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

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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

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Introducing the Featured Speakers
MODERATOR FEATURED SPEAKER
Paul Dvorak
Editorial Director
Windpower Engineering
& Development
Abraham Aguilar
Director of Business Development
Lufft USA Inc.

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a passion for precision · passion pour la précision · pasión por la precisión · passione per la precisione · a passion for precision · passion pour la
précision

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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

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Present:
›  More than 130 years of Business
›  Headquarters in Fellbach, Germany
›  Subsidiaries in USA and China
›  Part of a $20-Billion organizaQon

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1903: Lu+ became market leader in the ﬁeld of metal barometer.

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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

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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

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» 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

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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

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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

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$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

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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

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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
Annual Replacement
due to failure
$40/hour lost
x 14 days unQl
sensor icing

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$1,219.30
$1,707.02
$2,194.74
$2,682.46
$3,170.18
$2,112.30
CumulaEve Cost
Year
Mechanical
Return on Investment on
the 3rd Year
Assuming No
AddiQonal Signal
CondiQoning or
Wiring Costs

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$1,819.30
$2,547.02
$3,274.74
$4,002.46
$4,730.18
$2,112.30
CumulaEve Cost
CumulaQve Cost of past 4 years
at 40% replacement due to
failure

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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

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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
CumulaEve Cost
Mechanical (Heated) Ultrasonic

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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
Annual Replacement
due to failure
$40/hour lost
x 14 days unQl
sensor icing

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$1,819.30
$2,547.02
$3,274.74
$4,002.46
$4,730.18
$2,112.30
CumulaEve Cost
(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!

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$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

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Analysis of a 100-
turbine wind farm with
1.5-3 MW turbines

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Ventus ultrasonic anemometer on wind turbines
Ventus

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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

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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

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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

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