1) A presentation was given on retrofitting control systems in wind turbines. Retrofitting control systems can improve power output, availability, and reduce operation and maintenance costs. 2) A case study was presented on retrofitting the control systems on 50 Bonus 1.3MW turbines. The retrofit improved the power curve, replaced pitch and main controllers, and added remote monitoring capabilities. 3) The retrofit paid for itself in less than 3 years through increased revenue from higher output and reduced operation costs from improvements like fewer yaw motor replacements. Retrofitting control systems was shown to be more profitable than other wind turbine upgrades.

1. Retrofit of control systems in wind turbines
AWEA Wind Project O&M and Safety Seminar 2015, San Diego, California
03.02.2015 Rasmus Nielsen, Technical Product Manager
Niels K. Christensen, Sales Manager
[To be shared after presentation]

2. Agenda
What to expect?
1. Our track record in wind turbine control systems
2. Why retrofit a control system?
3. Case: Bonus 1.3 MW
4. Results / lessons learned
5. Show me the money
Retrofit of turbine controls systems2

3. Looking back
Our track record in wind turbine control systems
Retrofit of turbine controls systems3
1990 ->
Sole supplier of
control systems to
Bonus/Siemens
1978
We develop the
world’s first control
system for a modern
wind turbine – a
50kW Windmatic
2012
KK retrofits a V80
turbine incl.
converter
2014
KK develops retrofit
solutions for Bonus 1.3
MW and Vestas V47
turbines incl. SCADA
TODAY we have ~20.000 control systems installed globally and 60%
of all offshore turbines are equipped with a control system from
KK Wind Solutions
WTC1 WTC2 WTC3 WTC6

4. Why retrofit the control system?
Voice of the turbine owner/operator
Retrofit of turbine controls systems4
• Economic feasibility
• Mechanical loads
• Communication with sub systems
• Communication with SCADA system
ConcernsBenefits
• Increase output
• Lower O&M costs
• Secure data access and quality
• Enable asset management
• Enable in-sourcing of service
• Secure spare part availability
• Enable optimization with configuration
layer and source code
• Automatic/remote reset of alarms
• Intelligent power reduction instead of
stopping

5. Bonus 1.3 MW case
What’s in the box?
Mandatory
• Main controller
• Grid measurement module
• IO modules (Input/Output)
• Pitch control module
Optional
• Accelerometer
• WiFi access for service
• Datalogger
• Service tablet
IO Module
IO Module
Accelerometer
Pitch control module
IO ModuleDatalogger
Main controller Grid measurement
Service tablet
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6. Bonus 1.3 MW case
Pitch control replacement
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7. Bonus 1.3 MW case
Nacelle control replacement
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8. New O&M Interface
Improved data access, remote control and root cause analysis tools
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• New web based service interface for local and remote operation
• New web based SCADA system for park level monitoring
• Customize interface e.g. with site specific service procedures
• Upgrade turbine software remotely
• Use extensive statistics and detailed data for analyzing problem root causes

9. Results
Improved power curve
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0
200
400
600
800
1000
1200
1400
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Wind Speed [m/s]
Power Curve [kW]
Before
After

10. Results
Improved remote control and statistics
Remote reset of known alarms provides higher availability and lowers maintenance
Improved operation statistics enables root cause analysis and lower O&M costs
Retrofit of turbine controls systems10
Yaw activity measured to
be ~165,000 starts/year.
This is reduced around
50%, providing less yaw
motor replacements

11. Assumptions:
Number of turbines: 50
Price per MWh: 55$
Installation time: 2 days
Retrofit of turbine controls systems11
Show me the money
Payback time less than 3 years
Investment $ 818,000
Availability improvements
Yaw $ 41,323
Pitch $ 75,490
Other $ 49,560
Total $ 166,373
O&M cost reduction
Yaw $ 11,390
Pitch $ 23,737
Other $ 16,030
Total $ 51,157
Power curve improvement $ 103,975
Total added revenue per year $ 321,505
Payback time in years 2.5
As well as economical feasibility, retrofit
also reduces the risk of accidents due to
improved safety components.

12. Recap
Main conclusions
Retrofit of Bonus 1.3MW turbines show economical feasibility
and payback time of less than three years
Retrofit has shown improvements in Power curve, Availability,
Safety and O&M-effort
Solutions for Bonus 1.3MW and Vestas V47 are now
commercial available
Retrofit of turbine controls systems12

13. Controls upgrades are
substantially more profitable
than other value chain elements
of turbine sales or service.
Source: MAKE Consulting – Global Wind Turbine Trends 2014, page 32
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14. Thank you for your attention
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