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BDE SC3.3 Workshop - BDE Pilot case for Wind Turbine condition monitoring research

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BDE Pilot case for Wind Turbine condition monitoring research (Mr. F. Mouzakis, CRES) at the BigDataEurope Workshop, Amsterdam, Novermber 2017

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BDE SC3.3 Workshop - BDE Pilot case for Wind Turbine condition monitoring research

  1. 1. Big Data Europe for System Monitoring BigDataEurope 3rd Workshop Amsterdam 28/11/1725-janv.-18 F. Mouzakis, D. Foussekis and BDE consortium
  2. 2. BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.2 Overview  CRES challenge  Data acquisition challenge  Research case in WT monitoring www.big-data-europe.eu
  3. 3. BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.3 www.big-data-europe.eu CRES Wind Department - Testing  Wind potential measurement campaigns & Lidar  Power Performance Measurements  Electrical Power Quality of Wind Turbine Generators  Mechanical Load measurements  Blade testing (<30m) and coupon testing  Research on testing
  4. 4. BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.4 www.big-data-europe.eu
  5. 5. BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.5 www.big-data-europe.eu CRES challenges  Exploit the capabilities of the new data distributed DAQ with high-throughput rates for research  Utilize the open Big Data technology tool Background:  Fully instrumented WT in WF with no fiber optic connection (24MBps ADSL, Upload speeds <1Mbps)  Cluster of 16 x [ 8core-CPUs, 16GB RAM + 256GB SSD ]  150TB in 5 x NAS [8 x 4TB in 1disk-redundancy RAID]
  6. 6. General requirements in System monitoring  Modular distributed system using standard Ethernet network  Specs compliant with International Standards  Robust and reliable for 24/7 standalone non-stop operation  Scalable and reconfigurable  Time Synchronization across all modules (GPS or Master module)  Embedded processing capabilities  Send notifications and alarms  Data storage www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.6
  7. 7. Typical DAQ system core component (1/2)  NI-CompactRIO platform http://www.ni.com/compactrio/  Designed for harsh environments -20º to -55ºC temperature, 5grms vibration, 30g shock  Low power requirements ~10W at 9-30V for battery powered standalone operation  Data acquisition based on FPGA hardware offering fast I/O response times and increased reliability www.big-data-europe.eu Source: NI.com BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.7
  8. 8. Field-Programmable Gate Array (FPGA) www.big-data-europe.eu - Reconfigurable Hardware chip. - Analogous to a printed circuit board with unconnected components on it. - Connections in an FPGA circuit are dynamically defined in software. BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.8
  9. 9. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.9 Benefits of FPGA in wind energy applications Inline processing: Reduce the noise of a periodic signal by averaging the samples as acquired on the FPGA Average 1,024 records, 1 million samples long with 16 bits of resolution
  10. 10. Typical configuration www.big-data-europe.eu . . . Gigabit Local Area Network (LAN) Network Attached Storage (NAS)System Monitoring PC BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.10
  11. 11. Raw Data storage – Existing File Formats www.big-data-europe.eu ASCII files + Human-readable + Portable / MS Excel - Significantly larger disk footprint - Slow read and write BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.11 Binary + Compact file size + Fast streaming (read & write) - Not human-readable - Not easily exchangeable XML + Stores complex data structures + Web browser / text editor - Even larger disk footprint - Front-end schema design - Does not streamDatabase files + Store data centrally + Organize and query test results with SQL - Time intensive startup effort - Requires maintenance - Potentially high cost
  12. 12. Raw Data storage – Existing File Formats www.big-data-europe.eu Binary Structured (TDMS – NI Technical Data Management Technology, Physical Acoustics Format) Characteristics • Single streaming binary file • Three levels of hierarchy for better organization File, groups, and channels • Customizable, descriptive properties at each level • User-defined Meta data for campaign properties Considerations • Third party format BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.12
  13. 13. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.13 Type: SCADA and CMS data on a Wind Turbine specifically instrumented for BDE Status: Open Sensors: Operational parameters, Vibration, Mechanical Loading, Power Quality, AE Format: Third party (TDMS technical data management streaming) – preprocessing foreseen Acquisition technology: Field Programmable Gate Arrays (FPGA) Sampling rate: from 10s/s for operational parameters up to 64ks/s for vibration & power quality Streaming volume: 3 distributed units yield ~14Gb/hour continuously Scope: Research on condition monitoring based on long term data Analytics: engineering signal analysis, research on parametrics, fault identification and loop with updated methodologies on raw data Operation of pilot:1 year (on-going) Primary Content/Data Involved
  14. 14. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.14 CRES Wind Farm Monitored WT Neg-Micon 750kW
  15. 15. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.15 The monitoring system provides indicatively the following data for the condition monitoring system: - system operational status/parameters - wind turbine output electrical power - nacelle yaw position, yaw motor electrical power - wind speed from nacelle anemometer (1~10s/s) and additionally: - mechanical loads on tower top and base cross section (~100s/s) - rotor thrust & tower torsion - HSS torque (on shaft coupling the gearbox with the generator) (64ks/s) - power quality current & voltage (64ks/s) - vibration at gearbox various stages (64ks/s) - acoustic emission signals at gearbox (10Ms/s) CRES CM system on NegMicon 750kW WT
  16. 16. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.16 SC3 Pilot measuring system Gearbox and Drive train DAQ systems Operation DAQ system Supervising PC Local storage unit
  17. 17. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.17 Bearing vibration sensors at gearbox HSS (accelerometers) Power Quality voltage and current probes SC3 Pilot sample sensors
  18. 18. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.18 SC3 Pilot sample sensors Conventional vibration CMS (dynamic content ~3kHz) Acoustic emission CMS (dynamic content 100~400kHz)
  19. 19. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.19 BDE pilot CM module topology 7.2Gb/hour (i2) 0.1Gb/hour (r4) 7.2Gb/hour (i2) Source: NI.com 15Gb/h Condition based
  20. 20. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.20 Pilot Data Acquisition module Access through TeamViewer
  21. 21. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.21 Pilot Data Acquisition module Bending Moment signals for Mechanical Loading Monitoring
  22. 22. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.22 Pilot Data Acquisition module Vibration signal for Gearbox monitoring
  23. 23. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.23 Pilot Data Acquisition module Electrical signals for Power Quality Monitoring
  24. 24. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.24 OPC An Industrial Interoperability Standard for Open Platform Communications https://opcfoundation.org/ Pilot Data Acquisition module – On line component
  25. 25. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.25 Pilot Data Acquisition module – On line component OPC Server operating at: opc.tcp://193.92.104.xxx:49580 Object name: PrjBDE.WT.StatAve Encryption: SHA256 Data type: 1D- float Array- 52 elements Transferred parameters: On-line statistical properties Refresh rate: 2Hz Server: CompactRIO running NI Real-Time Linux OS Client: Industrial PC running LabVIEW
  26. 26. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.26 OPC server monitor on DAQ app Pilot Data Acquisition module – On line component
  27. 27. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.27 Pilot Data Acquisition module – AE component ◎ 4 AE (R30) sensors were installed • Main bearing, gearbox (LSS side, INT & HSS generator side) ◎ DAQ system records data at a rate of 10~20GB/hour depending on threshold (research item) ◎ Data preprocessor module binary- binary ◎ Additional feature module
  28. 28. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.28 ◎ Addition of new descriptive features and optimize parameters (multiple signal analysis) ◎ Describe normal operation signature Source: Hit Detection and Determination in AE Bursts, InTechOpen AE module: research aspects
  29. 29. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.29 Basic analytics Raw time series Statistics and correlations Dynamic analysis Fatigue analysis
  30. 30. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.30 Feature scales 1min10 min 10 min 10 min
  31. 31. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.31 Feature scales and patterns ~3700 per minute
  32. 32. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.32 Pilot concept
  33. 33. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.33 Pilot concept
  34. 34. www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring – Research pilots p.34 Research concluding steps ◎ Conclusion of data collection ◎ Assessment of added features in AE analysis ◎ Define the operational envelope for the current status of the WT (distribution parameters) ◎ Assessment of timewise distribution changes
  35. 35. BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.35 www.big-data-europe.eu Final Remarks – BDE opportunities  Big Data Europe offers a easy-to-use generic platform to encourage community’s entrance to big data technologies You are invited to implement your case with BDE: https://www.big-data-europe.eu/bdi-components/ https://www.big-data-europe.eu/howto-install-the-bde-platform/ https://github.com/big-data-europe Getting Started With BDE Platform
  36. 36. Thank you for your attention BDE consortium www.big-data-europe.eu BigDataEurope 3rd Workshop in WindEurope Conference & Exhibition, Amsterdam 28/11/17 System Monitoring p.36

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