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Cost Benefit Analysis and Argument in Favor of Replacement of Mechanical Turbine Control Wind Sensors

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This webinar will address the costs and benefits of replacing mechanical wind sensors with ultrasonic wind sensors for Operations & Maintenance (O&M) service providers to utility-scale wind energy projects. Costs and benefits will include both financial and risk considerations over the typical lifespan of a wind farm.

Watch the webinar: http://www.windpowerengineering.com/webinars/cost-benefit-analysis-replacement-mechanical-turbine/

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Cost Benefit Analysis and Argument in Favor of Replacement of Mechanical Turbine Control Wind Sensors

  1. 1. #WindWebinar
  2. 2. #WindWebinar q  This webinar will be available afterwards at www.windpowerengineering.com & email q  Q&A at the end of the presentation q  Hashtag for this webinar: #WindWebinar Before We Start
  3. 3. #WindWebinar Introducing the Featured Speakers MODERATOR FEATURED SPEAKER Paul Dvorak Editorial Director Windpower Engineering & Development Abraham Aguilar Director of Business Development Lufft USA Inc.
  4. 4. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for precision · passion pour la précision
  5. 5. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Lufft history 1881 Present1989 Go#hilf Lu+ founded the company "Mech. Werksta# G. Lu+" in Stu#gart Part of
  6. 6. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Present: ›  More than 130 years of Business ›  Headquarters in Fellbach, Germany ›  Subsidiaries in USA and China ›  Part of a $20-Billion organizaQon
  7. 7. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec 1903: Lu+ became market leader in the field of metal barometer.
  8. 8. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Traffic Road Weather Mobile Weather Airports, Offshore, Trains Wind & Weather Renewable Energy Meteorology & Hydrology Building AutomaQon Industry Handheld devices for CalibraQon verificaQon Wall Mount-Control Cabinets Sensors/ Loggers TransportaQon sensors with Datalogging capabiliQes Present: Lu+ Covers a Wide Array of Industries and Markets
  9. 9. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Feedback from Wind Turbine O&M companies q  OperaQons and Maintenance (O&M) company’s are looking for ways to reduce Cost and Increase producQon q  Icing on Wind Sensors cause producQon loss q  Need a simple to implement SoluQon q  Added Costs with Mechanical sensors Replacements and Yearly RecalibraQon needs q  Need a Low Cost, Robust Sensor (bo#om-line impact) q  Meet Nuclear Regulatory Commission Requirements
  10. 10. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec » Halt-Report » Corrosion » VibraEon » Ice-free » IP66 Ventus Lufft Ventus for Wind Turbines ü  Every sensor comes with a Factory CalibraEon cerEficate ü  No Moving Parts, No Need to Recalibrate ü  Dual Heaters prevents Ice from AccumulaEng, Prevents Rimming ü  Digital and Analog Outputs directly from the sensor, for a simple soluEon ü  Meets or Exceeds the NRC Regulatory Guide (RG) 1.23 requirements1 ü  Wind DirecEon ± 2° ü  Wind Speed ± 0.45 mph
  11. 11. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Cup AnemometerUltrasonic Anemometer Vane Anemometer •  No moving parts •  Includes temperature control for icing events •  Lifespan of approximately 5 years •  Higher upfront cost •  Provides more turbine controls for higher accuracy and power generation •  Provides wind speed and direction •  Includes Digital and Analog communication protocol •  Moving mechanical parts are subject to weathering •  Weight and inertia of moving cups may negatively impact accuracy of reading •  Low system power requirement •  Inexpensive upfront cost •  Mechanical failure rate is as high as once per year •  May have frequent recalibration requirements •  Low upfront investment cost •  Subject to same mechanical failure issues as cup anemometer •  Freezing temperatures and weather-related buildup require replacement or repair •  Higher starting threshold •  Requires signal translation/conditioning: pulse counter input and analog input required •  Noise from analog signals reduces accuracy in readings
  12. 12. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Assumptions and Information for Analysis •  Interviews with O&Ms reported: 40% of all mechanical sensors need annual replacement from failure •  Wind turbine technicians on average make $23.46/hour2 •  Five-hour maintenance Qme to repair or replace mechanical sensor3 •  Signal CondiQoning needs to performed with addiQonal Wiring leading to addiQonal costs4 •  Industry reports that icing occurs about 5x per year per farm (assumed to be 100 turbines) probability per turbine = 0.05 (5%) •  InformaQon gathered informed us that $40/hour lost producQon x 24 hours x 14 days unQl a replacement sensor is delivered 1.  h#p://www.nrc.gov/docs/ML0703/ML070350028.pdf 2.  h#p://www.bls.gov/ooh/installaQon-maintenance-and-repair/wind-turbine-technicians.htm 3.  h#p://analysis.windenergyupdate.com/operaQons-maintenance/role-sensors-wind-turbine-om 4.  h#p://hps.ne.uiuc.edu/numug/archive/2000/Wastrack.pdf Sources
  13. 13. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,819.30 $2,547.02 $3,274.74 $4,002.46 $4,730.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Mechanical Ultrasonic Return on Investment on the 1st Year
  14. 14. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec How was $1,819 calculated for Mechanical Sensor? =300+50 + (23.46*5) + (40*5*0.4) + 400 + 200 + (40*24*14*0.05) Base Price for Mechanical Sensor Shipping Cost $23.45 technician cost/ hour x 5 hours Signal CondiQoning costs AddiQonal Wiring costs $40/hour lost producEon cost x 5-hrs for repair x 40% Annual Replacement due to failure $40/hour lost producEon x 24 hours x 14 days unQl replacement of sensor x 5% of probability of sensor icing
  15. 15. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Brings the cost to $1,219.30 for the 1st year of a Mechanical Sensor? =300+50 + (23.46*5) + (40*5*0.4) + 0 + 0 + (40*24*14*0.05) Base Price for Mechanical Sensor Shipping Cost $23.45 technician cost/ hour x 5 hours Signal CondiQoning costs AddiQonal Wiring costs $40/hour lost producEon cost x 5-hrs for repair x 40% Annual Replacement due to failure $40/hour lost producEon x 24 hours x 14 days unQl replacement of sensor x 5% of probability of sensor icing
  16. 16. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,219.30 $1,707.02 $2,194.74 $2,682.46 $3,170.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Year Mechanical Return on Investment on the 3rd Year Assuming No AddiQonal Signal CondiQoning or Wiring Costs
  17. 17. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,819.30 $2,547.02 $3,274.74 $4,002.46 $4,730.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Mechanical Ultrasonic Return on Investment on the 1st Year
  18. 18. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,819.30 $2,547.02 $3,274.74 $4,002.46 $4,730.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Mechanical Ultrasonic CumulaQve Cost of past 4 years at 40% replacement due to failure
  19. 19. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec How was $2,112.30 calculated for Ventus Ultrasonic Sensor? =1945.00 + 50 + (23.46*5) + 0 + 0 + 0 + 0 Base Price for Ventus Ultrasonic Sensor Shipping Cost $23.45 technician cost/ hour x 5 hours Signal CondiQoning costs AddiQonal Wiring costs $40/hour lost producQon cost x 5 for repair x 40% Annual Replacement due to failure $40/hour lost producQon x 24 hours x 14 days unQl replacement of sensor x 5% of probability of sensor icing
  20. 20. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec IniQal Sensor Costs $900.00 =900+50+(23.46*5)+(40*5*0.4)+ 400+200+(40*24*14*0.05) $2,419.30 $3,387.02 $4,354.74 $5,322.46 $6,290.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Mechanical (Heated) Ultrasonic
  21. 21. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Brings the cost to $1,819.30 for the 1st year of a Mechanical (Heated) Sensor? =900+50 + (23.46*5) + (40*5*0.4) + 0 + 0 + (40*24*14*0.05) Base Price for Mechanical Sensor Shipping Cost $23.45 technician cost/ hour x 5 hours Signal CondiQoning costs AddiQonal Wiring costs $40/hour lost producEon cost x 5-hrs for repair x 40% Annual Replacement due to failure $40/hour lost producEon x 24 hours x 14 days unQl replacement of sensor x 5% of probability of sensor icing
  22. 22. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $1,819.30 $2,547.02 $3,274.74 $4,002.46 $4,730.18 $2,112.30 Year 1 Year 2 Year 3 Year 4 Year 5 CumulaEve Cost Mechanical Ultrasonic (Heated) Assuming No AddiQonal Signal CondiQoning or Wiring Costs IniQal Cost is the Same for Heated as Non-Heated with addiQonal SC and Wiring costs with the same ROI within the 1 Year!
  23. 23. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec $6,308 $4,335 $6,948 $2,112 $- $1,000 $2,000 $3,000 $4,000 $5,000 $6,000 $7,000 Mechanical (non- heated) Mechanical (heated) Mechanical (with communication protocol) Ultrasonic FiveYearCostPerTurbine Anemometer Type Power Production Losses: Icing Additional Wiring Signal Conditioning Power Production Losses: Mechanical Failure Maintenance 53%of cost due to Icing 48% of cost due to Icing
  24. 24. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Analysis of a 100- turbine wind farm with 1.5-3 MW turbines
  25. 25. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Ventus ultrasonic anemometer on wind turbines Ventus
  26. 26. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec American Wind Energy Association data Total number of operaQng uQlity-scale wind turbines: > 48,000 Source: http://www.awea.org/Resources/Content.aspx?ItemNumber=5059
  27. 27. #WindWebinar a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for prec Save in Operational Costs and Increase Production Contact us: www.Lu+.com Abraham Aguilar Abraham.Aguilar@lu+usainc.com (888) 519-8443 (805) 618-2958
  28. 28. #WindWebinar Questions? MODERATOR FEATURED SPEAKER Paul Dvorak Editorial Director Windpower Engineering & Development pdvorak@wtwhmedia.com Abraham Aguilar Director of Business Development Lufft USA Inc. Abraham.Aguilar@lufftusainc.com
  29. 29. #WindWebinar q  This webinar will be available at www.windpowerengineering.com & email q  Tweet with hashtag #WindWebinar q  Connect with Windpower Engineering & Development q  Discuss this on EngineeringExchange.com Don’t Forget!
  30. 30. #WindWebinar

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