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Overview
As the demand for wind power continues to increase, the current priority must be to reduce O&M costs and improve its stability. At present, the O&M cost of wind power generation remains high, so the global acceptance of wind power generation is also limited. With a low-cost online status monitoring system, failure and maintenance needs can be predicted to reduce maintenance operations and reduce O&M costs. Due to the limitation of environmental conditions, wind power plants are often located remotely and the vertical distance between the unit and the ground is extremely high, so the maintenance cost of wind turbines is also extremely expensive. In addition, the wind turbine assembly has also been designed to lighten its weight and is therefore prone to failure due to stress.
Condition monitoring requirements
The current trend of wind power generation is to set up large-scale wind turbines in remote areas, so they are often located offshore and can obtain better wind conditions. However, compared with the traditional power generation system, the problem of the remoteness of the equipment volume and location has caused maintenance problems:
1. It is not possible to patrol and maintain at any time - Unlike other power generation equipment, it is difficult for wind turbines to schedule repairs by maintenance personnel at any time.
2. High maintenance costs - Since it is necessary to travel to remote areas, generator sets are also placed at a very high distance from the ground, so the maintenance costs are also high.
3. High probability of failure - Gearboxes and related components are designed specifically for weight and are therefore more susceptible to failure due to stress.
In addition, the load and operating conditions are constantly changing, so wind turbines must withstand higher mechanical stress. Under high stress conditions, maintenance operations are even more necessary.
Wind power generation is generally Reactive or Run-to-Failure maintenance. This type of maintenance is also the highest cost O&M.
Therefore, in addition to increasing the cost of O&M, it will also affect the estimated energy cost (COE) of project feasibility and investment income.
The Electric Power Research Institute (EPRI) has provided a complete case study for the power industry, and response maintenance (continuous operation of the machine until failure) is the most efficient and cost-effective way to maintain power generation equipment. The maintenance costs provided by EPRI are listed below:
1. Responsive (damage) maintenance costs, the annual single horsepower will need to start from $17.
2. Preventive maintenance is carried out according to the manufacturer's recommended maintenance cycle. The annual single horsepower costs 24 US dollars; about 24% of the cost of response maintenance can be saved.
3. Predictive maintenance is the status of monitoring and maintenance operations required to predict, the annual cost of a single horsepower costs 9 US dollars; about 47% of the cost of response maintenance can be saved.
If turbine components continue to operate until failure, the overall power generation will be greatly affected by unplanned downtime. At the same time, the cost of frequently operating parts and lifting operations, coupled with the damage caused by falling parts, will increase maintenance costs. Compared with the predictive maintenance of online condition monitoring systems, the cost of interactive maintenance is indeed much higher. The function of the condition monitoring system is to continuously monitor components and predict machine problems so that operators can schedule maintenance as soon as possible and avoid major losses.
Condition Monitoring Solution
NI provides dedicated solutions for status monitoring operations. For generator/gearbox manufacturers or wind turbine integrators, NI provides the necessary hardware and software to design high-performance, low-cost, and proprietary wind turbine monitoring solutions. NI also continues to provide the latest signal processing algorithms based on industry trends to identify the key features of the signals and predict the state of the machine components. These algorithms include order analysis, cepstral analysis, bearing modulation monitoring, wavelet, AR modelling, power quality, power factor, rainfall analysis of rainfall stress cycles, and many statistical analysis algorithms. With NI LabVIEW software, you can use these built-in signal processing algorithms, import text program code (such as C and other math scripts), and easily design entirely new algorithms.
Taking the research results as an example, the wind turbine gearbox and its bearings are the components with the highest failure rate. Vibration analysis of gearboxes and bearings monitors and predicts possible faults through acceleration rules. However, if the wind turbine uses a multi-stage gearbox, excessive vibration sources will cause complex vibration, modulation, and vibration at operating speeds.
To analyze the vibration of the gearbox correctly, a high-resolution spectrum analyzer is required. Basically, this will require a multi-bandwidth vibration signal sampling instrument to record long-term waveforms. In other words, the condition monitoring solution must be able to achieve a sampling rate of more than 51.2 kHz and can store more than 2 MB of binary time waveforms. The NI CompactRIO platform has this feature. High-order spectroscopic analysis includes a zoom FFT and Zoom orderspectrum to further identify high-frequency vibration characteristics without missing Sideband data. Sideband analysis helps analysts find faulty gears.
This flexible and open NI LabVIEW and CompactRIO environment has the following advantages:
1. Lower Cost - NI continues to develop low-cost, high-performance technologies that are only designed to provide integrators and OEMs with superior technology.
2. Customer Solutions - Developers can easily design proprietary monitoring solutions that far exceed the capabilities of traditional state monitoring solutions.
3. OEM-specific NI-plus, with more than 900 development partners, can significantly reduce costs and reach ready-to-use solutions.
4. Integrated Control and Monitoring - The NI platform can be equipped with control and monitoring capabilities in a single system for high-level, model-based monitoring operations.
Control System Integration and Communication Protocol Support
If compared with other products, NI system can achieve the lower cost and dedicated signal processing functions. The biggest difference is that it can integrate the functions of the control system. Through the NI platform, you can integrate control and monitoring capabilities with a single device or multiple sets of devices. The NI platform can interface with Ethernet, RS232/RS485, Modbus, OPC, CAN, Fieldbus, PROFIBUS, or even patented communication protocols. This flexible communication function allows the NI system to easily integrate other units of the wind turbine.
NI Products for Condition Monitoring
National Instruments offers a variety of signal processing devices that can interface with different sensors, including vibration, strain, audio, temperature, voltage, current, and power. Through the standard communication protocol, oil particle (Oilparticulate) counting and optical sensing functions can be added to the status monitoring device. Diverse and flexible features allow NI to stay ahead of state monitoring applications.
As the demand for wind power continues to increase, the current priority must be to reduce O&M costs and improve its stability. At present, the O&M cost of wind power generation remains high, so the global acceptance of wind power generation is also limited. With a low-cost online status monitoring system, failure and maintenance needs can be predicted to reduce maintenance operations and reduce O&M costs. Due to the limitation of environmental conditions, wind power plants are often located remotely and the vertical distance between the unit and the ground is extremely high, so the maintenance cost of wind turbines is also extremely expensive. In addition, the wind turbine assembly has also been designed to lighten its weight and is therefore prone to failure due to stress.
Condition monitoring requirements
The current trend of wind power generation is to set up large-scale wind turbines in remote areas, so they are often located offshore and can obtain better wind conditions. However, compared with the traditional power generation system, the problem of the remoteness of the equipment volume and location has caused maintenance problems:
1. It is not possible to patrol and maintain at any time - Unlike other power generation equipment, it is difficult for wind turbines to schedule repairs by maintenance personnel at any time.
2. High maintenance costs - Since it is necessary to travel to remote areas, generator sets are also placed at a very high distance from the ground, so the maintenance costs are also high.
3. High probability of failure - Gearboxes and related components are designed specifically for weight and are therefore more susceptible to failure due to stress.
In addition, the load and operating conditions are constantly changing, so wind turbines must withstand higher mechanical stress. Under high stress conditions, maintenance operations are even more necessary.
Wind power generation is generally Reactive or Run-to-Failure maintenance. This type of maintenance is also the highest cost O&M.
Therefore, in addition to increasing the cost of O&M, it will also affect the estimated energy cost (COE) of project feasibility and investment income.
The Electric Power Research Institute (EPRI) has provided a complete case study for the power industry, and response maintenance (continuous operation of the machine until failure) is the most efficient and cost-effective way to maintain power generation equipment. The maintenance costs provided by EPRI are listed below:
1. Responsive (damage) maintenance costs, the annual single horsepower will need to start from $17.
2. Preventive maintenance is carried out according to the manufacturer's recommended maintenance cycle. The annual single horsepower costs 24 US dollars; about 24% of the cost of response maintenance can be saved.
3. Predictive maintenance is the status of monitoring and maintenance operations required to predict, the annual cost of a single horsepower costs 9 US dollars; about 47% of the cost of response maintenance can be saved.
If turbine components continue to operate until failure, the overall power generation will be greatly affected by unplanned downtime. At the same time, the cost of frequently operating parts and lifting operations, coupled with the damage caused by falling parts, will increase maintenance costs. Compared with the predictive maintenance of online condition monitoring systems, the cost of interactive maintenance is indeed much higher. The function of the condition monitoring system is to continuously monitor components and predict machine problems so that operators can schedule maintenance as soon as possible and avoid major losses.
Condition Monitoring Solution
NI provides dedicated solutions for status monitoring operations. For generator/gearbox manufacturers or wind turbine integrators, NI provides the necessary hardware and software to design high-performance, low-cost, and proprietary wind turbine monitoring solutions. NI also continues to provide the latest signal processing algorithms based on industry trends to identify the key features of the signals and predict the state of the machine components. These algorithms include order analysis, cepstral analysis, bearing modulation monitoring, wavelet, AR modelling, power quality, power factor, rainfall analysis of rainfall stress cycles, and many statistical analysis algorithms. With NI LabVIEW software, you can use these built-in signal processing algorithms, import text program code (such as C and other math scripts), and easily design entirely new algorithms.
Taking the research results as an example, the wind turbine gearbox and its bearings are the components with the highest failure rate. Vibration analysis of gearboxes and bearings monitors and predicts possible faults through acceleration rules. However, if the wind turbine uses a multi-stage gearbox, excessive vibration sources will cause complex vibration, modulation, and vibration at operating speeds.
To analyze the vibration of the gearbox correctly, a high-resolution spectrum analyzer is required. Basically, this will require a multi-bandwidth vibration signal sampling instrument to record long-term waveforms. In other words, the condition monitoring solution must be able to achieve a sampling rate of more than 51.2 kHz and can store more than 2 MB of binary time waveforms. The NI CompactRIO platform has this feature. High-order spectroscopic analysis includes a zoom FFT and Zoom orderspectrum to further identify high-frequency vibration characteristics without missing Sideband data. Sideband analysis helps analysts find faulty gears.
This flexible and open NI LabVIEW and CompactRIO environment has the following advantages:
1. Lower Cost - NI continues to develop low-cost, high-performance technologies that are only designed to provide integrators and OEMs with superior technology.
2. Customer Solutions - Developers can easily design proprietary monitoring solutions that far exceed the capabilities of traditional state monitoring solutions.
3. OEM-specific NI-plus, with more than 900 development partners, can significantly reduce costs and reach ready-to-use solutions.
4. Integrated Control and Monitoring - The NI platform can be equipped with control and monitoring capabilities in a single system for high-level, model-based monitoring operations.
Control System Integration and Communication Protocol Support
If compared with other products, NI system can achieve the lower cost and dedicated signal processing functions. The biggest difference is that it can integrate the functions of the control system. Through the NI platform, you can integrate control and monitoring capabilities with a single device or multiple sets of devices. The NI platform can interface with Ethernet, RS232/RS485, Modbus, OPC, CAN, Fieldbus, PROFIBUS, or even patented communication protocols. This flexible communication function allows the NI system to easily integrate other units of the wind turbine.
NI Products for Condition Monitoring
National Instruments offers a variety of signal processing devices that can interface with different sensors, including vibration, strain, audio, temperature, voltage, current, and power. Through the standard communication protocol, oil particle (Oilparticulate) counting and optical sensing functions can be added to the status monitoring device. Diverse and flexible features allow NI to stay ahead of state monitoring applications.
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