M Robichaud Senior Engineer WINDExchange NREL DOE Office of Indian Energy Policy and Programs DOE Office of Energy Efficiency and Renewable Energy Tribal Energy Program Western Area Power Administration
Wind O&M - Topical Outline • Utility-scale (1 -3 MW) – O&M R & D – O&M Cost Trends • Distributed-scale (1 -1500 k. W) – O&M Cost Trends 2
Utility-scale - O&M - Type of Costs • Annual Fixed Costs – Scheduled maintenance • Oil & lubricants • Sensor evaluation – – Condition Monitoring Leasing Taxes Insurance • Annual Variable Costs – Unscheduled maintenance • Worn out parts • Catastrophic failures 3
Utility-scale - O&M Costs Generally, the annual costs increase over the life of the turbine – especially in later years of 20 -25 year useful life There are industry recommended practices for all aspects of wind turbine maintenance: Towers; rotors/blades/hubs; gearboxes; generators; balance of plant; data collection/reporting; end of warranty O & M Costs expressed as: $/k. W/yr (capacity-based) $/MWh/yr or $/k. Wh/yr (energy-based) $/yr (simple) 4
Major Components at Risk Equipment breaks – usually after the warranty expires Structural Gearbox Rebuild Warranty Repair Cost Blade Replacement K RIS Yaw Drive, Pitch Drive Generator Bearings Motors and Switchgear Control & Sensors 5 5 Reference: Chris Walford: GEC (now DNV GL) 10 20 years
NREL Wind O&M Research & Development 6 Source: Report on Wind Turbine Subsystem Reliability – A Survey of Various Databases, Sheng, S. 2013: NREL Publication Database: NREL/PR-5000 -59111
NREL Reliability Research Strategy Identify the high O&M cost issues (data base) Quantify failure probability statistics (data base) Develop reliability driven design and O&M COE model(s) Understand the component root causes of failures (GRC) Develop O&M management tools Design high reliability solutions Test solutions and O&M tools at reference sites Integrate long term solutions into the design process Failure Probability • • I II III Goal Component life 7 Source: Presentation by S. Butterfield, at FEDWEATS at NREL February 2009
Sandia National Lab CREW: Failure Rate and Downtime Goals: Reduce the number of failures per year Reduce time per failure BOTH strategies have positive long term impacts on turbine life and O&M costs 8 Source: Report on Wind Turbine Subsystem Reliability – A Survey of Various Databases, Sheng, S. 2013: NREL Publication Database: NREL/PR-5000 -59111
Cost Concerns & Strategies for O&M Cost Control Costs for Unscheduled O&M can spiral high quickly (e. g. , gearbox failure) • $150 k for mobilization/demobilization of crane • $200 -350 k full cost – included downtime, parts, equipment, labor – 1 -3 months Strategies for Cost Control • Work with OEM or Plant Manager - use real-time, condition monitoring system • Plan maintenance for the “low wind season” – Minimize financial impacts – Lessen potential for it being “too windy to do O&M” – Maximize use of costly crane - schedule crane for continuous use 9
Benefits of Condition Monitoring § Early deterioration detection to avoid catastrophic failure; § Accurate evaluation of damage state of the monitored structure, and subsequently a cost effective maintenance planning or component replacement; § Root cause analysis and subsequently, improved operational strategy to reduce chances of structure deterioration. 10
O&M Cost Trends: Average O&M Costs for Available Data Years 11 Source: 2012 Wind Technologies Market Report, Wiser et al, 2013 DOE Publication: DOE/GO-102013 -3948
Median Annual O&M Costs by Project Age and Commercial Operation Date 12 Source: 2012 Wind Technologies Market Report, Wiser et al, 2013 DOE Publication: DOE/GO-102013 -3948
Ranges of LCOE and LCOE Elements for Land-Based and Offshore Wind in 2011 Report: 2011 Cost of Wind Energy Review Levelized Cost of Energy – Range for O&M Costs for Utility-scale Wind Turbines in Wind Farms 13 Source: 2011 Cost of Wind Energy Review , Tegen et al, 2013 NREL Publication Database: NREL/TP-5000 -56266
Distributed Wind – Lots of Turbines, Not So Much Data Distributed-scale (1 -1500 k. W) Installations in 2011 14 Installations in 2012 Source: DOE/EERE/Wind Program 2012 Market Report on Wind Technologies in Distributed Applications http: //energy. gov/sites/prod/files/2013/12/f 5/2012_distributed_wind_technologies_marke
US Distributed Wind Capacity by Turbine Type/Size 15 Source: DOE/EERE/Wind Program 2012 Market Report on Wind Technologies in Distributed Applications http: //energy. gov/sites/prod/files/2013/12/f 5/2012_distributed_wind_technologies_marke
Small Wind O&M Cost Estimates Vary Widely Annual O&M cost estimates from manufacturers & installers Preliminary Small Wind Annual O&M Cost Assumptions Used in JEDI (Tegen 2013) 16 Source: DOE/EERE/Wind Program 2012 Market Report on Wind Technologies in Distributed Applications http: //energy. gov/sites/prod/files/2013/12/f 5/2012_distributed_wind_technologies_marke
Small Wind O&M Activities Follow manufacturer/installer recommendations: • Schedule routine maintenance (semi-annual or annual) per manufacturer guidelines • If you find a good contractor, keep using the same one – experience and familiarity with a particular turbine is good If you are a “do-it-yourselfer” AND you can climb a tower or have a tilt-down turbine or small bucket lifter: Semi-annual or annual: Follow manufacturer recommendations • Tighten screws & bolts – electrical & mechanical • Check for frayed wires • Check for insect or other debris build-up on blades and clean off (water no solvents) • Check for rust – remove and using manufacturer’s recommended lubricant 17
Questions • Answers to all questions submitted electronically during today’s webinar will be posted on WAPA’s website within a few weeks. • To view and download presentations and corresponding Q&As from the 2014 Tribal Energy Webinar Series, please visit www. wapa. gov and click on Renewables in the top navigation. • To submit follow-up questions regarding the material covered in today’s webinar, please contact: Robichaud Senior Engineer, WINDExchange NREL robichaud@nrel. gov 18
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