PES Wind 2 2019

“DELIVERING INDUSTRY-LEADING SURVEY PERFORMANCE AND DATA RESOLUTION TO OUR CLIENTS” MMT.SE

THINK TANK The necessity of maintaining a healthy drivetrain inspection programme Words: Daryl Hickey, senior inspections and reliability engineer with Natural Power The drivetrain of a wind turbine generator is an expensive but important component of the energy generating system. It’s composed of the main bearing, main shaft, gearbox, brake, generator shaft, and generator. The multi-physical complexity of this arrangement and the expense involved in downtime and maintenance due to failure, ensures that it is both recommended and normal for turbines to have several measures in place to monitor the health of the components. Daryl Hickey 102 PES WIND

Figure 0.1: Elevated Particle Count THINK TANK The most common remote monitoring systems are SCADA and vibration monitoring, collectively known as a condition monitoring system (CMS). SCADA offers an excellent approach for analysis of low frequency signals coming from sensors measuring temperatures, pressures, particle count, current, shaft speeds, and so on. A good analyst will filter the data and trend the results to look for anomalies across a wind farm, or to detect differences in data across a reference, for example, wind speed. Specifically, within a gearbox sump an oil particle count and temperature events at relatively low data rates can provide invaluable information regarding the wear of components and subsequent friction that would occur as a result of contaminated oil. A system will contain limit settings, that when breached will trigger an alarm and a service team can be deployed accordingly. However, by the time a temperature limit or particle count is reached it can be argued that this is too late. Figures 0.1 and 0.2 demonstrate analysis that uncovered an elevating particle count trend and abnormal temperature readings across a wind farm. Vibration monitoring provides a superior method of damage detection, albeit at a higher monetary cost. Utilising spectral techniques, phenomena in data can be uncovered. Damage can be pin-pointed to a component location likely to be undergoing some structural change. Classical spectral methods, such as the fast Fourier transform (FFT), provide valuable information on frequency information, directly related to the kinematics of a gear or bearing. The rotational nature of the drivetrain lends itself nicely to being able to mathematically determine events per cycle that allow pinpoint accuracy when detecting and locating damage. Further analysis in orders and harmonic analysis for sidebands provides useful information when making decisions on the type of damage that a signal analyst could be looking at. In addition to the mathematics that are involved the decision making, the process is also assisted with the provision of ISO codes that provide useful advisory limits when triggering alerts or alarms within horizontal axis wind turbines with a gearbox, specifically 10816-21. A downside to this type of analysis is the data rates involved are high and the systems are complicated and require highly qualified signal analysts to interpret the data. Figure 0.3 reveals a vibration analysis that uncovers an increasing amplitude trend at a known frequency to be problematic within the drivetrain. A third technique offers visibility on the type of damage that is taking place. A good servicing and maintenance plan should involve visual inspections. The routine checking of a gearbox with an endoscope can provide excellent supporting documentation WWW.PESWIND.COM 103

THINK TANK Figure 0.2: Temperature Anomalies patterns. Monitoring does not always need Figure 0.3: Increasing trend toward higher amplitudes of vibration at known problematic frequencies. to be site-based, nor involve sophisticated technology. Data in the form of an image can be just as important and informative as any signal. A well-balanced combination of the above methods will provide confidence and assurance that a drivetrain is in a good state of health. The disadvantages of each method are overcome through minimising downtime and assisting in a well-managed predictive maintenance plan. Predictive maintenance A predictive approach to maintenance inspections means that you can detect, categorise and quantify damage and defects on a wind turbine generator and track its progression. Predictive maintenance allows asset operators to plan scheduled maintenance ahead of catastrophic failure and during periods of low power production. By adopting this approach to monitoring, a good reliability engineer will add value to a client by uncovering minor, stand-alone or serial defect issues affecting the efficiency of a wind turbine. This minimises downtime and reduces the amount of major component replacements. The flow chart in Figure 0.5 demonstrates a good approach to inspecting the turbine through all available data and attempting to isolate maintenance to up-tower, as much as is reasonably practical. It is important to note that failure is a process and not a single event. The optimum window for fault detection is right after the beginning of the fault propagation and before serious wear and secondary damage occur. For example, as a bearing fault starts to grow, more and more wear debris is shed and is to any vibratory or measured signal. Figure 0.4: damage detection from an endoscopic inspection. Surface degradation on a gear surface is located. This method involves a site visit to physically stop the turbine and is not always attractive to operators or owners. To assist an inspector in decision making there exists ISO 10825 ‘Gears - wear and damage to gear teeth - terminology’ and ISO 15243 ‘Rolling bearings — damage and failures — terms, characteristics and causes’. A good inspector should have intricate working knowledge of mechanical components and be suitably qualified to work at heights. Figure 0.4 demonstrates imagery of a defect within a wind turbine gear component. To allow this damage to progress would lead to further oil contamination and increased temperatures, which could cause secondary damage to other drivetrain components. Misalignment can occur leading to further issues with the generator or main bearing. Dealing with the issue early can prevent all secondary damage and ensure the repair cost in minimised. To confidently understand a drivetrain’s internals, it is a must to be able to detect, characterise, quantify and locate damage 104 PES WIND

THINK TANK ‘The ultimate-goal is to be able to utilise a good maintenance and inspection program coupled with excellent data analysis and combine the results to predict damage, schedule repair accordingly in times of minimum production and availability and avoid high maintenance costs and secondary damage.’ Figure 0.5: Flow chart demonstrating a good approach to predictive maintenance. carried by the lubrication system. Debris minimum production and availability and www.naturalpower.com particles travelling through the gearbox, avoid high maintenance costs and www.twitter.com/Natural_Power where they can find their way into other gear secondary damage. This would be the ideal w ww.linkedin.com/company/natural-power and bearing designations, usually cause solution to the headache of crane costs and further damage escalating the repair costs. unplanned downtime. Avoiding this secondary damage is the key to saving money. Estimated Crane Costs Up-tower Down-tower Table 1.2: Estimated Crane Costs GBP 7-14 k GBP 170-340 k Table 1.2 below provides the differential cost of up-tower versus down-tower repair. The ultimate-goal is to be able to utilise a good maintenance and inspection program coupled with excellent data analysis and combine the results to predict damage, schedule repair accordingly in times of Natural Power Daryl Hickey heavily involved in troubleshooting and analysis exercises on turbine main Natural Power is an independent Daryl Hickey is a senior inspections and components, mechanical and hydraulic consultancy and service provider that reliability engineer with Natural Power systems, SCADA and energy management supports a global client base in the and takes a leading role in the technical control systems. effective delivery of a wide range of and innovation side of the inspections renewable projects including onshore team. He joined the business in 2015 and Utilising his skills in computer wind, solar, renewable heat, energy has conducted more than 1,000 programming, signal processing and storage and offshore technologies. drivetrain inspections and has been statistical analysis, Daryl routinely delivers involved in more than 20 end of warranty high quality SCADA and CMS reviews to It has a global reach, employing more inspection campaigns. clients to assess the reliability, than 365 staff across 11 international productivity, performance and efficiency offices. Its experience extends across all Daryl has a PhD in Mechanical Engineering of wind turbines across a site. phases of the project lifecycle from and utilises his academic skills to provide initial feasibility, through construction engineering support and implementation Daryl is a Chartered Engineer with the to operations and throughout all stages on instrumentation campaigns. He is also Institute of Mechanical Engineers. of the transaction cycle. WWW.PESWIND.COM 105

COMMENT: LEGISLATION Planning policy and case law developments for the renewables sector Words: Jennifer Holgate, Managing Associate, and Holly Wood-Pinkham, Paralegal at law firm Womble Bond Dickinson This briefing is intended as an update on three key policy and case law developments that have taken place over the summer. Jennifer Holgate 1 N ew European Court ruling – ‘Sweetman then the developer must consider if II’ there are conditions or restrictions Holly Wood-Pinkham (mitigation) that can be imposed to On 25 July 2018, the Court of Justice of the render the project acceptable. If that is 106 PES WIND European Union (the Court) delivered its not possible, alternative solutions should ruling in the case of Edel Grace and Peter be considered. Sweetman v An Bord Pleanala, or ‘Sweetman II’ (also known by some in the industry as (iv) ‘IROPI’: if there are no alternative ‘People over Wind II’.) The judgment solutions, the proposed development developed the position taken in People Over must demonstrate imperative reasons of Wind and Peter Sweetman v Coillte Teoranta overriding public interest (‘IROPI’). The (‘Sweetman I’), delivered in April this year. developer will need to demonstrate that there are reasons of economic, social, The Court again focused on the human health, public safety or important interpretation of Article 6 of the Habitats environmental benefits as to why the Directive, which concerns the need for an project should be carried out. The appropriate assessment where a project is developer must also consider appropriate likely to have a significant effect on a site compensatory measures that may be (onshore or offshore) designated as a special introduced when granting consent. protection area or a special area of conservation (SPAs and SACs) The key The case question for the Court was at what point in the assessment under this Directive should Sweetman II concerned the proposed mitigation measures be taken into account. development of an onshore wind farm which would be partially located within an SPA Current practice relating to appropriate identified as a habitat of hen harriers, a assessment is based on a four-stage protected bird under the Birds Directive. The approach. Briefly, these stages are: development included a Species and Habitat Management Plan, which detailed measures (i) Screening to establish whether a likely to address the potential effects of the wind significant effect may exist on the farm on the hen harrier’s foraging habitat. integrity of a designated site. If it does, The An Bord Pleanala (the planning authority the developer will need to undertake; in Ireland) gave permission for the development on 22 July 2014 on the grounds (ii) The appropriate assessment that it would not adversely affect the integrity of the SPA. Ms Grace and Mr (iii) A ssessment of alternatives; if it cannot Sweetman challenged this, arguing that the be ascertained that the project will not adversely affect the integrity of a site,

COMMENT: LEGISLATION Species and Habitat Management Plan several significant references to the July 2018. The NIA sets out the Commission’s constituted compensatory measures, and so renewables sector. recommendations in the short, medium and the An Bord ought to have considered the long term for the government to meet the criteria laid out in Article 6(4) of the Habitat The draft version of NPPF2, published in country’s infrastructure needs. The Directive when making their decision (IROPI). March 2018, included controversial wording government has committed to laying the NIA from a Written Ministerial Statement made before parliament and to respond to its The ruling the then Secretary of State for Communities recommendations within six months, with a and Local Government, Greg Clarke, in 2015. final deadline of a year. The Court concluded that ‘the fact that a In his statement, Clarke announced that project includes measures to ensure…the onshore wind developments should only be One of the six key areas on which the part of the site that is in fact likely to provide permissible where they have been included in Commission made recommendations was a suitable habitat will not be reduced and a Local Plan and, following consultation, any the switch to low carbon energy by 2050. The indeed may be enhanced may not be taken impacts caused by the development have Commission’s recommendations are a vote into account for the purpose of the been addressed and have backing of the local of confidence in renewables as the energy assessment that must be carried out in community. source of the future. The NIA acknowledges accordance with Article 6(3) of the directive that reducing emissions through renewables to ensure that the project in question will not Many industry bodies responded to the draft has been seen as ‘costly and difficult’, but adversely affect the integrity of the site NPPF2 with serious concerns over the asserts that this is no longer accurate and concerned; that fact falls to be considered, if inclusion of this wording, highlighting its that we must act now in moving away from need be, under Article 6(4) of the directive.’ contradiction with the framework’s wider fossils fuels and towards a low carbon future. emphasis on the need for ‘radical reductions Research conducted by the Commission and What next? in greenhouse gas emissions’. Subsequently, detailed in the NIA finds that renewable the final version of NPPF2 retains the energy is both safer and more cost The ruling in Sweetman I effectively moved wording but includes the following exception: competitive than nuclear power stations. all mitigation apart from ‘embedded’ International trends indicate that the cost mitigation from the screening stage down to E xcept for applications for the repowering associated with the expansion of nuclear the appropriate assessment stage. of existing wind turbines, a proposed wind energy is less likely to fall due to, for example, Sweetman II expands this, pushing certain energy development involving one or more improvements in technology, than in the forms mitigation down one stage further, to turbines should not be considered renewable sector. the IROPI stage or ‘test’ (Article 6(4)). In acceptable unless it is in an area identified addition, the ruling means that for mitigation as suitable for wind energy development in The Commission therefore concludes that to be included at the appropriate assessment the development plan; and, following ‘Given the balance of cost and risk, a stage, it must either form part of the project consultation, it can be demonstrated that renewables based system looks like a safer or be a protective measure which the the planning impacts identified by the bet at present than constructing multiple new developer can show is completely affected local community have been fully nuclear power plants’. It is recommended that scientifically proven to not affect the addressed and the proposal has their a ‘one by one’ approach to new nuclear plants, integrity of the conservation area. This backing. (Footnote 48) rather than a ‘fleet’, is adopted and that the increases the likelihood of a negative Government should not agree support for appropriate assessment for future projects. This exception has been received with some more than one nuclear power station beyond As a result, developers are now more likely to relief by the industry, and hailed as the first Hinkley Point C before 2025. need to show imperative reasons of step, however small, to moving onshore wind overriding public interest as to why the policy forward since the 2015 Statement. The Commission favours the use of existing project should be allowed. market mechanisms – Contracts for Another important inclusion in NPPF2 is Difference and the capacity market – ‘where On 15 August 2018, the implications of the specific reference to the need to take a possible, to avoid creating more uncertainty, ruling in Sweetman I were considered by Sir ‘proactive approach’ to planning to adapt for but incremental improvements could be Ross Cranston, in the case of R (Langton) vs climate change ‘in line with the objectives made’. It is recommended that the Secretary of State for Environment, Food and provisions of the Climate Change Act distribution of technologies is revised and Rural Affairs and Natural England. The 2008’. This reaffirms the Government’s between ‘pot one’ and ‘pot two’ for CfDs and claimant was seeking judicial review of commitment to ensuring an 80% cut in reinstating a pipeline of pot 1 auctions, in Natural England’s decision to license for the emissions of greenhouse gases by 2050. This order to enable the lowest cost renewable culling of badgers in 11 different areas, some specific reference was reinstated following generation mix to be brought forward in the of which were in the vicinity of SPAs. Part of an omission in the March draft. 2020s. This would mean that onshore wind, the claimant’s argument in this case was that which would still be subject to planning the conditions that Natural England had A notable omission in NPPF2 came at restrictions in England (although note NPPF2). attached to the culling licenses, which paragraph 177, concerning appropriate On the other hand, projects in Wales and included limits on the location and timing of assessment, which remained unchanged Scotland ‘would no longer be held back’. Pot 2 the culling, should not have been taken into despite the aforementioned ECJ ruling in auctions could then be used to allocate small account at the screening stage, in light of the Sweetman I. NPPF2 retains the position that amounts of support to emerging Sweetman I decision. However, Sir Ross the presumption in favour of sustainable technologies. In this regard, the Commission Cranston held that the conditions were development does not apply where considers that tidal power should not receive ‘integral features’ of the project, which appropriate assessment is required. Whilst it any ‘special treatment’ through bilaterally Natural England needed to assess under the had been hoped it had been hoped that the agreed contracts, however it should compete Habitats Regulations’ (i.e. it was effectively Government would use the NPPF2 to clarify on an equal basis with other technologies. embedded mitigation) and so dismissed the this position for developers, it now seems claim that Sweetman I was relevant. likely that this will continue to be area of In the near term, the Assessment contention until further guidance is issued. recommends that a 50 per cent renewable 1 T he revised National Planning Policy generation by 2050 and highlights offshore Framework 1 The National Infrastructure Assessment wind as an example of a renewable technology which has recently become cost competitive. On 24 July 2018, the Government published The National Infrastructure Commission (the the revised National Planning Policy Commission) published the first National www.womblebonddickinson.com Framework (‘NPPF2’). NPPF2 contains Infrastructure Assessment (the NIA) on 10 WWW.PESWIND.COM 107

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